Other Catalogs
Connect to CPS
CPS Blog

Monday, August 23, 2010

Plastisol Liners: The Sound of Safety

If you have ever opened up a glass jar with a metal lid, you might have noticed a gratifying "schlurrr-pop" sound (yep, that’s the technical term). I love this sound because it reassures me that I’m the first to open this container since it left the manufacturer. It means that I don’t have to worry whether or not the driver, shelf-stocking boy, or Suzie-Test-Before-Buying has opened my container and put their fingers or other things in my food.

So, the reason for this post, other than my affection for tamper evident solutions, is to talk about Plastisol liners. Plastisol liners are one method that helps seal metal closures onto containers. Plastisol is a PVC gasket that is used in metal continuous thread and lug (sometimes called twist) closures. It is normally applied to metal lids in a ring shape on the inside of the lid at the point where it will match up with the landing of the bottle.


Plastisol material starts out as a solid. After being heated properly, Plastisol becomes liquidus and forms around the landing of the container that is being sealed. When the material cools it begins to cure, or solidifies, which then creates a tight vacuum seal that produces those comforting sounds mentioned earlier.

Now that we have established a solid foundation of knowledge in Plastisol, it would be good to discuss when it is appropriate to use this sealing method. The key temperature for Plastisol is 212° F. Plastisol can be used to seal glass containers that are hot filled up to 212° F or go through a pasteurization process up to 212° F for 1 hour. It is recommended that Plastisol Liners not be used in home pressure canning processes since the temperature goes well above 212° F, and can distort the Plastisol, and make it ineffective. The correct liner to use in pressure canning is a Retort Plastisol liner, which can resist higher temperatures.

As always, it is highly recommended that you test your product and process with this liner before purchasing a larger amount. This will provide you with the ease of mind that your product is safe and your customers—be it the general public, or grandson Billy—will know this as well.
Posted by Stephen Post at 10:50 AM
Labels: , , ,

50 comments:

  2. The Plastisol Liners that are used in the lids that we stock have two coats. The primer coat does contain Bisphenol A (BPA) but is covered by a topcoat that does not contain BPA. So the revolutionary product that you are selling will not come in contact with the BPA material in the Plastisol Liner. More reassurance that your product is safe.
    ReplyDelete
  3. I'd also like to add that standard home canning hot bathing processes with plastisol work just fine. So your pickles, tomatoes, canned peaches, applesauce, jams, jellies, and so on that you hot bath will work just fine with these plastisol lids. Oh, and if you're shopping for plastisol lids, here's our list of plastisol right here: http://www.containerandpackaging.com/SiteSearch.asp?Search=Plastisol
    ReplyDelete
  4. so when the plastic is being heated overtop of your food...some of that heated plastic would leach downward into your food, correct? An airtight seal with plastic vapor in there sounds inevitable.
    ReplyDelete
  5. Hi Tyler. Thanks for your comment. That's a good question, and not being a scientist, I don't know that I can accurately answer the question. I suppose that an airtight seal could trap plastic vapors. However, the plastisol can take quite a bit of heat before it would begin to break apart. Plastisol, when heated become liquidous ... which means that it still remains completely intact and bonded to itself. It doesn't sweat or leach; it becomes softer so that as the bottle of food cools it creates a vacuum inside the bottle and pulls the softened plastisol tight against the landing of the bottle. As the plastisol cools it also hardens. Vapors, perhaps. Leaching, unlikely.
    ReplyDelete
  6. I'm with Keith, I have read a little on this before and have come up with the same information.
    The Plastisol shouldn't leak any or break into pieces under normal heating and cooling.
    ReplyDelete
  7. I am looking to bottle my owe barbeque sauce what would be the right method to sell.
    ReplyDelete
  8. Dear Anonymous Barbeque Saucer,

    I'm not sure exactly what you mean by "method to sell." But I think that you would want to (1) pick a container (http://www.containerandpackaging.com/itemlist.asp?itemtype=Sauces-Syrups), (2) select a lid to go with it, (3) hire a designer (we have design on staff, 1-800-473-4144), (4) get it decorated, and (5) start selling it. You could sell it online, in grocery stores, at farmer's markets or at the fair.
    ReplyDelete
  9. Thank you for the information. I am curious what the actual detailed proper suggested heating process is. Is it enough to just heat the lids to 212 degrees and then cover jar and wait to cool and seal?
    ReplyDelete
  10. Hi Viva ... I am not a master canner. I have done some canning, and I the process you have suggested is the proper way to go about getting the lid to seal (it's also how I have done it). Most of the plastisol lids have a "button" that gets pulled down, letting you know that a vacuum seal has been achieved.
    ReplyDelete
  11. I am doing the exact same thing and seeking a safe way to seal a dry bbq spice rub. So you are saying to put the product into your selected bottle, then screw on a cap that has been heated to 212 degrees (in the oven I'm assuming for control of temp?) and then screw the warm cap over your filled jar? Did I understand you correctly? I am trying to wholesale my product and want to do it by the book but will be doing my own packaging since my start up quantity will be small batches done in a rented commercial kitchen.
    ReplyDelete
  12. Hi Anonymous ... excellent question. I don't know that using a plastisol lid for a dry bbq spice rub product would work. It might, but you'd definitely want to test it. The plastisol lid has a button that gets pulled down, and that usually only happens as the product inside the container cools. I'm not sure, but I think that the moisture inherent to jams, jellies, fruits, and other liquid products is critical to getting that vacuum seal.

    Would packaging your product like a spice work? For example, putting your dry rub product in a container, using a heat induction sea liner and then maybe using a shrink band on the lid? If your dry product can sit out in the open air for an extended period of time, this might be the option to go. Another idea would be to use a heavy ml bag and melt-seal the opening ...
    ReplyDelete
  13. Hi. I make and sell small batch jams, jellies, sauces, condiments and pickles. Currently, I use various home methods and would like to use these lids. Can you tell me if 1. there is any regulation against this 2. what other way can I do this?
    thank you for your help!
    Kelli Hanley
    Hanley Homegrown
    ReplyDelete
  14. So if I am making a homemade corn salsa I can just put those plastisol lids in a hot water bath that heats up the lid to 212 degrees? Do my ingredients in the jar have to be hot?
    ReplyDelete
  15. I'm not a master canner, but yes, I believe the ingredients need to be a wet product and they need to be hot bathed. The lid vacuum seals as bottled product cools. I BELIEVE the process would be to (1) fill your jar (2) clean the lid mouth/landing, (3) put a plastisol cap on the jar (that has been boiled for several minutes), and then (4) hot bath the entire jar/ingredients/lid combination and finally, (5) set it out to cool. As it cools, the plastisol lid button should depress, showing you have a vacuum seal.
    ReplyDelete
  16. Hi Kelli, these plastisol lids are just like the standard/traditional lid and ring combo you probably use for homecanning. The only difference really is that the ring is built into the lid. I don't know of any regulations, but you would probably want to do some research or take a walk down the grocery aisle and see what they're doing there. Also, I would ALWAYS test the lid first. (1) Make sure that it works, (2) compare it to your traditional lid and method, (3) compare the process: does it take longer for you to use the new lid or the lid you've been using.
    ReplyDelete
  17. Hello, everyone I am making blueberry jam as a favor for my daughters baby shower, I have read up a lot, but my one question is once you sterilize both jar and tops put the hot liquid in the jar, clean the top, place the lid on and bath in 212 degree boiling water but, for how long? How long do I bath it for?
    ReplyDelete
  18. Dear blueberry-jam-anonymous maker,

    If you fill the jars with jam that has been boiled long enough to be ready to be preserved (please refer to recipe) and then put the plastisol lid on immediately after it's filled (while the jam is still hot) the plastisol lid should create a vacuum seal as the jam cools. You'll want to test it though to make sure. Hot bathing may not be necessary. Of course ... be sure to test it, you always want to test it before you commit to an entire batch.
    ReplyDelete
  19. Not all plastisol jars have that button on top. Any suggestions for those Keith???

    Thanks
    ReplyDelete
  20. Blueberry jam maker... if you boil the lids, you will lose the plastisol seal.. don't boil the lids!!!! Tell her that keith!
    ReplyDelete
  21. Thanks Anonymous. Yes, don't boil the plastisol lids ... you can boil the disc/ring ones because these have a rubber material which is more tolerant to those higher temperatures. You just want to put the plastisol lid on the container when it's hot and its contents are hot. It will seal as the jar/contents cool.
    ReplyDelete
  22. True ... not all plastisol lids have the button on the top. You'll know if the top of the lid is firm. If you press on it (as if a button were there) and it is firm--as opposed to flexible, then you'll know that you've got a vacuum seal.
    ReplyDelete
  23. Do the Foodsaver Ball&Kerr lid sealers work also on plastisol lids for vacuum storage of dry goods?
    ReplyDelete
  24. Hi Anonymous, you raise an interesting question. I'm not sure that a plastisol lid would be your best closure option for storing dry goods. Keith made this point in an above comment, "I think that the moisture inherent to jams, jellies, fruits, and other liquid products is critical to getting that vacuum seal" and I agree. Plastisol liners work best when sealing a liquid based product.

    I don't know a lot about Ball & Kerr lid sealers,those may work, but I would also recommend looking through our food storage containers (http://www.containerandpackaging.com/FoodStorage/foodstorage.asp)to get some ideas as well. Let us know if you have any other questions.
    ReplyDelete
  25. okay, a little confusing and mixed messages. In one post it is stated :
    Keith McCauley said...
    I'm not a master canner, but yes, I believe the ingredients need to be a wet product and they need to be hot bathed. The lid vacuum seals as bottled product cools. I BELIEVE the process would be to (1) fill your jar (2) clean the lid mouth/landing, (3) put a plastisol cap on the jar (that has been boiled for several minutes), and then (4) hot bath the entire jar/ingredients/lid combination and finally, (5) set it out to cool. As it cools, the plastisol lid button should depress, showing you have a vacuum seal

    Then:
    Keith McCauley said...
    Thanks Anonymous. Yes, don't boil the plastisol lids ... you can boil the disc/ring ones because these have a rubber material which is more tolerant to those higher temperatures. You just want to put the plastisol lid on the container when it's hot and its contents are hot. It will seal as the jar/contents cool.

    So how do we sterilize the plastisol lids prior to canning, and can they "boiled" while canning things needing a hot water bath?
    Thanks
    ReplyDelete
  26. Hi Anonymous,
    Thanks for the comment. We appreciate the opportunity to clear up any misunderstandings communicated through the blog.

    To answer your first question, we recommend lids to be cleaned with soap and warm water to be sterilized.

    This article states that, "Plastisol can be used to seal glass containers that are hot filled up to 212° F". This means this type of lid should not be boiled. Other non-plastisol canning lids (those equipped with a rubber disc/ring, capable of enduring high temperatures)are suitable for boiling. Let us know if you have any other questions.
    ReplyDelete
  27. I am confused. Isn't 212 degrees F the boiling point of water? So can't these lids be attached to the jar of hot jam/jellies/sauces and be water bathed?
    ReplyDelete
  28. Hi Jen, You are correct,212° F is the boiling point of water. Plastisol lined closures can be attached to containers filled with hot fill products and can be processed in a water bath, the same way a two-piece canning lid works. The above comment references boiling the plastisol lids alone, before being placed on filled containers, which we do not recommend.
    ReplyDelete
  29. Hi I have a seasoning company, and they told me these plastisol lids with the pop button would be best to lower my ph level, my question is my product is an all natural spanish seasoning mix of all type of vegetables and stuff, Can I just heat the plastisol lined caps in the oven or boil water and put the lined caps in there then add the caps to the respectful jar and close em, will this create the tight vacuum sealing Im looking?
    ReplyDelete
  30. Hi Anonymous, thanks for your comment. Plastisol lids are very useful closures, but it may not be the best option for you, for a few reasons.

    First, this closure will not change the pH level of your product. Some plastisol lids are equipped with a pop button and can create a vacuum seal, when paired with a glass container.

    What kind of container do you use to package your seasoning? Take a look at our spice containers and matching closures here - http://www.containerandpackaging.com/itemlist.asp?itemtype=Spice_Bottles. These bottles may be better options for your product. If you were looking for the vacuum seal for tamper-evident purposes you might consider using a shrink band to protect your product instead. We're happy to help, so give us a call at 1-800-473-4144 if you need any assistance.
    ReplyDelete
  31. This Blog was very helpful, I'm going to be canning a large batch of homemade salsa tonight and I use the two piece lids from "Ball" in the past but have a set of 6oz sample jars and plastisol lids to try. I'm used to boiling the two piece lids first, putting the cooked/heated salsa in the jars, putting the lids on and then hot bathing the product for about 30 minutes to help create the vacuum seal. Seems to work pretty good but I'm glad the comments about boiling the Plastisol seals alone is not needed just pour my heated product into the jars, add the plastisol lid, water boil the filled & sealed jars for 30 minutes and set out to cool down and seal. Very helpfull and would have probably did this the other way around if I didn't research and read this blog so thank you.
    ReplyDelete
  32. Hi Doug, I'm glad our conversation on plastisol liners was available to help guide your canning process. If you're interested, check out our "Food and Water Storage" tag for additional posts on canning. Thanks for commenting and be sure to let us know what you think of the plastisol lids!
    ReplyDelete
  33. Keith and everyone,
    Thanks a TON for all of the info on plastisol lids. I use them for my small jam business and understand better now how the lids work. Appreciate it!
    ReplyDelete
  34. Hi,

    I want to give out samples of my home made barbecue sauce (high acidity) as baby shower favors. I was thinking in choosing a small container less than 6 oz. I wanted to know if there is a way of safely "canning" by the boiling water method into a plastic bottle similar to commercial bbq sauces. Also, is there a cap other than plastisol that is able to create a vacuum seal? If glass is my only option I was considering the 5 oz glass (http://www.containerandpackaging.com/item.asp?item=G330) but there is only a PP lid available for that size of bottle. Would that type of lid work too? Thanks.
    ReplyDelete
  35. Hi Sue, we're glad this post on plastisol has helped you! Visit the blog often for new informative articles. You might also be interested in a recent post on fruit spreads (http://blog.containerandpackaging.com/2011/05/canning-101-fruit-spreads.html), since you're a jammer! Best of luck with your business!
    ReplyDelete
  36. Hi Gustavo,

    Thanks for your question. First off, it is very important to follow approved recipes when canning food. In the case of your home made barbecue sauce, I would compare your recipe to an approved source like the Ball Blue Book Guide to Preserving. Always follow the safety approved recipe when canning food.

    Secondly, using plastic bottles for any kind of canning is highly discouraged and dangerous. Only use glass containers of approved capacity. For instance, a canned barbecue sauce typically yields half-pints (8 oz) or pints (16 oz) of product, which means you should only use glass containers of those sizes. Also, only pair your canning jar with a plastisol or two-piece canning lid. Other closures are not capable of achieving a vacuum seal.

    To wrap up, err on the side of caution. Follow approved recipes, use glass containers of approved capacity and appropriate vacuum seal closures. Thanks for reading and good luck with your barbecue favors!
    ReplyDelete
  37. I would like to know how to properly seal the plastisol lined caps on to glass jars so that the seal properly does its job?
    ReplyDelete
  38. Hi dblonsky,
    Thanks for your question.
    If you are boiling-water canning food place the lids on your hot filled jars before processing. Later, when the jars cool the lid will seal.
    If you're not canning, the product that you are packaging must be liquid and at a hot temperature in order for the plastisol lids to work. The heat will enable the lid to seal to the glass container. Thanks for reading and let us know if you have any other questions!
    ReplyDelete
  39. Thanks for the information here. I have just started using the plastisol lids for the first time. Made my boyesenberry jam, placed hot jam in jar and waterbathed for 10 minutes. I did boil the lids first and tighten down as hard as I could. I see boiling the lid was mistake # one. When I opened a jar this morning it opened very easily and there was no "schlurrr-pop" sound. I made 5 jars and 3 seem to be firm and one other is still flexible.

    Can you give some instructions on how tight the lids need to be when you put them on. Even though the recipe calls for 10 waterbath is that long enough to seal the jar?

    If a jar has not sealed properly can it be re-sealed. When this happens with regaular Ball jars you can re-seal within 24 hours by applying a new lid and waterbath again. Is it the same for plastisol?

    Thanks for oyour help.
    ReplyDelete
  40. Hi Anonymous,

    Unfortunately, there is not a precise science to using plastisol lids. But here are a few suggestions for you.

    First off, do not boil the plastisol lids. You mentioned that you thought this may have been a source of your problems, and I agree. The lids do not need to be preheated.

    I cannot be positive, but I'm guessing you boiled out the entire plastisol liner when heating up the two lids that didn't seal to your jam jars. Since this is the case I would not recommend re-processing your jam, it wouldn't make a difference.

    Secondly, no suggested "tightness" standard exists for using plastisol lids. Like typical canning rings, they should be applied firmly, but not so tight that they are extremely difficult to open later.

    And lastly, always follow your processing instructions. It isn't so much the heating (processing) time that is important to achieve a plastisol vacuum seal, but the cooling time, which takes place following processing. When your hear the lids "pop" during cooling, you know the vacuum seal has been created.

    Hopefully things will work better for you next time. Thanks for reading and submitting your question. Comment anytime!
    ReplyDelete
  41. Hi,
    Is there a plastisol lid that fits regular mouth and wide mouth canning jars?
    Also, I want to bottle grape juice in used Knudsen Juice glass jars that take a size 48 lid. Would the plastisol lids be the best option for that?
    Are the plastisol lids re-usable with re-heating?
    Thanks!
    Wade
    ReplyDelete
  42. Hi Wade,
    The key is to match the neck finish size of the canning jar with a plastisol lid of the same size. Here's a link to all of our plastisol lids: http://www.containerandpackaging.com/itemlist.asp?itemtype=Metal_Lids. We do have a few 48TW options. If you need help finding the right closure size give us a call (1-800-473-4144)and we'll help you place a sample order of different sized lids.

    Also, you can use plastisol closures when bottling grape juice but the plastisol liner is single use, it cannot be reheated or reused.

    Thanks for commenting! Please let us know if you have any other questions.
    ReplyDelete
  43. Will bleach sterilzation damage the plastisol lid? I soak the glass jar and lids in water/bleach mix (4:1) then rinse with sterile water to remove bleach. Thoughts.
    ReplyDelete
  44. Hi Anonymous,

    That's a great question. We typically recommend that customers sterilize lids in hot water only, and since CPS does not practice product testing in different solutions I cannot be sure as to how bleach might interact with the liner.

    In such a limited amount, I (and our plastisol lid manufacturer)don't think the bleach will damage the plastisol liner, but I would suggest running a test batch with a few lids in the bleach solution before using your entire stock.

    Thanks for the comment and let us know if you have any other questions!
    ReplyDelete
  45. Hi,
    I have a raw food that can not be heated. I just bought a lot of plastisol lids with jars from your company (recommended by CAP rep). How can I only heat the lid for a tight seal and not compromise my food. Are there any other heat sealing methods for the plastisol lids or do I just screw them on and not use have them "sealed"?
    ReplyDelete
  46. Hi Anonymous,
    First off, thanks for trying our plastisol lids! What kind of food are you packaging? Are you canning this food? If so, here are some insights about canning with plastisol closures.

    Heat is required to ensure a plastisol closure's airtight seal, as you explained above. The lids retrieve heat from the food product they're packaging, they should not be heated via other means.

    Boiling water should be used in raw pack canning. According to food safety guidelines, even though your food product is not cooked, boiling water should be added to prevent risks of food spoilage. The moisture and heat of the product should enable the plastisol lid to work.

    Plastisol will perform differently in various situations. The key is to test and see what works for your product, but keep in mind that heat is essential.

    Write back with any other questions. Thanks for your business!
    ReplyDelete
  47. Hi Kayla,
    My company wants to send an electrode (imagine shipping an i-phone) overseas inside a jar. We have been having problem with the electrode that got shipped, which might be caused by the pressure difference while inside the airplane. We want to make sure that the jar is vacuum. Notice that we are shipping a dry component. Will this product work in sealing the jar? If yes, how to do this, since we DO NOT want to wet the electrode component inside the glass jar.
    ReplyDelete
  48. Hi Anonymous,

    Unfortunately, I don't think a plastisol lid is the right packaging solution for you.

    This type of closure requires heat and must be paired with a glass jar in order to create the seal that you are after. I think a glass jar will be too fragile to contain your product during travel.

    Feel free to give us a call at 1-800-473-4144. If you tell us a bit more about your product and what you're looking for we'll do our best to find the right packaging for you.
    ReplyDelete
  49. Hi Kayla,
    How do I boil in raw pack canning. It is a raw dip I'm canning. Can I just boil the lids and place on the jar?
    ReplyDelete
  50. Hi Anonymous,

    Thanks for the post. That's a great question. We have a post completely dedicated to canning (http://blog.containerandpackaging.com/2011/05/canning-101-high-acid-foods.html). That post will explain how to can using the raw pack method.

    In short, you firmly fill the jars with cold, unheated food then top it off with food juice, water or syrup at a boiling hot temperature. That's how the closure gets the heat it needs in order to seal.

    I'm not sure if the additional juice or water would damage your dip, but those are the food safety approved directions for raw pack canning. You may want to research methods of raw canning products similar to your own.

    We don't recommend boiling the lids because it may cause the plastisol liner to separate from the closure, leaving them unable to create a seal.

    Does that answer your question? Be sure to write back if you have any others!
    ReplyDelete

Subscribe to: Post Comments (Atom)
Loading