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An Ultimate Guide to Top Score with Grade A+
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Definition of Packaging in a dictionary - ans"A protective unit for storing or shipping a commodity" (too limiting.) Definition of Packaging in a textbook - ans"Coordinated system of preparing goods for transport , distribution, storage, retailing and use of goods." (still doesn't cover it well) How the Clemson Packaging Program defines it - ans"It is a field that involves the use of materials, methods and machinery (3M,s) to develop and produce the packages that protect and preserve a product, help market the product and instruct the consumer in its proper use." Earliest packaging - ansConsider what life was like in ancient days Packaging provided simple function of containment Earliest packages were from natural sources (grass, seashells, wood) Notable developments in Ancient Man-made Packages 3000 B.C - ansEgyptians learn to blow and cast glass Notable developments in Ancient Man-made Packages 105 A.D - ansPaper was invented in China Notable developments in Ancient Man-made Packages c. 1500 - ansCork stopper used for wine bottles (First protective packaging) without you get "spontaneous generation"--- pasture bends flask Notable Developments During the Industrial Revolution 1809 - ansNicholas Appert- Canning process Notable Developments During the Industrial Revolution 1810 - ansPeter Durand- Develops "canister" Notable Developments During the Industrial Revolution 1868 - ansJohn Hyatt - patent for celluloid, leading to development of cellulose, first "plastic" Notable Developments During the Industrial Revolution c. 1895 - ansToothpaste first offered in tubes Notable Developments During the Industrial Revolution 1877 - ansQuaker oats first used the "Quaker man" to represent their product Notable Developments During the Industrial Revolution 1897 - ansFirst major use of paperboard for National Biscuit Company "Unedda" Biscuit product Notable Developments During the Industrial Revolution Late 1800's- early 1900's - ansFirst major use of graphics to sell product End of Industrial Revolution and around WWII - ansMovement from bulk packaging to retail packaging Illustrates how social changes interact with packaging developments End of Industrial Revolution and around WWII 1930 - anspolyethylene discovered in England, eventually one of the most commonly used packaging plastics (ziploc) Late 20th Century Packaging 1950's-60's - ansConvience and Brand expansion Late 20th Century Packaging 1970's - ansImprovements in distribution Late 20th Century Packaging 1980's - ansImprovements barrier films and microwave packages Late 20th Century Packaging 1990's - ansEnvironmental awareness and market globalization Late 20th Century Packaging 1954 - ansPolypropylene second most used packaging plastic Late 20th Century Packaging
An Ultimate Guide to Top Score with Grade A+
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1960 - 1970 - ansLaws clarified and improved Late 20th Century Packaging 1987 - ansNJ enacts the first statewide recycling law Late 20th Century Packaging 1990 - ansNutritional Labeling and Education Act Review of Timelines Earliest - ans(Unrecorded) Review of Timelines Ancient Man-made - ans(3000 B.C- 1500) Review of Timelines Industrial Revolution Developments - ans(1800's to early 1900's) Review of Timelines Late 20th Century - ans(Post WWII - present) Importance of packaging to society - ansEssential for us to have and get what we want Reduces waste In underdeveloped countries - ans50% of food produced never reaches consumers In U.S. - ansOnly 3% for Processed food and 10-15% for fresh is wasted Future Trends - ansAway from glass and metal toward plastics and composites Away from toward flexible and semi-rigid Metallized instead of foil laminates Tamper evident and anti-theft devices More informative ex.) OTC drug pkgs Convenience ex.) easy open/reseal Reduced packaging Incorporation of more recycled materials More technically complex packaging:breathable, temp. sensors, oxygen absorbers, holographic images Packaging Users/Producers - ansMost companies are either users or suppliers Some larger companies can be users and suppliers A raw material producer may also be a converter Packaging Functions Overview - ansContain Protect/ Preserve Inform/ Sell Provide convenience or utility of use Levels of Packaging Primary - ansPackage directly in contact with the product Ex. Cereal bag inside a box Levels of Packaging Secondary - ansPackage holding one or more primary package Ex. Box holding bagged cereal Levels of Packaging Tertiary - ansShipping or distribution package, "shippers" Ex. Corrugated box used to ship a number of cereal boxes Levels of Packaging Quaternary - ansUnit load Ex. Stretch wrapper pallet load of corrugated shipping containers Many Products do not require all four levels of packaging. - ansEx. Corrugated container holding a fridge can be a primary and tertiary at the same time. Ex. Deodorant sticks have primary package, no 2nd, but 3rd and 4th.
An Ultimate Guide to Top Score with Grade A+
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Wood contains - ans50% cellulose 30% lingin 20% carbohydrates Cellulose - ansStructure for paper and paperboard Lignin - ansBrown, Sticky substance Paper - ans0.012" thick Paperboard - ansGrater than .012" thick Thickness is referred to as "points" .001" = 1 Point Ex. 14 point paperboard = 0.014" Three ways to make pulp Mechanical - ansLeast expensive for 2 reasons Doesn't use chemicals Uses all of the wood Low brightness and strength Usually combined with other pulps Three ways to make pulp Chemical - ansKraft=Strength Sulfate (kraft)-- most widely used Sulfate Soda Higher quality than mechanical pulp Three ways to make pulp Semi-Chemical - ansCook wood in chemicals Grind in disc refiner Not used much except for corrugated media Paper making Machinery is large - ansSpeed: 3000 ft./min Web width: 30ft Production: 800 miles/ day Two types of paper making machines - ansFourdrinier- for paper or paperboard Cylinder- for paperboard only General procedure for both processes - ansScreen Squeeze Dry Calendaring - ansPaper runs through stacks of rollers Increases density and smoothness Important for strength and print quality Paper/ Paperboard Specifications - ansBasis Weight- lbs./sq. ft. Paper: lbs./ 3000 sq. ft. Paperboard: lbs./ 1000sq. ft. Thickness - ansMeasured and expressed in inches for paper Measured in inches but expressed as points for paperboard Ream = 500 sheets of paper Advantages - ansRenewable Recyclable Inexpensive Easily printed upon Disadvantages - ansPorous to moisture and oxygen Looses strength when wet
An Ultimate Guide to Top Score with Grade A+
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Combustible Paperboard - ansBending grade board
- Used for folding cartons Types of board
- Clay coated news back
- SBS Uses
- Cereal boxes, Cake mix boxes Variety of Design Styles - ansTube- Straight tuck, reverse tuck, seal end Tray- beers, bright wood, walker Hybrid- milk carton, ice cream Layout - ansCAD Die board Coordinate with graphics electronically Solid Fiberboard - ansSeveral plies of paperboard laminated together Uses (Distribution Packaging) Shipping containers Dividers Corner supports Corrugated Paperboard - ansBasic Construction Corrugated medium (flutes) A,B,C,E,F flutes Liner-board Comes in different basis weights Specified with burst or edge crush test Single face, single wall, double wall and triple wall Three important features - ansHeight of flute Distance between flute "peaks" Type of linerboard Design - ansCAD Specifications of Freight truck and Railroad Associations. Product requirements Shipping/storage/handeling conditions Must account for scoring allowances Flutes should be oriented parallel to depth dimension for best stacking strength Scoring allowances - ansAmount of material taken up in the fold (score) A,B,C flutes in double and triple wall - ansShipping boxes Point of Purchase display E and F flutes - ansRetail boxes for small appliances or bulky items Fast food packaging RSC - ansRegular slotted container ECT - ansEdge Crush Test Steel - ansNon-beverage cans in U.S. Beverage cans in Europe Drums, Strapping... etc.... Aluminum - ansBeverage cans Trays Foil (bare or laminated) Three piece can - ansRectangle formed into cylinder Seal side seam of cylinder
An Ultimate Guide to Top Score with Grade A+
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Furnace IS Machine (Individual Section Machine) Annealing Lehr Inspection Packing and Shipping How hot does the furnace get? - ans2700-3000F Glass- Two Forming Methods - ansIS Machines (Individual Section) Blow and Blow for narrow neck containers Press and Blow uses a plunger in the first step for wide mouth containers allows better control of glass distribution Steps in Bottle Formation - ansLoading- What is a gob? Settle Blow Counter BLow Inverasion Invert/Finish Mold Dwell/Reheat Blow head in Final Blow Takeout Glass- Annealing - ansPurpose of Annealing is to reduce internal stress Process of gradually heating containers 1050F and gradually reducing temp Improves strength of finished container Glass Advantages - ansAlmost completely inert to most products Absolute barrier to gasses and bacteria Transparent Perceived quality image Glass Disadvantages - ansBreakable Heavy Weight Energy Intensive Manufacturing Process Polymers Background - ansPackaging is the largest user of plastics 30% of total plastics "plastics"="polymers" Polymers History - ans1843 Maylasia Gutta Percha derived from latex of tropical trees (Getah-sap) (percha-strips of cloth) Used for knife handles and picture frames Polymers History: Alfred Critchlow - ansPro-phy-lac-tic Brush Co. dies and presses for shellac, straw pulp and gutta percha for buttons, checkers Polymers History: Civil War - ans$10,000 reward for substitute for ivory billiard balls. John Hyatt developed celluloid from cellulose, nitrate and camphor led to cellophane. Polymers History: Dr. Lea Backeland - ansPatented controlled reaction between phenoland formaldehyde. Resulted in Bakellte- First synthetic resin Polymers History: 1930 - ansPolyethylene first developed Nomenclature Film
An Ultimate Guide to Top Score with Grade A+
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Thickness terminology - ansFilm= less than or equal to .001" thick Thickness terminolog: Gauge, Mil, Inches .001'=1mil=100 gauge. Sheet= greater than 1 mil thick PE - ansPolyethylene- Available in different densities (LDPE, HDPE, LLDPE) used for bread bags to milk jugs. PP - ansPolypropylene- Strong, stiff, used for caps with hinges, "living hinges"---> wont stress crack PET - ansPolyethylene terapthiate----> polyester- used for carbonated beverage caps PVC - ansPolyvinyl chloride- used for fresh meat overwrap (bad oxygen barrier) PVDC - ansPolyvinylidene chloride- (trade-name- saran) used as barrier coating HDPE - ansless branching come in close contact LDPE - ansLots of branching, prevents close contact LLDPE - ansLost of branches but they're short, allow contact Density - ansAmount of molecules that can pack in a given space Yield - ansAmount of finished material (area) can be produced from raw material (lbs) Thermoset - ansWhen exposed to high temperatures, bonds are set, cant be unlocked. Thermoplastic - ansWhen exposed to high temperatures, bonds are loose and will form again upon cooling Plastic Processing - ansExtruder Slot die extrusion (cast film) Ring die extrusion (blown film) Orientation Co-extrusiojn Injection molding Blow molding Thermoforming Orientation - ansProcess of aligning molecules in the direction in which they are being pulled MD= Machine Direction CD= Cross Direction Biaxially oriented film- film that has been stretched "oriented" in MD and CD Important for shrink film- necessary for equal strength upon shrinkage MD - ansMachine Direction- created by casting rolls Pulled upward CD - ansCross Direction- Created by tenter frame As bubble expands CO-extrusion - ansUsed for films, sheets and bottles 5 - 7 layers are common Injection Molding - ansUsed for cups, caps, small tubes etc Parison - ansHollow tube which exits extruder and will be inflated into the final shape of a bottle Injection Blow Molding - ansTwo step expansion Preform- detailed finish and initial body formed, reheated and expanded to form bottle Injection Stretch Blow Molding - ansUses a pin and air to help stretch preform into the final bottle shape Extrusion Blow Mold Advantages: - ansRequires single mold Handle-ware readily produced Injection Blow Molding Disadvantages - ansRequires single two mold sets
An Ultimate Guide to Top Score with Grade A+
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Closure - Types and Uses Roll on - ansBeer, Soft Drinks Closure - Types and Uses Lug/ Interrupted Thread - ansJams & Jellys Closure - Types and Uses Press on - ansBaby Food Other Types of Closures - ansChild Resistant Tamper Evident Decorative or Product Identity Dispenser or Pump Style Semi Rigid Packaging Forms Paperboard - ansFolding cartons, backing for blister packages, pulp egg cartons and berry boxes Semi Rigid Packaging Forms Plastic - ansExtrusion Blow Molded Containers Injection Blow Molded Container Injection Stretch Blow Molded Containers Thermoformed Containers Semi Rigid Packaging Forms Metal - ansAluminum Foil containers Flexible Packaging Forms Paper - ansLabels, Bags Flexible Packaging Forms Plastic - ansCast and Blown Film Flexible Packaging Forms Metal - ansFoil Laminate and Metallized Films Flexible Packaging Forms Flexible Laminates - ansincludes Paper, Plastics, Foil and Metallized Purpose is to combine best properties, lowest cost Flexible Laminated Films Properties - ansStructural- Stiffness, Strength Barrier- Moisture, Gasses, Light Aesthetic- Metallic, Clarity, Feel Cost- Best performance at minimum cost Sealing- Heat seal, Cold Seal, Reseal Performance Properties - ansMachinability Coefficient of Friction (CoF) Body and Dead-fold Properties Tear Thermoforming Use Environment- Boil in bag, Microwave, Frozen Barrier Materials - ansMaterials Moisture Oxygen LDPE Fair Poor HDPE Excellent Poor EVOH Poor Excellent PVDC Excellent Excellent Nylon Poor Good PS Poor Poor
An Ultimate Guide to Top Score with Grade A+
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PET Fair Good OPP Good Poor CFR - ansCode of Federal Regulations FDCA - ansFood, Drug, and Cosmetic Act GRAS - ansGenerally Recognized As Safe PDP - ansPrinciple Display Panel OTC - ansOver The Counter RCRA - ansResource Conservation and Recovery Act VOC - ansVolatile Organic Corrosives SPI - ansSociety of Plastics Industry PMMI - ansPackaging Machinery and Manufacturers Institute CPM - ansContainers Per Minute SOP's - ansStandards of Practice Critical Acceleration is - ansthe tendency to break when subjected to shock of "G" force what is the idea behind cushioning material - ansTo spread deceleration over time A cushioning curve can be used to - ansdetermine the how a cushioning material affects peak acceleration based on static loading. An example of static compression would be? - ans Machinery - ansOften, individual machines are made by individual companies but they must operate together in a packaging line. Filler is almost always? - ansThe slowest (cpm) machine health laws - ansfocused at federal level environmental laws - ansfocused at state and local level issues indirectly related to packaging - ansVOCs water based inks (ink seeping into water) incinerators solvent recovery special case: CFC and formed plastics (ESP) federal laws and regs (environmental) - ansRCRA (deals with solid waste issues) clean water act clean air act Bottle laws - ans11 states California proposition 65 - ansground water contamination prevention- made carcinogens and substances that caused birth defects to be known Iowa groundwater protection act - anspackages proven to affect groundwater banned mandatory recycling laws - ansMore like mandatory separation of trash and recycling solid waste recycling and source reductions laws - anspackaging review boards-some states had them degradable "high cone"-6 pack holders pull tab can bans- tab must remain on can (not FL) aseptic "brick pack" bans- bans box juice boxes does packaging contribute to solid waste? - anslargest contributor to solid waste (30%) most solid waste in landfills isn't incinerated with heat recovery recycling helps but doesn't solve solid waste problems recycling advancements - ansusually just mandatory separation from trash not everything can be recycled FDA has regulations dealing with food container recycling
An Ultimate Guide to Top Score with Grade A+
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ingredients listed in descending order of prominence name and address of company/distributer detailed format for quantity declaration Must appear on lower 30% of PDP poison prevention act 1 970 - anscaused by significant accidental poisonings included aspirin, vitamins, furniture polish created child resistant packaging & warnings revised with new testing standards Nutrition labeling and education act 1990 - ansrevised 1966 requirements specific label formats new diet standards (2000 calories) defined statements such as "low fat" does not include dietary supplements Tamper evident act 1982 - anscaused by tylenol- cyanide incident created tamper evident (not proof or resistant) required for all OTC pharmaceuticals freshness indicator in food packaging Transportation safety act 1974 - anscovers transportation of hazardous material 1990 - HM181(little signs on mac truck trailers) adopted global standards Department of Transportation - ansRegulating body Package developments are the responsibility of? - ansOne or more persons- NEVER a committee. National motor freight classification and uniform freight classification (rail) - ansspecified standard practice Ex. rule 41 item 222: specifies design, style, and materials in shipping packaging if damage or injury occurs when standards aren't followed damages are valid R&D is housed in what 3 levels - ansCorporate level (less applied) Division level Plant technical departments (more applied) Four types of package development projects - ansModification of existing package for existing product. (PET bottle with PE cup Base) Expansion of product line through use of existing package that has been used for similar or different products. (Tennis ball container for Pringles) Development of new package for old product. (plastic ketchup bottle instead of glass) Development of new package for new product (modified atmosphere for precut salads) (MAP) Total Systems Path - ansMain path. Product and package developed TOGETHER. Two Development Paths - ansTotal System Path-
- The main path.
- Product and Package developed together Package Development Path-
- Used by package companies
- Develop a package first then get feedback from users.
- INEFFICIENT METHOD Package Development Path - ansused by packaging companies
An Ultimate Guide to Top Score with Grade A+
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develop package then test and get feedback INEFFICIENT METHOD! After Initial Development - ansEnvironmental tests (accelerated testing) Simulated and Real Shipping Test. (All of the above done in conjunction with marketing & manufacturing but, Development will not be market driven.) Typical Package Development Sequence - ansStart with need (marketing) Use or develop basic product information Develop the package using:
- Laws (food contact etc)
- How materials behave in combinations
- Kind of machinery required
- Shape and graphics constraints
- Environmental considerations Also use basic functions as guide. (All of the above done in conjunction with marketing & manufacturing but, Development will not be market driven.) Gantt Chart Shows - ansDevelopment progress by Month. Gantt charts illustrate the start and finish dates of the terminal elements and summary elements of a project. Terminal elements and summary elements constitute the work breakdown structure of the project. Modern Gantt charts also show the dependency (i.e., precedence network) relationships between activities. The two general types of packaging tests - ansSimulated and Actual purpose of simulated testing - ansuniformity and shorter testing time Five areas of Simulated Testing - ansDrop Impact Vibration Compression Climatic condition 90 - 100% of next day packages are dropped - ans30 inches or more (waist height) lighter weight packages are dropped from - ansgreater heights average impact speed of a package - ans5mph thicker cushion absorbs ______ energy and allows for a ______ static load - ansmore, greater more fragile items can handle a _____ g factor - anslower initial shock impulses ______ over time - ansspreads out sources of vibration very from ________ Hz ones closer to truck bed vibrate at ____ frequency - ans2-50, lower boxes vibrate when? - answhen they match the same frequency as the truck bed as frequency goes up an object responds by - ansit is affected more and more to a certain point (around 80) Hz and then becomes less affected over time box strength ______ - ansdecreases how can overhang affect stacking strength? - anscan reduce it by up to 46% what becomes primary support when stacking? - ansprimary package bulging sides do what to stacking strength? - ansit reduces the stacking strength what type of systems provide best stacking strength? - ansmulticomponent systems find how much a box can handle using weight and compression factor - ansstacking method, overhang, and warehousing give you compression factor. then you multiply compression factor by weight on top of the box to see how much it can hold
An Ultimate Guide to Top Score with Grade A+
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Uses gravity to pull filler into package pressure and vacuum filling machine - ansuses vacuums and pump to fill. For thicker foamy products. dry filling uses 3 properties - ansvolume weight number count piston filler machine - ansuses piston that acts as pump and vacuum. Used for thick, paste products and liquids net weight filler - answeighs products only. Scales weigh product as package is formed, drops exact amount into package. gross weight filler - ansIncludes weight of package and product together. ex.) Scale subtracts weight of package and adds product until it reaches given fill weight. downsides of gross weight filler - ansFaster, but also has more chance of giveaway. Set scale for heaviest possible package weight so you never oversell. packaging machinery - ansuses packages but DOES NOT make them. Includes code marking but DOES NOT include printing. many other types of machinery (that we probably don't have to know) - anscase packer, accumulator, conveyers, unscramblers, stretch wrapper, shrink wrapper, palletizer, case sealer/loader, form/fill/seal, cartoner, capper, gluer, taper/stapler, labeler/code marker, heat sealer, vacuum former converting machinery - ansMakes the package, so converting operations NOT considered part of packaging machinery. Product Lifecycle (All products go through the Product Lifecycle.) - ansIntroduction Growth Maturity Decline Innovations in Packaging. - ansInnovation:
- Helps boost sales in Mature/Decline phase.
- Changes with consumer demands.
- Changes with technological developments Factors Driving Innovations Currently. - ansConvenience is #1 Demand Recloseable/Resealable. Easier access for Child resistant packaging For safety assurance Active Packaging Systems - ansPackages that change the consumers experience. Ingredient Release (Active Packaging) Types - ansAntimicrobial agents Antioxidants Flavor enhancement Aroma enhancement Nutritional value enhancement Controlled/Modified atmosphere Enzymes embedded into the package to remove lactose or cholesterol Chitosan- an edible film that can reduce fat and serve as a joint supplement and prevent microbial growth. Scavenging Systems (Active Packaging) - ans-Iron sachet packets for absorbing oxygen
- Oxygen scavenging additives built into the film (not recyclable)
- Cap liners
- Ethylene Control
- Moisture control- silica packets, non-fogging films
An Ultimate Guide to Top Score with Grade A+
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(New Polymer(s)) PEN - ansPolyethylene naphthalate
- Improved barrier properties compared to PET Use: Carbonated beverage bottles (soda bottles) Shaped/ Textured Packaging (Active Packaging) - ans-Cans
- Stand up pouches
- Squeeze tubes
- shaped shrink labels Anti-theft Devices (Active Packaging) - ansDevices that emit an electromagnetic field that can be deactivated upon purchase Ultra-thin sensor embedded into paperboard. Irridation - ansIndirect thermal sterilization Already used for years by army Electro beam or cobalt 60 are the energy sources Irradiation facility Store Brands - ansPackaging for all products in the store with store "theme" Selective susceptors - ansMicrowaved foods Sensors - ansTemperature Time-freshness Abuse-physical and temperature Packages with motion or sounds - ansHolographic movies - up to 30 secs Talking packages Lenticular Cards- 42 lenses per card, can have up to 120 Frosted or metallic coatings for glass or plastic bottles Self Heating Packages
- Iron or Limestone + water = exothermic reaction Solid Modeling - ans3D digital model Used for designing prototype bottles Helps for more accurate mold design Simulated computer testing on model Connivance Features - ansChewing gum dispenser Selective deodorant aerosol Hard boiled eggs by the slice re-usable filtered water bottle Dose control More Variety - ansInternational foods Nutraceutical foods Indulgent foods (New Polymer(s)) LCP's - ansLCP's Liquid Crystal Polymer
- High barrier, temp resistance and strength
- Use: Thermally treated food packaging and medical packaging (plastic "cans" and trays) (New Polymer(s)) Metallocene Plastics - ans-Extremely though and strong
- Uses: Returnable/Reusable plastic packages (New Polymer(s)) Silica Coated Plastics - ans-High barrier, can be microwaved Use: Microwaveable crisping pouch In package design you want features and characteristics that...? - ansattract and inform customers motivate purchase What are the basic elements of design? - ansshape size
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how color influences flavor perception - ansDifferent colors make people think it is tastier than others. Red most flavorful. Basic Elements of design - ansshape color size texture- graphic patterns or textured materials Tone- lightness or darkness of colors Line- orientation evokes different meanings icons- adds equity can be most important in some cases (quaker oats person) Graphic Design - ansMust consider how product will look on shelf Different Fonts affect how consumers see the package - ans typography designed to communicate something about the product. - anssuch as thin letters for "weight loss" relief (raised image) - ansflexography, letter press, or offset letter press planographic (flat image) - anslithographic or offset lithography gravure (engraved image) Gravure Printing - ansrotogravure or intaglio Used for variety of web fed high volume jobs, labels, cartons, carton over-wraps, flexible mat'ls screen printing - ansfalls under category of "other" methods embossing - ans"other" method, design in relief, often used for aluminum foil holographic "printing" is a form of this (kids toys) solvent based - anstype of printing ink, must control emissions through solvent recovery, incineration, and is costly because of emissions control and solvent recovery water-based - anstype of printing ink, can't be used with all printing methods or substances yet, more environmentally friendly but not enough adhesion to substrate UV cure - anshelps dry inks, beer cans and ale. Seal on substrates color, text - ansfirst and last thing people recognize types of lines - ansstraight/up and down: dignity diagonally: vitality forward: lines running off product curved: graceful/feminine purpose of graphic design - ansfind out who the package is selling to, best manner in which to motivate a purchase decision in target audience chlorofluorocarbons - ansbad for ozone layer, found in styrofoam (polystyrene-PS) Litho-based on oil (image) and water (non-image) - ansUsed for paper and paperboard packages such as folding cartons and labels
