Design of adjustable packaging line

Diplomityön tavoite oli tutkia, mitä toimintoja ja tekniikoita uusi, joustava kartonkipakkauslinja sisältää ja mitkä suuntaukset pakkausteollisuudessa tulevat olemaan tärkeitä tulevaisuudessa. Pakkauslinjan päätoimintoja tarkasteltiin nykyisten jatulevaisuuden tekniikoiden pohjalta. Erityisesti tarkasteltiin laser-sovellusten käytön mahdollisuutta pakkauslinjan eri osatoiminnoissa. Katsaus pakkausteollisuuden tulevaisuuden näkymiin luotiin kirjallisuuden ja aikaisempien tutkimusten pohjalta, minkä perusteella työssä oletetaan, että yksilölliset ja monitoimipakkaukset tulevat lisääntymään tulevaisuudessa. Eri tuotantoerien välillä olevat asetusajat tulee saada minimoitua, mutta millä keinoin joustavuus on saavutettavissa? Yksi ratkaisu pakkausten valmistamisessa on käyttää robottisolua, mikä on mahdollista luultavasti ainakin kuppimuotoisten pakkausten kohdalla. Muutenkin robotiikka on lisääntymässä pakkausteollisuudessa. Digitaalisten painotekniikoiden kehitys on mahdollistanut yksilölliset painatukset. Tulevaisuudessa painatus on mahdollista tehdä pakkauslinjan loppupäässä, jopa vasta täytön ja suljennan jälkeen. Laserleikkaus on jo nyt käytössä, mutta tulevaisuudessa myös saumaus ja perinteinen nuuttaus on mahdollista tehdä lasersovelluksia käyttäen. Kehittynyt, väyläpohjainen ohjausjärjestelmä on tulevaisuudessa välttämätön joustavassa pakkauslinjassa. Internetin välityksellä toimiva etäohjattu virheenkorjausdiagnostiikka tulee myös olemaan itsestäänselvyys tulevaisuudessa. Kustannussäästöjä voidaan saavuttaa käyttämälläpakkauslinjassa modulaarista rakennetta. Standardiosien ja standardiosajärjestelmien käyttäminen pienentää myös käyttö- ja huoltokustannuksia. Tärkeää on kuitenkin muistaa, ettei joustavuutta voida saavuttaa pelkästään yhtä ominaisuutta tai tekniikkaa hyödyntäen vaan monia menetelmiä yhdistäen. Suunniteltavan pakkauslinjan toiminta on myös hyvä varmistaa käyttäen apuna mallinnusta ja simulointia.

Possibility of press forming wood films into primary packaging

In recent times the packaging industry is finding means to maximize profit. Wood used to be the most advantageous and everyday material for packaging, worktables, counters, constructions, interiors, tools and as materials and utensils in the food companies in the world. The use of wood has declined vigorously, and other materials like plastic, ceramic, stainless steel, concrete, and aluminum have taken its place. One way that the industry could reduce its cost is by finding possibilities of using wood for primary packaging after which it can be safely recycled or burned as a carbon source for energy. Therefore, the main objective of this thesis is to investigate the possibility of press-forming a wood film into primary packaging. In order to achieve the stated objectives, discussion on major characteristics of wood in terms of structure, types and application were studied. Two different wood species, pine and birch were used for the experimental work. These were provided by a local carpentry workshop in Lappeenranta and a workshop in Ruokolahti supervised by Professor Timo Kärki. Laboratory tests were carried out at Lappeenranta University of Technology FMS workshop on Stenhøj EPS40 M hydraulic C-frame press coupled with National Instruments VI Logger and on the Adjustable packaging line machine at LUT Packaging laboratory. The tests succeeded better on the LUT packaging line than on the Stenhoj equipment due to the integrated heating system in the machine. However, there is much work to be done before the quality of a tray produced from the wood film is comparable to that of the wood plastic composite tray.

Food packaging indicators and sensors

Various categories of food packaging indicators namely; VTT, Ageless Eye, Mocon, Åbo Akademi and Impak were selected and incorporated into food trays manufactured at LUT packaging laboratory. Each of these food packaging indicators was used to investigate (visually and qualitatively) the transmission of oxygen through the seal, and tray material, as well as to detect microbial activity within the content of the package. Applications of different methods of gas flushing, content variation and introduction of two distinct levels of oxygen scavengers were employed as treatments to evaluate the packaging performance of the food packaging indicators. Ease of handling of each food packaging indicator was also taken into considerations. Findings showed that for packages, which contained chicken product, the amount of oxygen in the package, measured immediately after the sealing operation on the first day gradually decreased to zero percent by the third day of the storage period. The oxygen level remained at this point throughout the duration of storage for the chicken packages. Besides, level of oxygen in the packages without product continued to increase with the storage time, at moderate rate of 0.1% for 100%N2 and 0.3% for 30%CO2/70%N2 empty packages. More carbon dioxide gas was recorded for packages flushed with 30%CO2/70%N2. Results also revealed that visual analysis of one of the color indicators for example Ageless Eye, conformed to the data derived from the luminescence food-packaging indicator. This shows that packaging operation of the packaging line was considerably stable, and efficient with negligible exception. However, it was found that most of the food packaging indicators investigated in this research study exhibited considerable packaging challenges, such as, reaction with the content of the package (Impak); over sensitivity (Åbo Akademi and Impak); ease of handling problem (Åbo Akademi); and ease of activation problem (VTT indicators). In this study, the strengths and limitations of different indicators were analyzed. This study demonstrates the applicability of various indicators in MAP using chicken package application.

The modular forming press for paperboard packages

In this master’s thesis the structural and functional features of a forming tool are developed to meet the needs of modern packaging production for paperboard packaging are studied. The goal of the study is to develop a new type of machine for the manufacture of the paperboard package by pressing. In the structure of the developed forming press the possibility to modify the packaging as well as the requirements of industrial production, food hygiene and other operational matters are accounted for. The press has been sized based on the main dimensions of a single food-grade paperboard tray. In the LUT Packaging Laboratory the forming press is designed suitable for on-line operation. In addition, suggestions for further development of packaging line and equipment have been made based on the information gathered during this thesis study.

Joustavan pakkauslinjan asiakastarvekartoitus

Diplomityön tavoitteena oli löytää uudentyyppiselle kartonkipakkauksien valmistuslinjalle potentiaalisia käyttäjäryhmiä, ja kartoittaa eri ryhmien pakkauslinjalle asettamat vaatimukset. Työn yhteydessä toteutettiin asiakastarvekartoitus, jonka avulla saatiin tietoa pakkauslinjaan kohdistuvista vaatimuksista neljästä eri käyttäjäryhmästä. Haastattelututkimuksena suoritetulla asiakastarvekartoituksella saatiin kerättyä monipuolisesti pakkauslinjan jatkokehityksessä hyödynnettävää käyttäjätietoa. Tehtyjen haastatteluiden perusteella pakkauslinjasta olivat kiinnostuneet erityisesti yli kymmenen henkilöä työllistävät leipomot, yli viisi henkilöä työllistävät liha-alan yritykset sekä osa vähittäiskaupoista. Näiden yritysorganisaatioiden lisäksi omia vaatimuksiaan pakkauslinjalle asettivat mainostoimisto ja tukkuliikkeet.

Kartonkipakkauslinjaston anturointi

Tässä diplomityössä tutkitaan kartonkiastioiden valmistukseen tarkoitetun linjaston ohjausjärjestelmän anturoinnin tarpeita. Linjasto on suunniteltu Lappeenrannan teknillisen ylipiston pakkauslaboratorioon vastaamaan nykyaikaisen pakkaustuotannon tarpeita. Linjasto on suunniteltu modulaariseksi sekä mahdollisimman helposti muunneltavaksi. Työn tavoitteena on selvittää anturoinnin tarpeet moduulikohtaisesti sekä tehdä tarvittava mekaniikkasuunnittelu. Suunnittelussa otetaan huomioon elintarvikehygienia, turvallisuus, modulaarisuuden vaatimukset, tuotantomäärän tarpeet sekä muut toiminnan kannalta kriittiset tekijät. Tutkimuksen lopputuloksena saadaan valmistettavan prototyypin oikean toiminnan edellyttämät edulliset anturointiratkaisut oleellisimpien moduuleiden osalta. Lisäksi työssä esitetään jatkokehitysehdotuksia kun prototyyppi saadaan valmiiksi jolloin mittaustuloksia voidaan alkaa tutkimaan.

Tulologistiikan kustannusanalyysi hankintojen näkökulmasta

Työssä tarkastellaan tulologistiikan toiminnoista syntyvien kustannuksien ja hankintatoimen päätösten välistä yhteyttä. Päätökset tilauseräkooista ja hankintalähteistä vaikuttavat kustannuksiin, joita tavaran käsittelystä syntyy. Oletuksena hankintatilanteissa ei yksin voi olla, että ostohinnaltaan halvin tuote olisi aina kaikkein edullisin vaihtoehto. Työssä on käyty läpi Wurth Oy:n tulologistiikan eri toimintoja ja määritelty näille kustannukset toimintoperusteisen kustannuslaskennan periaatteita noudattaen. Työn lopussa on myös hahmotettu sitä kokonaisuutta, josta tuotteen kustannukset muodostuvat. Työn lopputulos on laskentamalli, jolla tulologistiikan kustannukset voidaan huomioida hankinnan yhteydessä osana kokonaiskustannuksia. Yhteenvetona tuloksista voimme todeta, että logistiikan kustannukset eivät ole tuotetasolla mitenkään merkityksettömiä. Varsinkin pienten erien käsittely on kallista ja pakkaaminen itse aiheuttaa aina lisäkustannuksia.

Tulevaisuuden joustavan pakkauslinjaston muodonantolaitteen alaosan suunnittelu

Tässä kandidaatintyössä tutkitaan muodonantolaitteen alaosan rakennetta osana tulevaisuuden pakkauslinjastoa. Työn tarkoituksena on suunnitella muodonantoprässin vastinkappale kaikkine mekanismeineen ja toimilaitteineen käyttäen hyväksi systemaattisen koneensuunnittelun periaatteita sekä huomioiden koko pakkauslinjaston lähtökohdat.

Tulevaisuuden joustavan pakkauslinjan suunnittelu ja optimointi

Tässä diplomityössä tutkitaan kartonkiastioiden valmistukseen tarkoitetun linjaston prototyypin vastaavuutta suunnittelun tuloksiin ja niille annettuihin ohjearvoihin. Työssä vertaillaan eri suunnitteluvaiheiden vaikutusta linjaston osakokonaisuuksien eli moduulien onnistumisen kannalta. Työn lopuksi arvioidaan mahdollisia rakenteiden optimoinnin ja linjaston jatkokehityksen kannalta oleellisia kohteita laitteistossa.

Pressforming of a tray from a pulp sheet

The aim of this thesis work was to verify the possibility to produce tray packages directly from pulp sheets using press forming techniques. The different existing raw materials of pulp, various sources of molded pulp and different methods of production of molded pulp were studied. Nine different raw materials which were used for experimental work were provided by Stora Enso mills, and Stora Enso Research Centre, Imatra, Finland. The laboratory tests were carried out using LUT Adjustable packaging line at Lappeenranta University of Technology. The results prove that long virgin fibres of pine pulp seems to have better formability with high moisture content compared to others. No significant improvements were noticed with conditioned samples, never the less far studies has to be done to find optimal conditions for production. The results indicated the possibility for making pressformed tray from two different pulp qualities (Sunila pulp and Enopine). The method could prove to be beneficiary as the production line could be shortened and investment in board machines could be avoided if the trays were pressed directly from pulp sheets. Also the labour costs would be reduced. However, there is much work to be done before the quality of a tray produced out of a pulp sheet is comparable to a tray produced out of tray board.

Kartongin fysikaalisten ominaisuuksien vaikutus muovautuvuuteen

Työn tavoitteena oli kehittää menetelmä, jolla voitaisiin arvioida veto-ominaisuuksien avulla konvertointikoneen prässäysnopeuden ja muottien lämpötilan vaikutuksia kartongin muovautuvuuteen. Kirjallisuusosassa käsiteltiin kartongin muovautuvuuteen vaikuttavia ominaisuuksia sekä vetolujuuteen vaikuttavia tekijöitä. Lisäksi käsiteltiin kosteuden vaikutusta muovautuvuuteen sekä esiteltiin vuokakonvertointiprosessin periaate ja muovin sekä kartongin käyttäytymisen erot konvertointiprosessissa. Kokeellinen osa jakaantui kolmeen osaan. Esikokeissa tutkittiin laboratoriomittauksilla vetonopeuden ja kosteuden muutosten vaikutusta erilaisten kaupallisten kartonkimateriaalien vetolujuuteen ja murtovenymään. Tulosten perusteella valittiin prässäysnopeudet ja kosteustaso 2D- testauslaitteella suoritettuihin esi-pilot-mittakaavan kokeisiin sekä varsinaiseen pilot-koeajoon. Pilot-koeajossa pyrittiin arvioimaan prässäysnopeuden ja muottien lämpötilan vaikutuksia muovautuvuuteen vetolujuusarvojen avulla. Prässäysnopeudella ja vetolujuuslaitteen nopeudella ei havaittu yhteneväisyyksiä, jotta voitaisiin arvioida kartongin muovautuvuutta. Muovautuvuutta voidaan kuitenkin arvioida epäonnistuneisuusluvulla, jonka laskentapa kehitettiin työn aikana. Epäonnistuneisuusluku kuvaa hyvin kartongin muovautuvuutta ja on menetelmänä helppo, mutta sen heikkoutena on repeämien mittaamisen aiheuttama epätarkkuus. Esikokeissa havaittiin myös muovipäällysteiden veto-ominaisuuksien vastaavan kartongin ominaisuuksia 65 %:n suhteellisessa kosteudessa, jonka valittiin siten olevan optimaalinen olosuhde pilot-mittakaavan koeajoihin.

Encapsulation of packaging cell line results in successful retroviral-mediated transfer of a suicide gene in vivo in an experimental model of glioblastoma.

AIMS: Retroviral-mediated gene therapy has been proposed as a primary or adjuvant treatment for advanced cancer, because retroviruses selectively infect dividing cells. Efficacy of retroviral-mediated gene transfer, however, is limited in vivo. Although packaging cell lines can produce viral vectors continuously, such allo- or xenogeneic cells are normally rejected when used in vivo. Encapsulation using microporous membranes can protect the packaging cells from rejection. In this study, we used an encapsulated murine packaging cell line to test the effects of in situ delivery of a retrovirus bearing the herpes simplex virus thymidine kinase suicide gene in a rat model of orthotopic glioblastoma. MATERIALS AND METHODS: To test gene transfer in vitro, encapsulated murine psi2-VIK packaging cells were co-cultured with baby hamster kidney (BHK) cells, and the percentage of transfected BHK cells was determined. For in vivo experiments, orthotopic C6 glioblastomas were established in Wistar rats. Capsules containing psi2-VIK cells were stereotaxically implanted into these tumours and the animals were treated with ganciclovir (GCV). Tumours were harvested 14 days after initiation of GCV therapy for morphometric analysis. RESULTS: Encapsulation of psi2-VIK cells increased transfection rates of BHK target cells significantly in vitro compared to psi2-VIK conditioned medium (3 x 10(6) vs 2.3 x 10(4) cells; P<0.001). In vivo treatment with encapsulated packaging cells resulted in 3% to 5% of C6 tumour cells transduced and 45% of tumour volume replaced by necrosis after GCV (P<0.01 compared to controls). CONCLUSION: In this experimental model of glioblastoma, encapsulation of a xenogeneic packaging cell line increased half-life and transduction efficacy of retrovirus-mediated gene transfer and caused significant tumour necrosis.

Engineering an improved adenovirus packaging cell line

Recombinant human adenovirus (Ad) vectors are being extensively explored for their use in gene therapy and recombinant vaccines. Ad vectors are attractive for many reasons, including the fact that (1) they are relatively safe, based on their use as live oral vaccines, (2) they can accept large transgene inserts, (3) they can infect dividing and postmitotic cells, and (4) they can be produced to high titers. However, there are also a number of major problems associated with Ad vectors, including transient foreign gene expression due to host cellular immune responses, problems with humoral immunity, and the creation of replication competent adenoviruses (RCA). Most Ad vectors contain deletions in the E1 region that allow for insertion of a transgene. However, the E1 gene products are required for replication and thus must be supplied in trans by a helper ceillille that will allow for the growth and packaging of the defective virus. For this purpose the 293 cell line (Graham et al., 1977) is used most often; however, homologous recombination between the vector and the cell line often results in the generation of RCA. The presence of RCA in batches of adenoviral vectors for clinical use is a safety risk because tlley . may result in the mobilization and spread of the replication-defective vector viruses, and in significant tissue damage and pathogenicity. The present research focused on the alteration of the 293 cell line such that RCA formation can be eliminated. The strategy to modify the 293 cells involved the removal of the first 380 bp of the adenovirus genome through the process of homologous recombination. The first step towards this goal involved identifying and cloning the left-end cellular-viral jUl1ction from 293 cells to assemble sequences required for homologous recombination. Polymerase chain reaction (PCR) was performed to clone the junction, and the clone was verified through sequencing. The plasn1id PAM2 was then constructed, which served as the targeting cassette used to modify the 293 cells. The cassette consisted of (1) the cellular-viral junction as the left-end region of homology, (2) the neo gene to use for positive selection upon tranfection into 293 cells, (3) the adenoviral genome from bp 380 to bp 3438 as the right-end region of homology, and (4) the HSV-tk gene to use for negative selection. The plasmid PAM2 was linearized to produce a double strand break outside the region of homology, and transfected into 293 cells using the calcium-phosphate technique. Cells were first selected for their resistance to the drug G418, and subsequently for their resistance to the drug Gancyclovir (GANC). From 17 transfections, 100 pools of G418f and GANCf cells were picked using cloning lings and expanded for screening. Genomic DNA was isolated from the pools and screened for the presence of the 380 bps using PCR. Ten of the most promising pools were diluted to single cells and expanded in order to isolate homogeneous cell lines. From these, an additional 100 G41Sf and GANef foci were screened. These preliminary screening results appear promising for the detection of the desired cell line. Future work would include further cloning and purification of the promising cell lines that have potentially undergone homologous recombination, in order to isolate a homogeneous cell line of interest.

A stable human-derived packaging cell line for production of high titer retrovirus/vesicular stomatitis virus G pseudotypes.

We have generated a human 293-derived retroviral packaging cell line (293GPG) capable of producing high titers of recombinant Moloney murine leukemia virus particles that have incorporated the vesicular stomatitis virus G (VSV-G) protein. To achieve expression of the retroviral gag-pol polyprotein, the precise coding sequences for gag-pol were introduced into a vector which utilizes totally nonretroviral signals for gene expression. Because constitutive expression of the VSV-G protein is toxic in 293 cells, we used the tetR/VP 16 transactivator and teto minimal promoter system for inducible, tetracycline-regulatable expression of VSV-G. After stable transfection of the 293GPG packaging cell line with the MFG.SnlsLacZ retroviral vector construct, it was possible to readily isolate stable virus-producing cell lines with titers approaching 10(7) colony-forming units/ml. Transient transfection of 293GPG cells using a modified version of MFG.SnlsLacZ, in which the cytomegalovirus IE promoter was used to drive transcription of the proviral genome, led to titers of approximately 10(6) colony-forming units/ml. The retroviral/VSV-G pseudotypes generated using 293GPG cells were significantly more resistant to human complement than commonly used amphotropic vectors and could be highly concentrated (> 1000-fold). This new packaging cell line may prove to be particularly useful for assessing the potential use of retroviral vectors for direct in vivo gene transfer. The design of the cell line also provides at least theoretical advantages over existing cell lines with regard to the possible release of replication-competent virus.

Tetracycline-Inducible packaging cell line for production of Flavivirus replicon particles.

We have previously developed replicon vectors derived from the Australian flavivirus Kunjin that have a unique noncytopathic nature and have been shown to direct prolonged high-level expression of encoded heterologous genes in vitro and in vivo and to induce strong and long-lasting immune responses to encoded immunogens in mice. To facilitate further applications of these vectors in the form of virus-like particles (VLPs), we have now generated a stable BHK packaging cell line, tetKUNCprME, carrying a Kunjin structural gene cassette under the control of a tetracycline-inducible promoter. Withdrawal of tetracycline from the medium resulted in production of Kunjin structural proteins that were capable of packaging transfected and self-amplified Kunjin replicon RNA into the secreted VLPs at titers of up to 1.6 x 10(9) VLPs per ml. Furthermore, secreted KUN replicon VLPs from tetKUNCprME cells could be harvested continuously for as long as 10 days after RNA transfection, producing a total yield of more than 1010 VLPs per 106 transfected cells. Passaging of VLPs on Vero cells or intracerebral injection into 2- to 4-day-old suckling mice illustrated the complete absence of any infectious Kunjin virus. tetKUNCprME cells were also capable of packaging replicon RNA from closely and distantly related flaviviruses, West Nile virus and dengue virus type 2, respectively. The utility of high-titer KUN replicon VLPs was demonstrated by showing increasing CD8(+)-T-cell responses to encoded foreign protein with increasing doses of KUN VLPs. A single dose of 2.5 x 10(7) VLPs carrying the human respiratory syncytial virus M2 gene induced 1,400 CD8 T cells per 10(6) splenocytes in an ex vivo gamma interferon enzyme-linked immunospot assay. The packaging cell line thus represents a significant advance in the development of the noncytopathic Kunjin virus replicon-based gene expression system and may be widely applicable to the basic studies of flavivirus RNA packaging and virus assembly as well as to the development of gene expression systems based on replicons from different flaviviruses.