The lids of glass containers which have a 'twist-off' mechanism are manufactured from tinplate through a process of cutting and drawing. Previously, the tinplate was protected with a double layer of a certain epoxy-phenolic varnish. During cutting, the detachment of threads of varnish is produced, and these may reach more than 150 microns in diameter. These threads stick to the equipment, thus hindering the shaping process. After manufacturing thousands of lids, stops must inevitably be made in production in order to clean machinery. Through the application of a fractioned design of experiment (DoE) application, carried out on an industrial scale, the effect of a number of factors on the detachment of threads of varnish was studied. Some to these factors refer to coating, others to the substratum and others to the process of cutting and drawing. It is concluded that the detachment is greater in the disk areas which are parallel to the forward direction of the production line. This problem could be substantially reduced, and even eliminated, if the direction of the rolling of the sheet metal were perpendicular to that of the forward direction of the production line, if the blank-holder is situated at 4 bar, if the time between the curing process and cutting is no more than 3threedays, if the clearance in the cutting is situated at 0.06 mm, and if the grammage of the varnish and the grammage of the layer of tin are increased.
Keywords: curing temperature; cutting; design of experiments; drawing; grammage of varnish; hairing; tinplate; “twist off” lids.