← EXPLODED VIEWL01
MATERIAL-LAYER TECHNICAL DOSSIER
Water Interface
The true boundary between product and package, where heat, mass and migrating species are exchanged.
PRE-INDUSTRIAL R2FOOD-CONTACT BOUNDARY
01 · PRINCIPLE & RATIONALE
Intended function
and associated requirement.
The true boundary between product and package, where heat, mass and migrating species are exchanged.
Separating this interface prevents coupon performance from being confused with the behaviour of a complete package in real water contact.
The interface governs wetting, adsorption, organoleptic properties, overall and specific migration, NIAS and thermal kinetics.
02 · TECHNOLOGY STACK
Technologies, roles
and approval gates.
Material and process qualification
- Role
- Converts the design basis into a repeatable specification.
- Why
- Performance depends on the real commercial grade and process window.
- Approval gate
- Documented test evidence and approved specification.
03 · ARCHITECTURE
Function, material
and interfaces.
The inner surface must remain continuous, cleanable, drainable and compatible with filling, closing and shelf life.
- Packaged water
- Primary wall L02
- Filling process
- Closure system
- 01Continuous surface
- 02Controlled surface-to-volume ratio
- 03No undrainable pockets
- 04Protocol covering simulants and real water
04 · MASTER PARAMETER REGISTER
Everything to be defined,
measured or certified.
A field without evidence is never filled with an invented number: it remains “To be determined”, together with the method required to close it. This is what makes the technical record verifiable.
DESIGN BASISTARGETCALCULATED / MEASUREDTO BE VALIDATEDCERTIFICATION REQUIRED
01Identification & function1 PARAMETERS
| ID | Parameter | Symbol | Value | Unit | Tolerance | Condition | Method | Status |
|---|---|---|---|---|---|---|---|---|
| L01-X001 | Intended use | USE | To be determined | — | To be defined | Full use cycle | Design review + user study | TO BE VALIDATED |
02Geometry & metrology1 PARAMETERS
| ID | Parameter | Symbol | Value | Unit | Tolerance | Condition | Method | Status |
|---|---|---|---|---|---|---|---|---|
| L01-X002 | Nominal mass | m | To be determined | g | To be defined | 23 °C / 50% RH | Balance 0.001 g | TO BE VALIDATED |
03Material1 PARAMETERS
| ID | Parameter | Symbol | Value | Unit | Tolerance | Condition | Method | Status |
|---|---|---|---|---|---|---|---|---|
| L01-X003 | Commercial grade and supplier | GRADE | To be determined | — | Qualified grade | Production lot | CoA + traceability | TO BE VALIDATED |
04Thermal properties1 PARAMETERS
| ID | Parameter | Symbol | Value | Unit | Tolerance | Condition | Method | Status |
|---|---|---|---|---|---|---|---|---|
| L01-X004 | Service-temperature range | Tservice | To be determined | °C | To be defined | Use and transport | Climate chamber | TO BE VALIDATED |
05Mechanical properties1 PARAMETERS
| ID | Parameter | Symbol | Value | Unit | Tolerance | Condition | Method | Status |
|---|---|---|---|---|---|---|---|---|
| L01-X005 | Drop resistance | Hdrop | To be determined | m | To be defined | Defined orientations | Instrumented drop test | TO BE VALIDATED |
06Quality control1 PARAMETERS
| ID | Parameter | Symbol | Value | Unit | Tolerance | Condition | Method | Status |
|---|---|---|---|---|---|---|---|---|
| L01-X006 | Process capability | Cpk | To be determined | — | Target to be defined | Critical CTQ | SPC ≥30 samples | TO BE VALIDATED |
07Food contact1 PARAMETERS
| ID | Parameter | Symbol | Value | Unit | Tolerance | Condition | Method | Status |
|---|---|---|---|---|---|---|---|---|
| L01-X007 | Overall and specific migration | MIG | To be determined | mg/kg | Applicable limits | Simulant/time/temperature | Accredited methods | TO BE VALIDATED |
08Recyclability1 PARAMETERS
| ID | Parameter | Symbol | Value | Unit | Tolerance | Condition | Method | Status |
|---|---|---|---|---|---|---|---|---|
| L01-X008 | Territory-specific end-of-life route | EOL | To be determined | — | Country/area defined | Complete assembly | Infrastructure mapping | TO BE VALIDATED |
05 · INDUSTRIALISATION
From material
to final inspection.
Qualified material
Packaged water / internal AQUA-PHA surface
Process within window
Wall formation + line conditioning and rinsing
Controlled interfaces
Packaged water · Primary wall L02 · Filling process · Closure system
CTQ + traceability
Control starts with resin, drying and processing, then continues through rinsing, filling, particulate inspection and lot traceability.
06 · DVP&R
A function is approved
only after passing its test.
| Test | Requirement | Risk | Method | Condition | Samples | Acceptance | Output |
|---|---|---|---|---|---|---|---|
| DVP-05 | Condensation management | Wet grip | Climate + gravimetry | 25 °C/60% RH; water 4 °C | 30 | ≥60% less retained water | Mass + images |
| DVP-06 | ThermoSnow | Incorrect threshold | Thermal/colour cycles | 0–25 °C | 30 | 8±2 °C; ≤15 s | ΔE/T curves |
| DVP-12 | Food contact | Migration/NIAS | Overall/specific migration | Cold-fill water use | 3 lots | Applicable regulatory compliance | Signed report |
07 · FAILURE MODES
Failure modes,
causes and controls.
Body brittleness
EffectBreakage/leak
CausePHA thermal window
ControlDSC/TGA, rheology, process DOE
Non-uniform walls
EffectBuckling/drop failure
CauseAsymmetric geometry
ControlBlow-moulding CAE + micro-CT
AeroSkin detachment
EffectLoss of function/loose part
CauseInsufficient seal
ControlPeel, thermal cycling and drop
08 · EVIDENCE POLICY
Traceability
for every parameter.
Adds no mass, but determines which additives and processes are acceptable in the complete system.
This page is the technical register for the R2 configuration. It separates design values, targets, calculations, measurements and certifications. Open fields identify the exact test or document required to close them.