Beverage Can Inkjet Printing After Necking to Reduce Waste
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Solution Overview
Problem
Conventional methods for manufacturing beverage cans result in wasted cans when design changes or products are discontinued, as the diameter reduction process is typically performed after image formation, leading to inefficiencies and unnecessary production.
Innovation Solution
A method that involves a diameter decreasing process followed by image formation on the can bodies, with paint application on both inner and outer surfaces before diameter reduction, using an inkjet method without direct contact, and employing a support member to stabilize the can body during image formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the diameter decreasing process is performed after image formation, then the can body strength is improved, but the production efficiency deteriorates due to wasted cans when design changes occur
Solution Approach 1:
The diameter decreasing process is performed preliminarily before image formation. This allows the can body to be prepared in advance with the correct final dimensions, while the image formation is done afterward to match specific design requirements. When design changes occur, only the image formation step needs to be modified, not the entire production process, thus reducing waste and improving productivity while maintaining can strength.
2Ease of manufacture
If can bodies are stored with images formed on them, then the storage process is simplified, but the loss of substance increases when designs are changed or products are discontinued
Solution Approach 1:
The can bodies are prepared preliminarily with diameter reduction and basic coating, but the final image formation is delayed until after storage. This allows can bodies to be stored in a semi-finished state without committing to specific designs. When design changes or product discontinuations occur, the unfinished can bodies can be reprocessed or discarded with minimal waste, as they lack the final design-specific images.
3Device complexity
If image formation is performed by contact method, then the image formation process is simpler, but the can body surface is damaged during the process
Solution Approach 1:
The contact-based mechanical image formation method is replaced with a non-contact method. This substitution eliminates the mechanical contact that causes surface damage to the can body, while still achieving the desired image formation. The non-contact method reduces harmful mechanical factors without significantly increasing process complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces waste by allowing for flexible design changes without pre-formed images, improving production efficiency and minimizing damage to cans during processing.
Implementation Method 1
image formation is performed on the can body by use of an inkjet method
Implementation Method 2
the can body having been subjected to the diameter decreasing is supported by a support member having a function of sucking a bottom portion of the can body
Data Source
AI summary
A can body that has been subjected to outer surface painting (OV), inner surface painting (INS), and a neck process (SDN) but that has not been subjected to image formation is manufactured in a canning factory. The can body that has not been subjected to image formation is shipped to a beverage can manufacturing factory. At the beverage can manufacturing factory, an image formation process using a printer (PR) is performed. Specifically, ink is ejected from an inkjet head toward the can body, to thereby form an image on the outer circumferential surface of the can body. Thereafter, the can body is filled with beverage in a filler (FL), and then a can lid is attached to the can body in a seamer (SM).