gcm 210

midterm; lecture 1-4

what is packaging?

A coordinated system of preparing goods for transport, distribution, storage, retailing and use

what is consumer packaging?

A package that will ultimately reach the consumer as a unit of sale from a merchandising outlet

what is industrial packaging?

A package for delivering goods from manufacturer to manufacturer

• usually contains goods or materials for further processing

the three levels of packaging?

• primary

• secondary

• tertiary

what is primary packaging?

the first wrap or containment of the product that directly holds the product for sale

what is secondary packaging

a wrap or containment of the primary package

what is tertiary packaging

a wrap or containment whose prime purpose is to protect the product during distribution and to provide for efficient handling

what is a unit load

the three levels of packaging are assembled into a unit load form — a group of distribution packages assembled into a single unit for the purpose of mechanical handling, storage and shipping

5 functions of a package

1. contain

2. protect

3. preserve

4. create convenience

5. provide information

functions of a package; contain

keeps the product together

aims to prevent leaks and spills

functions of a package; protect

aims to prevent physical damage and pilferage

best scenario: no packaging material necessary because product has good durability

one of the most important factors to show service quality of manufacturers

what tests are conduct to check the package’s protection performance

• compression test

• vibration test

• impact tests (drop test, incline test)

functions of a package; preserve

mostly refers to the extension of shelf life beyond the product’s natural life or the maintenance of sterility in food or medical products

biotic vs abiotic spoilage

biotic: caused by microorganisms

abiotic: caused by external factors (oxygen, moisture, light, temperature, loss/gain of volatiles

examples of preservation packaging problems and solutions?

• oxygen → determine required barrier level

• carbon dioxide → determine required barrier level

• other volatiles → determine nature and barrier level

• light → design opaque package

• spoilage → determine nature/chemistry

• biological deterioration → determine nature

• deterioration over time →determine required shelf life

what can be used to extend shelf life?

• oxygen scavengers

• permeability of packaging materials

• modified atmosphere MAP packaging

functions of a package; convenience

convenience for consumers:

• special openings, reseals, lids, etc.

• universal packaging design

• barrier free packaging design

fillers/distributors/retailers:

• specialized structures, coding systems for tracking, display systems, easy to handle, minimize waste

functions of package; information

• packaging is the main way of identification

• communication

• last chance advertising

• legal regulations

• links multiple media/printing methods

the consumer packaging and labelling act

A. the common or generic name of the product

B. declaration of net quantity, generally in numerical count or metric units of measurement

C. identity and address of the person by or for whom the product was manufacturerd, sold or imported (dealer identification)

life cycle of packaging

raw material extraction → manufacturing → distribution → use → end of life

substrate vs materials

substrate in what we print on, materials are what we do not directly print on

• beer bottle; paper label = substrate, glass = material

glass (packaging)

one of the oldest forms of packaging, provides UV protection.

glass (packaging) workflow

ingredients are mixed → melted → formed → annealed → inspected → surface treatment → packaging and delivery

ingredients of glass

• silica sand, soda ash and limestone - cullet (recycled glass too)

• melted at temps over 1000-1500 deg

what is gob

the amount of glass needed to make a bottle

advantages of glass

1. inert (does not interact with what it contains)

2. great for long term storage

3. good vertical strength for stacking

4. can be hot filled

5. highly recyclable

disadvantages of glass

1. heavy

2. dangerous when broken

3. high energy costs for manufacturing

4. cleaning glass is not so GREEN

5. expensive equipment

forming of glass

first makes a parison or blank mold which is to be formed further by either:

• blow and blow BB

• press and blow PB

• narrow neck press and blow NNPB

annealing of glass

• glass leaves the former at around 450 dec. Celcius

• allowing glass to cool slowly to remove stresses + improve durability

surface treatment/coating of glass

glass is prone to surface scratches from friction → coating reduces this.

container design of glass

• round and cylindrical are stronger and easier to form

• tall narrow designs are more vulnerable to tipping

• tapered necks are required for pouring

• wide mouth works better for thicker semisolids

• recessed areas for labelling, or fired screen printing

types of metal cans - geometry

tall cans, short cans, shallow cans

materials for cans

metal is 60-70% of the cost in can making. made of:

• aluminum

• tinplate

composition of a 3 vs 2 piece can

3 piece can:

• bottom lid

• cylindrical body

• top lid

2 piece can:

• a bottom integrated with a bottom lid

• lid

benefits of 2 vs 3 piece cans?

manufacturing of 2 piece cans are faster than 3 piece cans, but limited in size

draw mechanisms for 2 piece cans

1. shallow draw (pull)

   1. depth no greater than diameter

      pet food cans, tuna cans

2. draw and redraw DRD - soup cans

   1. depth greater than diameter
      soup cans

3. draw and wall iron

   1. walls thinner than bottom
      soda cans

metal can closures

plain, ring pull and stay on tab

advantages of metal cans

• low cost

• thermally stable

• easy to process on high speed lines

• readily recyclable

• good moisture and light barriers

• excellent for long term storage

• strong

common can defects

1. all can bodies - low/uneven tin coating, badly formed flanges

2. coated surfaces - pinholes, poor adhesion, underfilm staining, cracks in coating

3. 3 piece can bodies - poor weld strength, badly formed

4. 2 piece draw and wall ironed bodies - pinholes in body

5. can ends (plain) - lining compound incorrect weight and bad placement

6. can ends (easy open) - broken/leaking rivets, residual score out of specification

what is paperboard

also known as cartonboard, cardboard, boxboard… grammage of 250 gsm or over

paperboard - pulp matters

1. mechanical pulp = stiffer but not as strong, lower density

2. chemical pup = stronger but not as stiff, higher density, better surface appearance

types of paperboard

1. solid bleached board SBB

2. solid unbleached board SUB

3. folding boxboard FBB

4. white lined chipboard WLC

solid bleached board SBB

paperboard made from virgin bleached chemical pulp

• also called SBS

solid unbleached board SUB

paperboard made mainly from unbleached virgin chemical pulp

• also called SUS

• a layer of bleached fibers is sometimes added to the top to provide greater whiteness

folding boxboard FBB

made from a layer or layers of mainly virgin mechanical pulp sandwiched between layers of virgin chemical pulp

corrugated paperboard - composition

• liner (outisde, medium, inside)

• corrugated medium (fluting)

• adhesive

types of corrugated paperboard

• single face = A liner + A medium

• single wall = two liners + A medium

• double wall = three liners + two mediums

• triple wall = four liners + three mediums

flutes sizes (thickest to thinnest)

A > C > B > E > F

the larger the flute, the ________ the strength

greater

the finer/smaller, the _________ the printing

better

grammage of corrugated paperboard (composition)

outside liner = 170

medium = 127C

inside = 170

what is ECT - corrugated paperboard

ECT = edge wise crush test

• the most significant of corrugated paperboard tests

• measures the amount of force required to crush a piece of board standing on its edge with its flutes vertical

• used to predict compression strength

types of boxes

• regular slotted containers RSCs

• Die cut containers

  • multi component designs

polymers vs monomers

polymers:

• plastics and natural materials such as rubber/cellulose are composed of very molycules called poluymers

monomers:

• polymers are constructed from relatively small molecular fragments knwon as monomesr that are joined together

two main class of plastics

thermoset plastics vs thermo plastics

thermoset plastics (thermosetting plastics)

• contain polymers that cross link together during the curing process to form an irreversible chemical bond

• always remain in a permanent solid state

• epoxy, melamine formaldehyde, polyester

thermo plastics

• the curing process is completely reversible

• can be remelted back into liquid

• generally used for packaging

• poyethylene, polyprophylene, polystyrene, nylon

pros and cons - thermoset plastics

pros

• more resistant to high temperatures than thermoplastics

• excellent aesthetic appearance

• high levels of dimensional stability

• cost effective

cons

• cannot be recycled

• cannot be remolded or reshaped

pros and cons - thermoplastics

pros

• highly recyclable

• high impact resistance

• remolding/reshaping capabilities

• chemical resistant

• eco friendly

cons:

• generally more expensive than thermoset

• can melt if heated

crystallinity

he degree of structural order in a solid, representing the percentage of a material that forms a highly ordered, repeating, 3D crystal lattice rather than a disordered (amorphous) structure.

• as crystallinity increases: density, tensile strength, compression strength increases. permeability and clarity decreases

types of PE

polyethylene = PE

1. low density LDPE

2. linear low density LLDPE

3. high density HDPE

density of plastic = densest to least

HDPE > LLDPE > LDPE

PE - LDPE

low density polyethylene

• flexible

• natural milky colour, transulcent

• predominantly used in film applications due to toughness, flexibility and relative transparency

• popular for heat sealing

• excellnt resistance to acids, bases and vegetable oils

PE - LDPE

low density polyethylene:

• common packaging applications (dry cleaning, newspapers, bread, frozen food, etc.)

• shrink wrap and stretch film

• coatings for paper milk cartons and hot/cold bev cups

• container lids

PE - LLDPE

linear low density polyethylene:

• flexibke

• natural milky colour, translucent

• common used for stretch wrap

PE - HDPE

high polyethyloene

• flexible

• milky white; more opaque than LDPE LLDPE

• common application:

  • milk bottles, water, juice, cosmetics

plastic — PP

polyprophylene

• common packaging material for

• margarine, takeout meals and deli meals packaging

• medicine bottles

• bottle caps and closures

• bottles for catsup and syrup

plastic — PET

polyethylene terephthalate

• excellent barrier to oxygen, water and carbon dioxide

• excellent resistance to most solvents

• safe but known to allow bacteria to accumulate

• food safe

plastic - PVP

polyvinyl chloride

• high impact strength, brilliant clairty, excellent processing performance

• good resistance to oil and grease and chemical

• construction purposes

plastic — PS

polystyrene

• rigid container having thin walls (ex. yoghurt)

• excellent moisture barrier for short shelf life products

• health risk when heated - toxic chemicals

types of plastic cushion foams

EPE and EPS

plastic cushion foams - EPE

expanded polyethylene

• made by expanding polyethylene beads with steam, pressure and blow agent

• lightweight, flexibke

  • strong cushioning, shock proofing capabilities

plastic cushion foams - EPS

expanded polystyrene

• made by expanding polystyrene beads with steam, pressure, and blow agent

• low thermal conductivity and excellent insulation

• STYROFOAM

• light and rigid

• lower material cost than EPE

labels - wet glue

“gummed”

• needs to have an adhesive applied before application

• beer, canned goods

• choose substrate based on application and storage

labels - in mould

provided preprinted and precut in stacks

• applied during manufacturing (placed in the mould)

• molten plastic is then injected

label - sleeves

aka shrink sleeves

• provides tamper evidence option

• can combine 2 packs into 1

• reverse printing is possible

advantages of aluminum foil

• resistance to corrosion (oxidation)

• non absorbent

• stable in cold conditions

• mostly no toxic residues or reaction

• conductive

disadvantages of aluminum foil

• loses strength above 150 deg. C

• not ductile

• prone to flex cracking

• corrods with strong acids, mild alkalines (soaps) and salts

two types of shoppers

planned finders vs exploratory shoppers

3 components of branding package

1. strucutral components - physical form

   1. dimension, shape, materials

2. graphic components - brand identity and information

   1. colours, pictures, logo and slogan

3. tactile components - physical experience

   1. material textures

stages of the product life cycle

1. introduction

2. growth

3. maturity

4. decline

5. time

when does brand packaging redesign typically occur?

• brand positioning has shifted

• target consumers have changed

• market competition has intensified

• sustainability or regulatory requirements evolve

• existing design no longer stands out