Geometric optimization and thickness reduction of metal packaging for the transportation of dangerous goods: A new design paradigm

• Danregous substances need proper package • Packaging needs to follow strict rules • Thickness reduction can save natural resources • Changing thickness needs numerical and laboratorial validation • Package thickness was successfully reduced based on numerical and experimental • New geometries for the package top was successfully tested • A new more sustainable package was designed • Methodology can be used for other similar situations Reducing raw material consumption in packaging manufacturing offers a range of undeniable advantages. First, packaging becomes more competitive, enabling lower sales prices. Transportation becomes easier due to reduced weight, while simultaneously mitigating environmental impact. Therefore, reducing the thickness of tinplate packaging becomes an attractive project for packaging companies. UN packaging, certified for the transport of dangerous goods, is subject to rigorous approval tests to ensure environmental and social safety during transportation. Optimizing the geometry of the packaging and its closure system is imperative. Therefore, the main goal of this work is to optimize packaging designed for the transport of dangerous goods, particularly paints, in accordance with ADR 2019, because there is a real gap in studies addressing this specific problem, generating extra motivation to develop this work. Through the execution of experimental tests, the current condition of the packaging was characterized, thereby facilitating the identification of its critical failure points. The proposed improvement solutions were based on quality tools, namely the Ishikawa Diagram. Additionally, benchmarking was conducted, and to complement the quality approach, numerical analysis using ABAQUS CAE® software was employed. Validation of the study was completed with the manufacture of prototypes incorporating different solutions for the packaging's flange and top. The tests demonstrated a significant improvement in strength and ease of opening for the end customer. The synergistic combination of these optimized solutions resulted in an overall improvement and the validation of more sustainable and robust packaging.