geekoftheweek
- Joined Oct 6, 2013
- 1,429
That is an interesting question that both pulled out some past experience, curiosity, and sent me on a small adventure across the internet.Using fewer types would be a start. Why do we need milk containers made from low density polyethylene, yogurt pots from polystyrene, and soft drink bottles from polyethylene terephthalate?
Milk jugs are actually HDPE (high density polyethylene). When I worked at a bottle manufacturer I remembered certain food bottles we made had a ethylene - vinyl - alcohol (EVAL EVOH) polymer layer also as a barrier layer. I will not bond with HDPE so an adhesive layer was also part of the mix on both sides. Some food bottles I produced were straight HDPE, but they were also foods that generally had long if not infinite shelf lives (I don't remember the details anymore). It seems the reason it is used for milk jugs is because milk has a fairly short shelf life. Recycled HDPE is only approved for direct contact with food an a case by case basis. We turned a lot of old milk jugs into fabric softener bottles.
Yogurt containers are actually polypropylene. Polystyrene is a foam (coffee cups). I did make a few bottles from polypropylene, but never knew what the advantage was. It seems it is a good material for resisting mold and bacteria in the plastic itself. The recycled material is approved for direct contact with food with no restrictions.
PET (polyethylene terephthalate) is kind of a super plastic from what I can tell in terms of food storage. PET is also approved for direct contact after being recycled. PET takes some specialized equipment (relative to other types) to produce the bottles along with some serious air pressure. The compressor that fed those two lines where I worked ran at 500 psi compared to the rest of the plant at 120 psi. It's also a two step process to actually form the bottles compared to all other plastic types. I don't know the details, but from what I saw the process itself is more than likely quite expensive compared to other types of plastics.
We did use some low density polyethylene in a few bottles to add a little bounce to them and allow for thinner walls. It was never used to produce an entire bottle, and only a couple bottles actually used it. It was a customer specification as far as I know.
Other than that I don't know anything else. A lot of that was what I could find online other than what I remember from making bottles.
Like everything else it probably boils down to which one is cheaper for the intended use, followed by which one will do the job better, and finally which one looks better. Some things will sell better with a more attractive container.
Plain HDPE was the simplest process and I would imagine the least expensive.
HDPE with barrier and polypropylene bottles used material dryers to both keep the material as dry as possible and helped regulate the raw material temperature which added to the cost I'm sure. Both types would beat you pretty good if the material conditions fluctuated too much. Keeping track of your levels and slow changes over time was the key.