The occurrence of deformation in plastic bottles is a common problem in the bottling industry where bottles are blow molded, hot filled at high temperatures and sealed. Plastics have unique properties that make it difficult to predict when and why such changes may occur. The root cause of such deformation is unknown by many bottle producers and recent attempts have been made to minimize the occurrence of such defects. The purpose of this research is to determine which variables involved in the bottle production process influence bottle shape. Earlier variables that were tested included both blow molding resin and total bottle sidewall thickness. The result of changing these variables did not create a decrease in defects. The use of an Ishikawa fishbone diagram identified hot filling temperature a major variable that influences final bottle shape. This research summarizes the results of a series of tests that were developed to observe the effect of hot filling temperature on final bottle shape. A positive correlation between sidewall deflection and liquid hot filling temperature was observed. A series of tensile tests were also developed to analyze the strength of various regions of a blow molded bottle. An early Pareto Analysis determined that the parting line is more susceptible to defects than any other region of the bottle. This weakness was confirmed after the tensile tests proved that there is a statistically significant difference between measurements on the sidewall and parting line (pvalue < .001). The results of this thesis highlight the consequences of arbitrarily choosing a filling temperature with little understanding of the bottle's strength at high temperatures. Plastic bottle producers and hot filling companies should unite to determine the appropriate hot filling temperature before bottles are molded and filled.

The effect of various inorganic and organic additives as possible nucleating agents on the crystallisation behaviour of P. E. T. and the suosequent influence on the morphological and mechanical properties has been examined. Various methods of mixing(: the polymer and additive were investigated and a method involving the screw-Extrusion of the polymer and the additive was ultimately adopted. Crystallisation studies were carried out using differential scanning calorimetry under dynamic and isothermal modes. The results produced under conditions of isothermal crystallisation were analysed by means of a computer. Despite differences between batches of polymer all the additives with the exception of indigo produced a nucleating effect in the polymer as indicated by an increase in the rate of crystallisation compared with that of the base polymer. Two organo-metallic substances (sodium benzoate and sodium stearate) proved to be the most effective in this respect by decreasing the degree of supercooling of the polymer by 20 [degrees]. Morphological studies were carried out on isothermally crystallised samples, after etching and replication using a transmission electron microscope. A nodular structure whose dimensions were sensitive to both the nucleating agent and the temperature of crystallisation was observed. Mechanical testing of samples direct from the D. S. C. was carried out using a compression method. The breaking loads were found to vary with both the type of nucleating agent used and the crystallisation temperature chosen. A separate study involving the exanination of the resulting fracture surfaces by scanning electron microscopy revealed that a, high breaking load was associated with a fine discontinuous structure whereas lower breaking loads were characterised by a more continuous linear appearance. This implies a higher energy of fracture due to the increased surface area of the fracture surface of the former.

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