QCS-006 Final Inspection of Foil
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PURPOSE
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To define the step-by-step evaluation, testing, and approval process for coated aluminium foil, to prevent defective material from being released for packaging or customer use.
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SCOPE
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This SOP is applicable to the Conversion Department.
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REFERENCE(S) & ATTACHMENTS
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References
- ISO 15378:2017
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Attachments
- Attachment- I : In-Process Quality Formats (see List of Formats - QC Conversion, Annexure)
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RESPONSIBILITY
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Production Head:
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To ensure the training of the SOP to all concerned department personnel involved in implementation of the SOP.
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To ensure the implementation of the SOP after training.
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Quality Assurance Person:
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To check the SOP.
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To maintain the original copy of the SOP.
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To issue controlled copy of the SOP.
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To maintain issuance record of SOP.
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To retrieve the controlled copy of the SOP when it is superseded/obsolete and maintain its record.
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QA Head:
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To approve new or revised SOP.
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To ensure the implementation of the defined system.
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Plant Head:
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To approve new or revised SOP.
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To ensure the implementation of the defined system.
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DISTRIBUTION
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Quality Control
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Production
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Quality Assurance
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DEFINITION(S) & ABBREVIATION(S)
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Definitions
- Nil
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Abbreviations
- GSM: Grams per Square Metre
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PROCEDURE
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Required Equipment & Materials:
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Digital/dial thickness gauge
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Calibrated steel scale or measuring tape
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Acetone and clean cotton swabs
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Analytical weighing balance
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Standard approved specimen/shade card
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Standard template (10 cm x 10 cm)
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Inspection Checkpoints:
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Visual & Physical Examination:
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1 Appearance: Unroll 1 to 3 metres of foil and visually check under daylight for cracks, pinholes, wrinkles, creases, and foreign particles. Edges must be smooth without dents.
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2 Dimensions: Use a calibrated scale to measure reel width and length against the specified Purchase Order (PO).
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3 Thickness & Grammage: Cut a 10 x 10 cm² piece of foil, weigh it on an analytical balance, and calculate thickness/grammage using the approved formula. To determine the coating GSM separately, remove the heat seal lacquer by rubbing with a cotton swab soaked in ethyl acetate to obtain the base foil GSM, then calculate: Combined GSM − Foil GSM = Coating GSM.
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4 Print Inspection: Verify colours, layout, and text against the approved shade card. The printing must be legible and clear.
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Coating & Lacquer Tests:
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Heat Seal Lacquer (HSL) Detection: Heat a copper wire in a Bunsen burner flame until red hot. Touch it to the coated side of the foil; if it leaves a residue/stickiness, the lacquer is properly present.
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VMCH Coating Test: Apply acetone to a finger and touch the reverse side of the foil (unprinted/unlaminated side). The foil will stick slightly to the finger if the VMCH coating is properly applied.
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Laminated Material Check Points:
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Visual inspection
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Peel strength / bond strength test
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GSM checking
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Thickness measurement
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Width measurement
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Bursting strength
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Heat seal test and its strength
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Ink adhesion test — plain and printed laminate
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Packaging & Labelling:
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Verify the foil rolls are properly wrapped in a polythene bag inside a corrugated/wooden box.
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Check the external labels for batch number, manufacturing date, product description, and net weight.
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Acceptance Quality Level (AQL):
- Follow the standard sampling plan; each and every roll shall be checked to determine acceptable batch sizes and identify non-conforming items.
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Documentation & Release:
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Record all observations, measurements, and test results in the approved Raw Data Sheet (RDS).
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If all parameters pass, the Quality Assurance (QA) Inspector and Manager shall sign the Certificate of Analysis (CoA) and issue a Release Tag.
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If the material fails, immediately place a REJECTED tag on the reels and move them to the rejected area.
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REVISION HISTORY
+----------------+----------------+----------------+----------------+----------------+----------------+ | Revision No. | 00 | Effective | | CC No. | | | | | Date | | | | +----------------+----------------+----------------+----------------+----------------+----------------+ | Details of revision: New SOP | +-----------------------------------------------------------------------------------------------------+
Attachment- I : List of Formats - QC Conversion
Sr. Format No. Format Description Type Size No. (mm)
1 SIPL/QCS/006/F01/00 In-Process Quality Inspection - Register A4 Rewinder Machine
2 SIPL/QCS/006/F02/00 In-Process Quality Inspection - Register A4 Rolling Mill
3 SIPL/QCS/006/F03/00 In-Process Quality Inspection - Register A4 Separator
4 SIPL/QCS/006/F04/00 In-Process Quality Inspection - Register A4 Annealing Furnace
5 SIPL/QCS/006/F05/00 In-Process Quality Inspection - Register A4 Coating
6 SIPL/QCS/006/F06/00 In-Process Quality Inspection - Register A4 Lamination
7 SIPL/QCS/006/F07/00 In-Process Quality Inspection - Register A4 Slitting
8 SIPL/QCS/006/F08/00 In-Process Quality Inspection - Soft Copy A4 Rolling Oil
9 SIPL/QCS/006/F09/00 In-Process Quality Inspection - Register A4 Foil Stock