It’s easy to throw around terms like quality control and testing but we appreciate that transparency builds trust. That’s why we’re pulling back the curtain on our quality control processes, such as the Flat Crush Test, and introducing you to our team members such as Bridget Byrne and Cillian Doyle. Up next is Ibrahim Darwish, our HSEQ Manager who joined the team in late 2022. With his background in engineering (BEng) and professional memberships with the Institution of Engineers of Ireland (MIEI) and Institution of Occupational Safety and Health (IOSH), Ibrahim brings a wealth of expertise to our quality assurance processes.
Ibrahim sat down with us for a Q&A about our radial crush testing procedures. This testing is crucial to make sure our cores and tubes meet the highest standards of structural integrity – a key concern for clients across various industries.
Understanding the Crush Test
- Can you explain what a Radial crush test for cores and tubes involves? What exactly are you testing for?
A Radial crush test measures the resistance of cylindrical cores and tubes (often made from paper, cardboard, or other materials) to radial pressure. The primary objective is to determine how well these structures can withstand compressive forces exerted along their radial axis. This helps to ensure that the product can endure external stresses during storage, handling, or transportation.
Structural Integrity
- Why is the Radial crush test important in the manufacturing process?
The test is essential to verify the structural integrity and mechanical strength of cores and tubes. It ensures that these products meet the required durability standards for their intended purpose, minimising the risk of failure during usage. This is especially critical in industries like paper, textile, and packaging, where tubes or cores are frequently exposed to considerable compressive forces.
High Quality Packaging
- At what stage in production do you conduct the Radial crush test, and how does it fit into the overall quality assurance process?
The Radial crush test is typically performed during intermediate or final quality assurance stages. It ensures that only compliant, high-quality products proceed to packaging and distribution. Incorporating the test at this stage helps manufacturers catch potential issues before the product reaches the end-user.
Crush Strength
- What parameters or specifications are you looking for during the Radial crush test?
Key parameters include:
- Maximum crush strength (measured in units such as bar)
- Consistency in material thickness and uniformity
- The specifications vary based on the intended use and industry standards but must align with mechanical strength requirements and customer specifications.
Durability Test
- How do you determine if a core or tube passes or fails the Radial crush test? What are the typical failure points?
A core or tube passes if it meets or exceeds the predefined strength and durability thresholds without significant deformation or cracking. Typical failure points include buckling under load, cracking, or permanent deformation. The failure is often observed at the weakest section of the material or where defects exist.
Product Uniformity
- Are there any specific standards or regulations that the Radial crush test needs to comply with?
Yes, there are several standards that may apply, depending on the industry and region. For example, ISO 11093-9 for paper and board cores outline methods for determining radial crush resistance. Compliance with such standards ensures uniformity and quality across products.
Compression Testing
- What kind of equipment or technology is used to perform the Radial crush test?
The test is conducted using a radial crush tester, which includes a compression testing machine fitted with a specially designed box to apply force along the radial axis.
Quality Monitoring
- How often is the test conducted, and how long does it typically take?
The frequency depends on production volume and quality assurance protocols. It may be conducted on a batch basis or as part of continuous quality monitoring. A single test usually takes a few minutes, depending on the machine’s configuration and the product’s dimensions.
Quality Control
- Are there any common challenges or issues that come up during the testing process?
Challenges can include:
- Calibration issues with the equipment leading to inaccurate readings
- Misalignment of the core or tube in the testing apparatus, causing uneven load distribution
- Quality Control and Improvements
Customer Satisfaction
- How does the Radial crush test help in maintaining the overall quality of the final product?
The test ensures that the product can withstand the stresses it will face during actual use, thereby maintaining customer satisfaction and reducing complaints or returns. It also helps prevent product failures that could damage equipment or disrupt processes downstream.
Test Improvement
- Have there been any recent improvements or innovations in the way the Radial crush test is conducted?
Advanced data analysis software that allows for better interpretation of results and real-time feedback for process adjustments
Reinforced Material
- How do you handle a failure in the Radial crush test? Is there a rework process, or do you scrap the parts?
Handling failures depends on the severity and type of failure. Minor issues may allow for rework or adjustments, such as reinforcing the material or improving bonding in composite structures. Severe failures often result in scrapping the part to maintain quality standards.
Production Schedules
- Does the Radial crush test affect production schedules, and if so, how do you manage that?
Yes, it can impact production timelines, especially if failures occur. To manage this, manufacturers often build buffer times into their schedules or use parallel testing lines to minimise downtime. Implementing efficient testing protocols and rapid analysis helps keep timelines intact.
Product Strength
- How do the results of the Radial crush test feed into continuous improvements or adjustments in the manufacturing process?
Test results provide data that can be analysed to identify trends and potential issues in the production line. Continuous monitoring allows manufacturers to make proactive adjustments, such as altering material composition or modifying the production process to enhance product strength and consistency.
Identifying Issues
- Have there been any specific cases where the Radial crush test helped identify a major issue early on?
Yes, manufacturers have identified issues such as uneven material distribution, poor bonding, or defects that might have led to significant failures during usage. By catching these problems early, corrective actions were taken to adjust production processes, ultimately saving time, reducing waste, and ensuring product reliability.
So that’s the low-down on Radial crush testing and thanks to Ibrahim for the detailed explanation. If you have any queries on this or other quality assurance processes that Industrial Packaging implements, please do contact us.