PKSC 1020 exam 1 2025

glass blown and casted by Egyptians

3000 BC

Paper invented in China

105 A.D.

cork stopper first used for wine

c.1500

Nicholas Appert: canning process

1809

Peter Durand develops "tin cannister"

1810

Quaker Oats first used the "quaker man" to represent their product (first icon used for packaging)

1877

First major use of paperboard: uneeda biscuit package markets by national biscuit company

1897

Late 1800/early 1900's

first major use of graphics to help sell products

Industrial Rev.

Movement from bulk packaging to retail, Social changes interacting w/ packaging developments

polyethylene was discovered in England

1930

Polypropylene used for packaging

1954

new jersey enacts first statewide recycling law for plastic containers

1987

Nutritional Labeling and Education Act

1990

Three M's of Packaging

Materials, methods, machinery

Ancient Man-Made Packages

sea shells, woven grass, wood, or animal parts used to contain

Trends

Convenience, on the go; Reduced packaging; Rigid -> flexible/semi-rigid; Foil laminate -> Metallized; Tamper evident/anti-theft; More informative packaging; use mostly plastic to avoid the weight of materials like glass and metal

21st century

Sustainability, active packaging

Users and Suppliers (know chart)

diagram from Test 1

Suppliers (Raw Materials -> Converters+Machinery+Services)

Users (Consumer+Industrial+Institutional)

Basic Functions:

contain, protect, inform/sell, utility of use

Contain

Oldest packaging function

Protect

First evidence: cork stopper; Protects from the elements (water, oxygen, light, germs); Shock/vibration (cushion); Protect consumer from corrosive or dangerous products (child-resistant); Tampering (tamper evident/resistant, never tamper proof)

Inform/Sell

Info required by law: contents, nutritional label, warnings, shipping info; Motivational info: type of material, shape and size, color, typography, symbols, photos, games, recipes

Utility of Use

For the consumer: easy opening, squeezable, microwavable, unit dose, For the retailer: size, orientation for shelf display, point of purchase displays, for the shipper/distributor: hand holds, fork truck cut outs, reusable totes

Trade Dress

combination of a package's color, shape, and typography, Covered under trademark law, Ex: Coca Cola, Disney characters, sports teams

Four Levels: Primary:

package directly in contact with the product (cereal bag)

Four Levels: Secondary:

package holding one or more primary packages (cereal box holding bag)

Four Levels: Tertiary:

shipping or distribution package (box used to ship several cereal boxes)

Four Levels: Quaternary:

unit load (shippers on a pallet, stretch wrapped)

Materials - Four Types

Paper and Paperboard, Metals, Glass, Plastic

Cellulose

structural component of paper and paperboard, hard and fibrous

Lignin

brown, sticky material that keeps fibers stuck together

Thickness: paper vs. paperboard

Paper: 0.012" thick or less; Paperboard: >0.012" points (0.001" = 1 point)

What "plastic" comes from wood?

Cellophane

Three ways to make pulp?

Mechanical, Chemical (Sulfate-Kraft most often), Semi-Chemical (corrugated)

Two ways to make paper/paperboard?

Fourdrinier: paper or paperboard, Cylinder: paperboard only

General procedure for making paper/paperboard

Screen, Squeeze, Dry

Calendering

Paper runs through a stack of rollers, Increases density and smoothness, Important for strength and print quality

Basis Weight for paper

Lbs./3000 sq ft.

Basis Weight for paperboard

Lbs./1000 sq ft.

Advantages of Paper/Paperboard

Renewable, Recyclable, Inexpensive, Easily printed upon

Disadvantages of Paper/Paperboard:

Porous to moisture and oxygen, Loses strength when wet, Combustible

Uses for bending grade board

Folding cartons

Three basic design styles for folding cartons?

Tube, Tray, Hybrid

Solid Fiberboard Definition and Uses

Several plies of paperboard laminated together; Shipping containers, dividers, corner supports

Five Corrugated Flute Styles

A, B, C, E, F

Corrugated Constructions

distance between flutes, height of flutes, type of linerboard

Uses for microflute

fast food packaging, bulk packaging for club stores, small appliances

Name of two tests used measure strength of corrugated

ECT (Edge Crush Test), Burst Test

What's an RSC?

Regular Slotted Container; Most common type of cardboard box

Steel

Non-beverage cans in U.S., Beverage cans in Europe, Drums, strapping

Aluminium

Beverage cans, Trays, Foil, Bare, Laminated, or Metallization

Two basic types of cans:

Three piece, Two piece

Methods of making cans?

Two piece: Drawn and Ironed; Draw, Redraw | Three piece: Rectangle into cylinder, continuous cast

Are there tin cans?

No, but steel may have microscopic tin coating

What's TFS?

Most common food cans; Tin-Free Steel cans

What's Black Plate?

Uncoated steel; Non-corrosive, non-food, such as industrial oil

Basebox

= 31,360 sq. in.

Plating weights measured in

lbs./basebox

Three ways to seal the side seam of a three piece can

Mechanical Cinch, Welded Seam, Adhesive Bonded

What's a double seam?

the part where the can body and the can end (lid) are mechanically joined

Aluminum - what is the raw material?

Bauxite

Steel.- what is the raw material?

Iron

Bayer Process

Produces aluminA: Digest bauxite in hot sodium hydroxide -> Forms sodium aluminate -> Filter, seed w/aluminum hydrate -> Crystallize out aluminum hydroxide -> Heated, forms alumina -> Reduce in reduction cell

Hall-Heroult Process

Produces AluminUM from alumina: Alumina dissolved in cryolite -> Molten aluminum & molten cryolite salt

How thin is aluminum foil?

0.0006"

Is aluminum used for packaging a pure metal?

No, alloy

What happens to WVTR as thickness of foil decreases? Why?

WATER VAPOR TRANSMISSION RATE: Increases, because more pinholes as foil gets thinner

What's the difference between a foil laminated film and a metallized film?

A foil laminate: bonding a foil substrate to a plastic substrate, Metallized: thin layer of aluminum deposited onto substrate

What simple experiment can you perform to see the difference?

Shine a light, If you see light through the package, metallized, If you don't, foil laminated

Advantages for Steel

pretty abundant, absolute barrier, unbreakable

Disadvantages for steel

rust/iron pickup if not coated, heavy, limited recycling

Advantages for Aluminum

relatively abundant, absolute barrier (depending on thickness), lightweight, unbreakable, doesn't contribute to off-taste (more than glass but less than steel), printable, recyclable

Disadvantages of Aluminum

energy intensive, relatively costly, not degradable (but nothing is, in a landfill)

Major ingredients of Glass

Sand, Soda ash (reduces melting temp), Limestone (hardness), Cullet (also reduces melting temp)

What is Cullet?

broken, melted glass

Two methods for making glass bottles.

Blow and blow- for narrow necked containers; Press and blow- uses a plunger in first step, for wide mouth containers, allows better control

What is a gob?

Precise, molten chunk of glass

What is annealing? Why is it important?

Gradual heating to ~1050 Farenheit and gradually reducing temp, Reduces internal stress, Improves strength

Parts of a bottle

Finish, Neck, Shoulder, Body, Heel, Pushup (on bottom)

Advantages of Glass

Won't interact with most products, Absolute barrier to gases and bacteria and moisture, Transparent, Percieved Quality Image

Disadvantages of Glass

Breakable (requires more cushioning), Heavy weight, Energy intensive manufacturing process