Characterisation of sustainable materials for can making

Steel packaging is the product of choice for many food and beverage applications. Being recyclable, it is increasingly being seen as a replacement for plastic packaging and also plays a key role in reducing food waste allowing safe CO2 free storage for extended periods. It is a $900Bn industry working across supply chains from substrate supplier through can make to food filler producing 98 billion units a year in Europe alone.

There has been significant R&D activity within the partner organisations in order to overcome the twin questions brought about by the need to eliminate Chrome V1 and BPA (Bis-Phenol-A) from the can manufacturing process. Replacement materials must meet the same stringent performance requirements when subjected to the harsh cooking process where the cans must endure high pressure and chemical (foodstuff) attack at steam temperatures of greater than 1200 C. The project will examine how alternative materials and processing can be used to improve the performance of developmental materials during the can making and cooking process. Utilising a suite of engineering and scientific techniques, the complex interactions between the substrate surface, mechanical forming and exposure conditions will be explored.

The successful candidate will join a well-resourced research group in packaging materials, offering plenty of opportunity for peer learning as well as access to training on a wide range of engineering and high-end analytical equipment. Crown packaging provides the highest quality steel packaging for premier international brand owners in food, beverage and premium goods. Crown have the European R&D centre in Wantage Oxfordshire and there is ample opportunity to make use of their facilities as part of the project if required. TATA packaging has their R&D base in Ijmuiden, the Netherlands. There is opportunity for research work to be carried out in the Netherlands if required. Both partners are open to technical and scientific publications with numerous examples of past studies in the public domain.

The project offers the opportunity for an enthusiastic researcher to develop scientific insight and innovative technical solutions to important commercial and academic issues.

The aims of the project are:
- Develop an understanding of the interactions of the impact of the mechanical, chemical and thermal stress on packaging steel during retort.
- Develop novel test methods which can measure and simulate the can forming/ retort process and
- Quantify the impact of surface structure on product performance

Ideally, a solution will be developed where a feature/ device is added, can be added/printed to steel packaging which provides additional benefits for the consumer, brand owner, filler and packaging decorator.

The CDT will produce 50 graduates with doctoral level knowledge and research skills focussed on the development and manufacture of functional industrial coatings. Key impact areas are:

Knowledge
- The development of new products and processes to address real scientific challenges existing in industry and to transfer this knowledge into partnering companies. The CDT will enable rapid knowledge transfer between academia and industry due to the co-created projects and co-supervision.
- The creation of knowledge sharing network for partner companies created by the environment of the CDT.
- On average 2-3 publications per RE. Publications in high impact factor journals. The scientific scope of the CDT comprises a mixture of interdisciplinary areas and as such a breadth of knowledge can be generated through the CDT. Examples would include Photovoltaic coatings - Journal of Materials Chemistry A (IF 8.867) and Anti-corrosion Coatings - Corrosion Science (IF 5.245), Progress in Organic Coatings (IF 2.903)
- REs will disseminate knowledge at leading conferences e.g. Materials Research Society (MRS), Meetings of the Electrochemical Society, and through trade associations and Institutes representing the coatings sector.
- A bespoke training package on the formulation, function, use, degradation and end of life that will embed the latest research and will be available to industry partners for employees to attend as CPD and for other PGRs demonstrating added value from the CDT environment.

Wealth Creation
- Value added products and processes created through the CDT will generate benefits for Industrial partners and supply chains helping to build a productive nation.
- Employment of graduates into industry will transfer their knowledge and skills into businesses enabling innovation within these companies.
- Swansea University will support potential spin out companies where appropriate through its dedicated EU funded commercialisation project, Agor IP.

Environment and society
- Functionalised surfaces can potentially improve human health through anti-microbial surfaces for health care infrastructure and treatment of water using photocatalytic coatings.
- Functionalised energy generation coatings will contribute towards national strategies regarding clean and secure energy.
- Responsible research and innovation is an overarching theme of the CDT with materials sustainability, ethics, energy and end of life considered throughout the development of new coatings and processes. Thus, REs will be trained to approach all future problems with this mind set.
- Outreach is a critical element of the training programme (for example, a module delivered by the Ri on public engagement) and our REs will have skills that enable the dissemination of their knowledge to wide audiences thus generating interest in science and engineering and the benefits that investments can bring.

People
- Highly employable doctoral gradates with a holistic knowledge of functional coatings manufacture who can make an immediate impact in industry or academia.
- The REs will have transferable skills that are pertinent across multiple sectors.
- The CDT will develop ethically aware engineers with sustainability embed throughout their training
- The promotion of equality, diversity and inclusivity within our cohorts through CDT and University wide initiatives.
- The development of alumni networks to grow new opportunities for our CDT and provide REs with mentors.