“Develop success from failures. Discouragement and failure are two of the surest stepping stones to success.”
Packaging
BASIC OF PACKAGING
Definition: Packaging is a techno-economic function aimed at minimizing costs of delivery while maximizing sales. It can be as a product made from any material such as paper, glass, plastic, aluminum and wood that is used for containment, protection, Information, identification, handling, delivery and presentation fog gods from raw to processed goods.
History: Although paper was made is china as early as 200BC, commercial production of paper started only about 1300 AD in the western countries. The principal packaging material until about 1200AD was not paper but were leather, cloth, wood, glass, metal and grass. Paper and paper product later becomes the principal packaging medium. Today this is the age of the plastics.
By the end of the 19th century, the industrial revolution had created a high level of productivity and mass transportation means for moving products to the customer.
Some historical events in the development of packaging:
1. Use of cast / brown glass bottles/jars
3000BC
2. Manufacture of paper
105AD
3. Corrugated fibre board
1856
4. Marketing of toothpaste in tubes
1895
5. Introduction of PVC
1927
6. Extrusion and blow molding
1937
7. Aluminum can for beverage
1959
Function of packaging: it are divided into primary, secondary, tertiary, function. In contrast with primary function which primarily concern the technical nature of the packaging and secondary function relate to communication. It are divided into the following sub-functions:
1. Primary function:
a. Protection function: it protect from environment. The inward protective function from climate conditions, such as temperature, humidity, precipitation and solar radiation.
The outward protection provided by the packaging must prevent any environment degradation by the goods. This requirement is of particular significance in the transport of hazardous materials with protection of human beings of primary important.
b. Storage function: the packaging materials and containers required for producing packages must be stored and many different locations both before packaging of the goods and once the package contents have been used.
c. Loading and transport function: convenient goods handling entails designing transport packaging in such a manner that it may be hold, lifted, moved, set down and stowed easily, efficiently and safely.
2. Secondary functions:
a. Sales function: the purples of the sales function of a package is to enable or promote the sales process and to make it more efficient.
b. Promotional function: promotional material placed on the packaging is intended to attract the potential purchaser’s attention and to have a positive impact upon the purchasing decision. It is directly addressed to the consumer.
c. Service function: the various items of information printed on packaging the consumer with details about the contents and use of particular product. Examples are the nutritional details or dosage information on medicines.
3. Tertiary function:
a. Additional function: it relates to the extent to which the packaging materials or packaging containers may be reused once the package contents have been used.
Purpose of packaging: with the increased importance placed on self-service marketing, the role of packaging is becoming quite significant should it include quality, safety, distinction, affordability, convenience, or aesthetic beauty?
1. Appearance: the appearance of a package is important from many angles and this aspect gains greater and greater important with the growing super-markets and cash carry system of marketing distribution.
a. Identify the product throughout the distribution channel.
b. Carry instruction for use and disposal.
c. Carry information about contents and satisfy legal requirements.
d. Act as an import and sales aid.
The appearance of a package is dependent on shape and surface decoration. While shape relates to the mechanical aspect providing a physical contribution, surface decoration is mainly a marketing tool.
2. Protection: protection is normally required from environmental and physical hazards.
3. Transport: to easily and safely move the product from the manufacturer perhaps to a warehouse then to the retailer and finally, to the consumer.
4. Information transmission: packages and labels communicate how to use, transport, recycle, or dispose of the package or when completed and or needed.
5. Display: to attractively display, to sell (a marketing tool). Size, cost, colors, brands, illustrations, and shape are all considered for display. As this country changed from the sales person mode to self-service, the package was needed to inform and sell the product.
6. Odor and flavor contamination: packaging should keep away external odor reaching the content of the packet, retaining at the same time the flavor of the product packaged, or in other words a package should be an effective odor barrier.
7. Shelf life: shelf life is the time after production and packaging that a product remains acceptable under defined environmental conditions. It is a function of the product, the package and the environment through which the product is transported, stored, and sold.
Factors affective shelf life:
1. Product: nature, shape and size of the product affect its shelf life.
2. Packaging: nature or types of packaging material and packaging process and same special treatment given to the packaging material like increasing, or transmission rate and making it moisture proof.
3. Storage method: store in specified temperature.
4. Handling:
Types of packaging: There are three types of packaging, depending on use. The container that directly holds the product is the primary packaging. That may be a can bottle, jar, tube, carton, drum etc.
Any outer wrappings that help to store transport inform display and protect the product are secondary packaging. The decorated carton or gift boxes are common examples.
Lastly, tertiary packaging is the grouping is the grouping of product for storage and transportation. The corrugated, brown carton is the most familiar. Large pallets of shrink-wrapped boxes are a common ware house sight reflecting tertiary packaging.
The main packaging material included in the regulations are:
1. Paper/fibre-board.
2. Plastic.
3. Glass.
4. Steel.
5. Aluminum: wood packaging and packaging made from other materials (for examples hessian, jute, cork, ceramics and so on) are also included.
PACKAGING DESIGN
1. Consumer research and sales promotion through package design:
a. The type of product that is to be packaged.
b. The cost of product.
c. The amount of handling the product has to go through.
d. Packaging should be such that it should facilitate handling.
e. Its ability to be reused. Ex- drinks served in bottles.
f. Its ability to be disposed.
g. Its effect on environment care should be taken that packaging material should riot harm the environment.
Product life cycle: a new product progresses through a sequence of stages from introduction to growth, maturity, and decline. This sequence is known of the product life cycle and is associated with changes in the marketing situation, thus impacting the marketing strategy and the marketing mix.
1. Introduction stage: the firm seeks to build product awareness and develop a market for the product.
a. Product: product branding and quality level is established and intellectual property protection such as patents and trademarks are obtained.
b. Pricing: pricing may be low penetration pricing to build market, share rapidly or high skim pricing to recover development costs.
c. Distribution: it is selective until consumers show acceptance of the product.
d. Promotion: it aimed at innovation and adaptors. Marketing communications seeks to build product awareness and to educate potential consumers about the product.
2. Growth stage: the firm seeks to build brands preference and increase market share.
a. Product: quality is maintained and additional features and support services may be added.
b. Pricing: is maintained as the firm enjoys increasing demand with little competition.
c. Distribution: channels are added as demand increases and customers accept the product.
d. Promotion: is aimed at a broader audience.
3. Maturity stage: the strong growth is sales diminishes, competitions may appear with similar products. The primary objective at this point is to defend market share while maximum profit.
a. Product: feature may be enhanced to differentiate the product from that of competitors.
b. Pricing: may be lower because of the new competition.
c. Distribution: becomes more intensive and incentives may be offered to encourage preference over competing product.
d. Promotion: emphasizes product differentiation.
4. Decline stage: the firm has several options.
a. Product: maintain the product, and adding new features and finding new uses.
b. Pricing: harvest product-reduce costs and continue to offer it, possibly to a loyal niche segment.
c. Distribution: discontinue the product, liquidating remaining inventory of selling it to another firm that is willing to continue the product.
The marketing mix decisions in the decline phase will depend on the selected strategy. For ex- the product may be changed if it is being rejuvenated, or left unchanged if it is being harvested or liquidated.
PLC: watching recorded television.
1. Introduction: 3D TVS.
2. Growth: blueray discs / DVR.
3. Maturity: DVD.
4. Decline: video cassette.
2. Explain factors influencing good packaged design:
Types of packaging: two types
a. Consumer oriented packaging in which packaging is designed for consumer convenience and appear marketing considerations and display.
b. Logistic oriented industrial packaging focuses on the handling convenience and protection during transportation material handling and storage.
Industrial packaging is performed in four stage:
a. First stage is packaging the product itself, for ex- soft drinks are packaged in cans.
b. Second stage is called master cartons- the product are packed in larger carton.
c. The third stage is that of formation of unit load- here the master cartons are consolidated into a single, large unit to facilitate handling, transportation, protection and storage. This process may involve palletization, where the master carton are mounted into a standard size rigid platform.
d. The fourth stage is called containerization- here the unit loads are placed in rigid contains for protection and handling facilitation. Containerization helps in improving the efficiency in transportation transfer, across vehicles and safe guarding from theft.
Factors influencing package design:
1. Product assessment:
a. Nature of the product.
b. It physical state.
c. Shape and size.
d. Its weight and density.
e. Its weakness- which part will break, bend, move.
f. Its strength: which part will stand Hard.
g. The effect of moisture, temperature change in the product.
h. Interaction with the pack or surroundings.
2. Hazard distribution: during transportation hazard.
a. Types of transport.
b. Form of transport.
c. The mechanical condition and duration of storage.
d. The nature and intensity of mechanical and climatic hazard in transport storage, retailing and use.
e. Weather handling aids are available for loading and off-loading at all points.
3. Marketing requirement:
4. Package and the image: the package projects the image not only of the importance but often also the company.
5. Packaging and self-service: the designer must ensure that a pack at the point of sale has the type of appeal which will make customer pick it up.
6. The package and the price of product: lowest possible price.
3. Surface design: package design involves the selection of materials and their use for packaging in the most cost effective way to provide the best end result. One can consider the package design related to the shape or structure of package.
Nature of material for packaging:
Machine considerations: material are always going to be converted into a pack of some sort, either one that is supplied in a readymade form or one which may be produced in-line or the material are selected to filling machine of which the most frequently seen are form fill-seal types from flexible packaging and cartons made from cartons board reels or pre-cut blanks.
1. Make all legal requirements.
2. Make economical use of material.
3. Fully protect the contents.
4. Be no larger than strictly necessary.
5. Have no interaction between pack and content.
6. Environment friendly.
7. Convenient in use.
8. Present all required information.
Factors influencing the design/ selection of package:
a. Product:
1. Product for consumer/industrial etc.
2. Physical state (solid/ liquid/ powder/ weight/ volume/ shape/ rigidity/ stability/ fragility/ surface film).
3. Content (vulnerabilities of contact).
b. Distribution: destination type of handling types of transport type of storage, atmospheric conditions making of goods it dangerous, degree of production needs from after environment hazard drop.
c. Marketing: type of consumer, sex, age, income, social, level customer, buying habit, location of market, consumer convenient in handling product, product apperance, color, size, language, disposability.
d. Statutory and regulation:
1. Standards of weights and measures.
2. Marking of MRP.
3. Safety points and consumer protection.
4. Legislation of importing countries.
e. Packaging operations: time factor, convenience factors, versatility, growth factor, consideration on seasons.
f. Cost factors: design cost, quality control cost, transportation and storage, operations cost, labour and overhead, maintenance and depreciation of machinery, loss and damage cost.
PACKAGING TECHNOLOGY
Material use in packaging:
1. Paper and board:
a. It is cheaper and easily available.
b. They provide attractive lock of the product.
c. Easily printable.
d. Recyclable and biodegradable.
e. Light and less bulky.
Limitation:
a. Resistance to economic impact is comparatively less.
b. Resistance to climatic hazards also limited.
2. Metal:
a. Used in manufacturing all kinds of containers like that of tin and aluminum.
b. Extra rigidity.
c. Highest strength.
d. Non-toxic.
e. Whiteness and shiny.
f. Printable.
g. Deformable to desirable extent.
a. Heavy In weight.
b. Comparatively costlier.
c. Formation is difficult.
3. Tin: it is easy to melt, and it mix with copper to make bronze. It is used for cans.
Properties: tin is an element with symbols Sn (stannum), and atomic number 50. It is obtained from the mineral causiterite, where it is occurs as tin dioxide SnO2. The melting point of 231.9681C, specify gravity (gray) of 5.75 or (white) 7.31.
a. Tin is a white metal at room temperature.
b. Tin is soft.
c. Tin is highly corrosion-resistant and fantigue-resistance.
d. Tin is non-toxic.
e. Tin is highly malleable (able to be shaped).
f. Tin alloys easily with other metals.
g. Tin has a low melting point (232C).
h. Tin is easy to recycle).
Uses: tin plate about 50% of tin is used as tinplate for canned foods and drinks, where steel cans are coated with tin to make them rust-resistance, more attractive, and more easily shaped and soldered. Steel alone would rust, and tin alone would be too soft and too expensive.
Solder about 30% of tin is used as a tin-lead solder in electronic parts, pluming, machinery and cars.
Bronze on alloy of copper and tin-used for statues bearing in car engines and heavy machinery, and musical instruments such as bells, symbols and gongs.
Tin oxide is used as a white glaze on pottery (including title) or glass where ware, and can be colored with other metal oxides, plate glass is made by floating molten glass on a bath of molten tin while it solidifies, giving the glass a very flat and polished surface.
This silvery, malleable post-transition metal not easily oxidized in air and issued to coat other metal to prevent corrosion. Another large application for tin is corrosion tin plating of steel.
Because of its low toxicity, tin plated metal is also used for food packaging, giving the name to tin cane which are made mostly of steel. Tin is used to coat other metals to prevent corrosion.
2. Aluminum: it is second most widely used metal in the world. It is low weight, high strength, superior malleability, easy machining, excellent corrosion resistance and good thermal and electrical conductivity are amongst aluminum’s most important properties.
Background: physically, chemically and mechanically aluminum is a metal like steel, brass, copper, zinc, lead or titanium.
Light weight: it is very light metal with a specific weight of 2.7g/cm3, about a third that of steel.
Corrosion resistance: aluminum naturally generates a protective oxide coating and is highly corrosion resistant.
Electrical and thermal conductivity: aluminum is an excellent heat and electricity conductor and in relation to its weight is almost twice as good as conductor as copper.
Reflectivity: aluminum is a good reflector of visible light as well as heat.
Ductility: aluminum is ductile and has a low melting point and density.
Impermeable and odorless: aluminum foil, even when it is rolled to only 0.007mm thickness.
Recyclability: aluminum is 100 percent recyclable with no downgrading of its quantities.
Non-magnetic: it has non-magnetic properties.
Non-toxic: aluminum is essentially non-toxic and it is used in cooking tencils without any harmful effect on the body.
It is self-heating and self-cooling can are produced.
3. Glass: glass is so much a part of our daily life that we cannot imagine living without it.
Three main component for glass making:
a. Viz silica sand (SiO2).
b. Soda ash (Na2CO3).
c. Lime (CaCO3).
Properties of glass:
a. Chemically insert: it has no inherent power of action, and this property enables the packaging of products without any danger of reaction or spoilage.
b. Non-permeable: glass does not allow gases, odor Vapours and liquids to pass through its walls.
c. Transparents: you can see what you pack in glass.
d. Moldable: glass containers can be molded easily in any shapes or size ranging from a tiny vial to a 13- gallon carboy.
e. Strength: the ultimate strength of glass is very high.
f. Light weight: glass is as light as aluminum roughly one-third the weight of steel or of a density 2 ½ time than of water.
g. Unlimited supply: glass containers can cater to an unlimited market.
Types of glass: in the US, British, German, Swiss and Indian pharmacopoeias, tests have been laid down to establish the properties of different type glass for use in the packaging of pharmaceuticals. The quality of glass is expressed in terms of its resistance to acid or alkali attack based on this, the three universally accepted standard are-
Type 3: all soda lime glasses are mainly type 3 and the limit of alkalinity prescribed for this glass is 8.5 ml of 1.2N acid. In the British, pharmacopoeia, there is a less alkaline glass prescribed as BP58.
Type 2: it is same as type 3, but the inside of the glass container is coated at the time o manufacture, usually with sulphur which coating de-alkalises the inside surface to obtain improvement in its chemical resistance.
Type 1: this is borosilicate glass, which has the added properly of almost complete neutrality, because of the utility large proportion of borax that comprises this glass, it is harder a more expensive to make than the ordinary soda lime glass, and it is principally used for injectibles and transfusions.
The limit of alkalinity here is 1.0 of 0.2N acid.
Many glass products serve the packaging needs of the pharmaceutical, Diary, liquor, varies food products, soft drinks, cosmetics, chemicals, inks and other industries.
Thinner, lighter and less expensive glass bottles are coming into use.
Advantage: the glass container will receive any product whether it is not or cold, without vacuum, sterilized or processed. The glass container does not taint, pollute or affect the quality of its contents. It has high shelf-life.
4. Plastic: the plastic form a comprehensive family with a wide range of properties which can meet almost every requirement of the packaging industry. Plastic can be trailer made to meet a specific requirement of packaging or achieve a combination of properties. The can be divided into two main group:
a. Thermoplastic: when the contact in heat then it is loss in mechanical or physical properties and not reuse.
b. Thermoset: it soften on the application of sufficient heat, but hardness cooling.
Plastic are used for making rigid containers, flexible container, films and laminations.
Advantage:
a. Plastics are light and less expensive than other packaging material.
b. They have better barrier properties moistures, odor oxygen and other glass.
c. They are resistant to most chemicals, non-toxic in nature.
d. Plastics can be processed into desired shapes of forms like films, sheets, bottles, tubes, pouches and crates.
e. Plastic material saves cost in storage and transportation because of less weight and less secondary packaging.
f. They do not promote bacterial growth.
g. Single-sever cost for food items, such as ketchups and small unit pack like sachets can be made at less cost.
h. Plastic packages are prefer-proof, tamper evident break resistant, corrosion resistant and leak proof.
i. Plastic packaging do not pose any major disposal problem since almost all the plastic can be recycled.
Polymer
major forms
LDPE, LLDPE
films
Lamination (films of paper of paper, foils)
Polypropylene
oriented PP,
Bi-axially oriented PP (BOPP)
Metallized BOPP
Injection molded closures, create, pallets
Woven sacks, immediate bulk containers
Blisters in packaging
Corrugation board
Polystyrene
injection molded container closure
Injection blow molded bottles
Bi-axially oriented films
Thermoformed cups, tubs
Foams
PVC
Rigid sheet for blister packaging
Stretched bottles.
Polyesters
films for lamination
Metallized films as replacement of aluminum of packaging
EVACL
thermoforming
Co-extrusion blow molded
Co-Injection stretch blow molding
Extrusion coating
Co-extruded films
Lamination.
Limitations of plastic packaging:
a. Some chemicals attach particular plastic.
b. Plastic are not total barriers to gases and water vapour, although some new barrier plastic have improved oxygen gas and odor impermeability.
c. Less abrasive resistance and puncture resistance.
1. Polypropylene (PP): polypropylene (PP), also known Poly-propene, is a thermoplastic polymer used in a wide variety of applications including packaging and labelling, textiles (e.g. ropes, thermal under wear and carpets), stationery, plastic parts and reusable containers of various types, polymer banknotes.
Most commercial polypropylene is isotactic and has an intermediate level of crystallinity between that of low density poly-ethylene (LDPE) and (HDPE).
Properties:
a. The monomer units is prop-lene.
b. It is harder and stronger than polyethylene.
c. Very low density (0.9gm/CC).
d. High stiffness and rigidity.
e. High tensile strength.
f. High resistance to chemicals and heat.
g. With sand continuous service temperature of 90 and intermediate temperature of 120C.
Application:
a. Packaging of textiles product.
b. Bakery product.
c. Packaging of shack foods, dry fruit etc.
d. For manufacturing liner of bags, lining material for TV.
e. For making ropes, fibers.
g. High transparency BOPP.
BOPP (bi-axially oriented polypropylene): which polypropylene film is extruded and stretched in both the machine direction and across machine direction. Bi-axially orientation increases strength and clarity.
Features of BOPP films:
a. Excellent clarity.
b. Good dimensional stability and flatness.
c. Low electrostatic charge.
d. Good barrier to water vapour.
e. High gloss.
f. Recyclable.
g. Resistant to oils and greases.
h. Not affected by moistures and does not wrinkles or shrink with environment charges.
It has range from 15 to 50 microns and most commonly 15 to 30 microns.
Applications:
a. Flexible packaging
b. Pressure sensitive tape.
c. Printing and lamination.
d. Stationery
e. Metallizing.
f. Flower sleeves.
g. Cable wrap and insulation.
h. Overwrapping of cigarette, carton (10 to 12 microns).
2. Polystyrene: it is hard, rigid and almost glass like. It is brittle and more easily broken then some other polymer not particular weather resistance so that usually stable for contact use.
a. It is transparent in nature.
b. Light weight.
c. Odorless, non-toxic.
d. Unlimited range of color.
e. Low shrinkage.
f. Little tendency to wrap.
a. For making not drink cups, toys, combs, household articles etc.
b. For making radio and TV bodies.
c. For making tiles.
d. They can be easily decorated by printing Metalishing, hot stamping etc.
3. PVC: polyvinyl chloride (PVC) has a linear structure similar to polyethylene but with a chlorine atom replacing a hydrogen atom on alternate carbon atoms.
It is third most used than polyethylene and polypropylene. It is not recommended for use above 70 celcius although it can be taken to 80 for short periods.
a. PVC is a hard horny material.
b. It is a thermoplastic polymer.
c. Glass like clarity and good mechanical strength.
d. Resistance to gases like oxygen and carbon-dioxide or water and chemicals.
e. Retention of flavor.
f. Lower weight/ volume ratio lower.
a. In the manufacturer of rain coats hand bags, curtain clothes, toys.
b. As a good insulating material in wires and others electrical goods.
c. PVC films the textiles industries as a replacement of cellophane film for packaging of textiles.
4. Polyethylene (PE): polyethylene is a type of polymer that is thermoplastic, meaning that it can melted to a liquid and remolded as it return to a solid state. It is chemically synthesized from ethylene, a compound that is usually made from petroleum or natural gas.
Uses: film, packaging, bags, pipins, industrial applications, containers, food packaging, lamination liners, wire cable. It can be harmful to human and to the environment.
Classification: it is classified into several different categories based mostly on its density and branching. It grade are HDPE, LLDPE, LDPE. It has density value ranging from 0.91 to 0.925 g/cm3, 0.918 to 0.94 g/cm3, 0.935 to 0.96g/cm3.
a. LDPE: it by the high pressure polymerization of ethylene. Its comparatively low density arises from the presence of a small amount of branching in the chain (on about 2% of the carbon atoms).
It is translucent to opaque and it is slowly attacked by strong oxidizing agent and some solvents will cause softening or swelling.
b. High density polyethylene (HDPE): HDPE is prepared from ethylene by a catalytic process. The absence of branching results in a more closely packed structure with a higher density. It higher chemical resistance than LDPE.HDPE is also somewhat harder and opaque. It is strong resistance to moisture, and most chemicals & relatively stable when heated.
Application: it is used to make bottle for milk, juice, water, laundary product, drum and other container. For many kinds of household and industrial chemical. The wrinkly kind of soopy.
c. (LLDPE): it is a sustaintially linear polymer (polyethylene) with significant numbers of short branches, commonly made by copolymerization of ethylene with longer chain olefins.
Features:
a. High strength, durable, weather resistance to high temperature oxidizing, non-toxic. It is used for plastic bags and sheets, plastic wrap, stretch wrap, pouches, toys, covers, lids, pipes, buckets.
5. Polyethylene terephthalate (PET): it is a thermo-plastic polymer resin of the Polyster family and is used in synthetic fibres, beverage, foods and other liquid containers.
Depending on its processing and thermal history, PET may exist both as a morphous (transparent) and as a semi-crystalline polymer. The semi crystalline material might appear transparent (particles size <500nm) or opaque and white particle size up to a few microns).
It is used for soft drink bottles. Or certain specially bottles, PET sandwiches an additional polyvinyl alcohol layer to further reduce its oxygen permeability. These properties flexible food packaging and thermal insulation such as “space blanket”.
PET to make packaging tray and blisters.
It is produced from ethylene glycol and dimethyl terephthalate (C6H4 (CO2CH3)2) or terephthalic acid.
PACKAGING MATERIAL
1. Paper and paperboard:
b. They provide attractive look of the product.
e. Light and bulky.
f. Cheap.
g. Easily deformable/ die-cutting.
h. Printable (any process can be adopted).
a. Resistance to mechanical impact is comparatively less.
b. Resistance to climatic hazards is also limited.
2. Corrugation board: resists mechanical impact, increase the time of impulsive forces.
Wood: wood pulp (sulphate process – corrugated board).
Components of corrugated board
a. Liner
b. Fluting
c. Adhesive
The process of running reels of paper into corrugated board is complex process the basic process is to take fluting paper, give it its characteristics wave formation, then stick it to one liner, at a later point in the machine the second liner is applied to fluting, giving to a finished pieces of corrugated board it is than curved cut into the required sizes.
Reel stand of the corrugators hold two reels of paper that are used to product corrugated board. There is at least one reel stand per liner and fluting a corrugated board.
Single facer could be considering the heart of corrugators in this section of the machine the actual wave formation of fluting paper is formed, and bonded to one liner surface among single face paper. Single face that has one liner and one fluting formation. Fluting paper is fed into the single facer from fluting reel stand. The paper passes through a set of corrugated rolls which are like two toothed roller. These rollers form and set the fluting paper into characteristic wave shape. At the same time, from the opposite side of the single facer, the inner of corrugated board is being fed into single facer forming reel stand.
a. Liner: craft paper of above 80 gsm up to 225 gsm is used preferably. The outermost liner used for a box should be of maximum grammage. Their function are.
1. Resist hazard like punter, burst, abrasion tear etc.
2. Properly hold the fluting medium when one combines.
3. Resists moisture or water either outsider or inside depending on the nature of product to the packed.
4. Be amicable for printing.
Water proof paper such as btumen coated, wax coated are also used for liner.
b. Fluting: paper obtained from semi-chemical pulp process are used which proved the good rigidity to the board. Its function are to:-
1. Provide necessary cushioning desired.
2. Provide rigidity to board.
3. Contribute to resistance to bending under stress.
The grammage of fluting medium may be in the region 80-150gsm.
c. Adhesive:
1. Usually starch based adhesive are used for joining the outer liner.
2. Sodium silicate are also used.
Classification: board consisting of one or more shades of fluted paper struck to a flat sheet of paper or board between several liners usually craft, this has following:
a. Single face corrugated
b. 3-ply corrugated
c. 5-ply corrugated
d. 7-ply corrugated
3. Flexible materials:
a. Paper coated with heat sealed thermoplastics: resin can be used for strip packaging of tablets which are hot sensitive to moisture. It can also be used for making pouches. Where pharmaceutical powders may be packed. The main advantage of paper as strip sealing material is its low cost.
b. Cellulose films: it are generated from cellulose and are used for packing pharmaceuticals. The cellulose film is given a specific coating treatment depending on the essential properties, it is required to offer nitrocellulose and poly-vinyledene chloride are used for coated films. It is surface present an usually glossy mirror lie finish and it can also be reverse printed. Polyethylene when laminated to cellulose film imparts strength and provides gas barrier properties. Thus satisfying the requirements that any one this film will not offer independently. This laminate can be sandwiched printed completely protected from abrasion and stretching. Pure cellulose film would not be suitable for packaging, being too rigid and brittle, in normal manufacture, it is suitably treated with softner, the composition and quantity of which influence the properties of the films. Thus, treated it is grease proof and can also be made moisture proof and water proof by adding suitable coating. It is printing qualities are very good. It trends itself readily to printing by gravure and flexography process.
c. Polythene film: it is one of most widely used packaging materials. Polythene resins from which the film is made is prepared from ethylene gas. The low density type of film has auxiliary and extremely flexible. The high density materials are stiffer-less ductile and permeable but more heat resistance. One of the outstanding qualifier of polythene films is that very high rear strength. But the best known characteristics is their extreme toughness polythene films is not as transparent as cellulose but strides has been made towards the development of types with higher transparents and surface gloss. Polythene film is process of gravure of flexographic process but treatment of the film is necessary.
Metal in packaging
Metals are widely used in the packaging industry for manufacturing all types of containers and other application to food industry. The material in regular use are- tin plates. Aluminum and black plate.
a. Aluminum foil: aluminum in the form of heat seal laminated foil has found extensive application in the packaging of pharmaceutical tablets. It can be classified into two group namely---
1. Foil coated with thermoplastic synthetic resinous compounds.
2. Foil coated with or laminated to thermoplastic film.
Film laminated to polyethylene has the advantage of offering double protection that form aluminum foil and for polyethylene because of its good heat seal properties polyethylene is generally used as the innermost layer to produce what is called a weld seal. Reverse printed cellulose acetate laminated to foil offer the advantage of a scuff resistance.
Flexible packaging material commonly used for bakery products can be classified as—
1. Natural cellulose: based such as paper and cellulose. Glossing grease proof paper.
2. Synthetic polymeric based materials such as low and high density polyethylene, polypropylene and their laminated.
3. Metal foil: based aluminum foil laminates and metalized polyester or poly-laminates.
4. Laminated of above 3 group packaging material depending upon their end used.
b. Foils: metal foil is an old packaging material with many new used. It is low made almost exclusively of aluminum through used as laminated or liner for a variety of purpose. It’s is main sphere is still in the production of food being completely moisture and odor proof. Foils makes an excellent container for dehyolraded foods. The principal characteristic which recommend aluminum foils for various packaging application are—
1. It is impervious to moisture and gases.
2. Insect proof.
3. Grease proof.
4. Shrink proof.
5. Non-absorptive, odorless and tasteless.
6. It is hygienic, non-toxic, resistance to corrosion and non-ageing.
Foils are strong folds neatly with precision and easily handled on machine. Foils combined with non-metallic sheets varying from heavy paper board to thin transparent. Cellulose or polythene sheeting offer a large range of container or wrapping to the packaging industry.
Plastics
1. Polyethylene
a. High molecular high density.
b. High density (HDPE).
c. Low density (LDPE).
d. Linear low density (LLDPE).
e. Shrinkable film.
f. Tape (HD).
2. Polypropylene:
a. PVC
b. Polystyrene
c. Polyester
3. Cellulose film.
ANCILLARY MATERIALS
1. Adhesive: based on application:
a. Drying adhesive: these adhesives are mixture of polymers dissolved in solvent.
For ex- white glue and rubber cement.
Process of drying- as the solvent evaporates the adhesive harder properties. These are typically weak and used for house hold application. Their adhering qualities is depend on their chemical composition.
b. Contact adhesive: these adhesive must be applied on both the surfaces and should be allow some time to dry before the two surfaces are pushed together once it is applied the bond form very quickly. So it is most necessary to applied pressure for a less tome. These adhesives are used in laminated such as bonding.
For ex- natural rubber and poly chlorprene.
c. Ultra-violet and light curing adhesive: low to high viscosity flexible to rigid transparent to colored, adhesion to glass or plastic or metal ceramic and depth of cure greater than 0.5”.
d. Pressure-sensitive adhesive: these adhesive form a bond by the application of pressure to adhere the adhesion with the adherent.
These design for either permanent or removable application.
Ex of permanent include safety labels power equipment and vibration dampening films.
e. Permanent pressure sensitive: adhesive may the initially removable built adhesion to a permanent bond after several hours or days. Removable adhesive are design to form a temporary bond can be removed after months or year without living residue on the adherent. These adhesives are used in the application such as surface protection films masking tapes, book marks and nose papers, price marking labels, promotional graphics material and for skin contact like wound care dressing, athletic tape and tattoos.
Selection of adhesive in packaging
1. For manufacture of packaging material:
a. Paper to paper laminates.
b. Paper to bond laminates.
c. Paper to plastic film as aluminum foil laminates.
d. Plastic film to plastic film laminates.
e. Film to printed paper board.
f. Case manufacturing.
g. Carton manufacturing.
h. Sack making (flap of cartons).
i. Tube winding labeling.
2. For sealing/closing and attaching:
a. Carton sealing.
b. Case sealing
c. Tray partition
d. Bottle labelling.
e. Can and or labelling and membrance (filter) sealing.
f. Palletizing (tapes or packaging).
3. In manufacturing packaging material but ultra-end
a. Co-effectionery wrapper.
b. Blister packaging (for tablets)
c. Self-adhesive labelling.
Besides meeting the function demand of bond performance i.e. providing good adhesion the good adhesive also has to fulfill the requirements of bond forming operations which includes some factors such as—
1. The variation in surfaces to be handle.
2. Several operating characteristics of adhesives such are
3. The mechanism adhesive either by mechanical or chemical method.
Cushioning materials: package cushioning is used to help protect fragile items during shipment. It is common for transport package to be dropped, kiched and impacted. These event may produce potentially damaging shocks, transportation vibration from conveyors, trucks, railroads or aircraft can also damage some items shocks and vibration are controlled by cushioning so that the change of product damage is greatly reduced.
Cushioning is usually inside a shipping container such as corrugated box. It is designed to deform or crush to help keep levels of shocks and vibration below levels that may damage produce inside the box. Depending on the specific situation, package cushioning can often be between 50 to 75 millimeter (two to three inches) thick.
Purpose of cushioning material: good are frequency transported from one place to another. These goods are sensitive to mechanical stresses. Hence, the good must be protected from damage due to impact, jointing or vibration in transmit. Ex: glass, ceramic, porecelain, electric products.
Mode of action cushioning material: cushioning materials absorb a proportion of the kinetic energy arising when the package suffers an impact.
Required characteristics of cushioning material:
1. Recovery: it ensure, that the package contents continue to be protected even when repeatedly subjected, to similar stresses. If recovery is too low. The breaking distance a centered exposure to stress such that resultance kinetic energy can be longer be absorbed and package may be damage.
2. Climate condition: these not must be insensitive to climate conditions such as moisture due to relative humidity, direct solar radiations and extreme variation in temperature. It protect from corrosion.
3. Interactivity: the cushioning material not package content should not interact and possibly impact each other properties.
4. Use of cushioning material should be effective, simple, environmentally compatible and cost effective.
Type of cushioning material:
1. Air bag: air bag consists of a plastic film which is inflated or fill cloth air when at not only the static lead generated by contents of package hear upec. Cushioning material. These are used in containers, rail road, freight cost and trucks.
a. Ease of handling.
b. Non-hygroscopic (moisture resistance).
c. Highly versatile (availability).
d. In sensitive to climate condition.
e. Good recovery.
2. Rubble film: they consist of two plastic films in which one is completely flat and other has round indentation. Once the necessary air. These are used inside packaging containers.
3. Rubberized fiber cushioning: this cushioning material it made from animal hairs or coconut fibre which are clean converted into material with vulcanized to form rapidly bonded sheet. These are in-sensitive to moisture and temperature and have good recovery. This material provides high quality protection.
4. Plastic form cushioning material: these are made from polystyrene (PS) poly-urethene (PU) and polyethylene (PE). These are available in flexible, semi-rigid and rigid forms.
5. Loose fill: some cushion products are flowable and are packed loosely around the items in the box. (Starch based foams).
6. Corrugated fibre board:
Factors considered for selection of cushioning material:
1. Sensitivity classification of the product: it is determined by ‘g’ value. 1g is the acceleration due to gravity 9.81m/sec. the forces, which usually applies to an object on earn.
2. Stresses during transport: the stresses arising during transport are second important parameters in a cushioning material. These stresses re highly variable and we do not know what type of stress- it will be the greatest stresses occur when dropped.
3. Static area load is important: the cushion is exposed to both dynamic and static forces during transport and cargo handling. During handling only the static stresses are known as the static area load acting upon a cushioning material.
Static area load = weight of packaging content/ working area (kg/cm2).
4. Recovery: recovery is the most important factor for the selection of cushioning material. If recovery is higher than the cushioning material will increase breaking distance and will absorb the kinetic energy and protects the product mom mechanical stress.
5. Specific weight: specified weight is started in kg/m3. It is a measure of the hardness of cushioning material. If the specific weight is more, then the hardness of cushion Aerials is more.
6. Resonance behavior: if the vibration frequency during transport reaches or equals the natural frequency of the packed, the resonance may occur. This will damage the product, so when transporting sensitive items, we should know and adjust the following.
a. Frequency value of the type of transport.
b. Natural frequency of the cushioning material.
c. Natural frequency of the packed product.
7. Stress range of the cushioning material: every cushioning material has a stress range. The effectiveness of the cushioning material is within this stress range.
Sealing tape: these are gum adhesive coated, material in the rolled form. They are used as sealing material. Since it is self-adhesive it needs nothing to stick. Since it is gummed or glued tape. It needs water to moisten it. It used for temporary & permanent adhesion between two surfaces. These tapes can be single sided or double sided.
These are three type:
1. Plastic sealing tape: there are three variety of plastic sealing tape.
a. Regenerated cellulose film: cellulose film in transparent or in color form. This type is used for the purpose or sealing, parcelling bundling. This tape is not waterproof but has resistance to oil, grease and many solvent.
b. cellulose acetate film: it suitable for making self-adhesive tape. These tapes are used for sealing in corrosive or damp conditions.
c. PVC: the general grade PVC is unplasticize and has low water vapour permeability. It has excellent moldability and it can be pasted or surface. It has hide sure cab and can withstand deep freeze condition.
2. Fabric sealing tape: bleached carton fabrics are used for making high-strength fabric sealing tape. These tapes are mainly used for sealing metal container, and fibre drum-closures. The low strength adhesive tapes are used as protection and masking tape.
3. Paper sealing tape: strong kraft paper is used in making moisture resistance paper tapes. The kraft paper used is coated on one side with the silicone resin. The silicon provides both moisture resistance and easy unwinding from the role. It has high strength and can be used in deep freeze condition.
Strapping: strapping is used to close bundle or bale items unitize palette loads or brace shipment of goods during transmit. There are four types of strapping materials. They are-
1. Steel strapping: steel strapping is commonly used for utilizing very heavy loads. Steel strapping is not used for shrinking loads but it has strength to hold highly compressed loads.it is mainly used in unitizing rigid loads. In general, steel strapping is used where high strength and high retained tension are hired.
2. Nylon strapping: it is commonly used to unitize shrinking loads of heavy item. It also elongates and recovers more tension then polyester or polypropylene strapping.
3. Polypropylene strapping: it generally used for lighter duty unitizing bundling and carton closure. Polypropylene strapping has high elongation and elongation but does not retain tension as well other plastic strapping materials.
4. Polyester strapping: polyester offers the greater strength and highest retained tension of the plastic strapping materials. It remain tight or rigid loads that require strapping tension throughout handling strapping and storage. It is commonly used in many applications, where high tensile strength, high retained tension and elongation are required.
Labels and labelling:
Levels: it is defined as slip of paper, card liner or metals for attaching to the surfaces of the object or product and indicating the nature name, owner, destination etc.
Labeling: it is the (process) act of attaching or applying such a label to an object. It is a process which takes place with greater or less regularity to every home, office and factory.
Labels are mainly made form paper board which are tied and stapled to particles, bottles, cans and packing cases.
Purpose of label:
1. Identification: identify of the product is of prime important as the consumer must be able to identify the contents. Identification of the manufacturer and the identity of brand name are also significant as the product is many times associated with the brand name.
2. Information: a label impart information as to the ingredients of the products and give any warning if necessary, it also mentions the quantity of contents within the container in term of eight weight, liquid measure, dry measure or numerical count.
3. Decoration: labels are part of product or the process of product presentation. When the product is choosely labelled in color, it acts as a “silent salesman”. The color and design should go well with the product and the label should have some relationship to the size and shape of the package and container.
Type of labels: paper labels may be classified according to the means used to effect adhesion and fall into and main categories:
1. Plain paper labels: it is cheaper than any other types of labels of equivalent quality. It is printing by standard or normal printing machinery. It is printed by ordinary printing varnishes, embossed without difficulty. It can be applied by simple hand application, semi-automatic, fully automatic procedure labelling 600 labels/minutes.
2. Pre-gummed paper labels: pre-gummed labels are prepared from paper coated with dextrin or gum Arabic and then calendared, flattened or non-curled by a special process. It advantage over plain paper is that they require only to be moistened with water for ready use as a postage stamp. Under suitable conditions, surprising high labelling speed can be attained-they can be damped and applied between 50% and 100% faster than plain paper can be gummed and applied.
3. Thermoplastic labels: heat fixed labels, dry labels are all term meaning the same thing. They are prepared from paper coated with a synthetic resin, which melts and becomes tacky on the application of heat. There is two varieties instant tack, and (b) delayed action. Since they are pre-coated require the addition of neither glue nor water, these labels offer good bond with many surfaces previously considered difficult. Not only will they adhere very well to paper. Paper board, glass, but also they give excellent adhesion to polysteren, urea and phenol/formaldehyde plastic. Before printing, the paper should be stored in a cool place and flat sheet should not be stacked more than 10 reams high, since elevant temperature and excessive pressure can produce partial activation of the coating with subsequent blocking. Printing inks & should be used in which the liquid phase or solvent does not activate the adhesive and should be heat resistant.
4. Pressure sensitive labels: it are the most advanced form of labelling and is a process where the label is in a stage of permanent activation and does not require heat, moisture or gum in order make it adhere to surface. They are applied to a surface by figure pressure and may be peeled off when no longer necessary.
Swing: tie on tags, a tag may be described as a marking device that is attaching to a container or product by some means other the types of slots and slits.
Caps & closures
Closures: glass containers require closure to provide sealing and closing. The closure may be made of aluminum, tin or plastic which provide hermetical seal for bottle. The main factors to be considered in selecting a closure or seal are:-
1. Self-effectiveness.
2. Easy opening and closing
3. Re-closure.
4. Dispensing.
5. Effect on decoration.
6. Packaging line problems.
7. Product compatibility.
8. Cost.
Features of closure: although the glass is a complete barrier to moisture gases and odor, the product can till deteriorate if proper sealing is not provided. The function of good closure are
1. To prevent the loss of product quality.
2. To provide total imperimance for any substrate from outside the container.
3. The closure should not react with contents of the container.
4. The closure should harmonize with the container.
Purpose of closure: many container and packages require a means of closing. It can be separate device or seal, or sometimes as integral latch or lock. Depending on the content and container closure have several functions.
1. Increase shelf life of product.
2. Provide a barrier to dirt, oxygen, moisture etc.
3. Secure product from undesired premature opening.
Types of material used: metals, wood, glass, cloth, rubber, papers, plastic.
Types of closure:
1. General closure types: this section covers closure that were utilized on a wide array of bottles or classes.
a. Cork closure.
b. Threaded closure: inside threaded stopper, external threaded cap.
c. Lightning: type closures.
d. Stopper: glass, glass & cork, metal & cork, rubber & other materials.
e. Other general closure type: non-threaded metal caps, cork-N-seal cap, Goldy cap.
2. Bottle type specific closure: this section cover types that were primarily used one or a very limited range of bottle types of classes.
a. Carbonated beverage bottle closure:
1. Cork.
2. Gravitation stopper.
3. Good’s ball stopper.
4. Hutchinson’s spring stopper.
5. Lightning type closures.
6. Baltimore loop or bottle seal.
7. Crown cap.
8. “PRIOF” closure.
9. Unusual soda/ beer closures.
b. Fruit/canning jar closures:
1. Lightning closure and related.
2. Thumb screw and stopper/lid.
3. Economy fruit jar closure.
c. Other vacuum seal food closure:
1. Phoenix.
2. Giles.
d. Milk bottle closure:
1. Liquor flask closure.
2. C newsman’s patent 1876.
3. Double screw cap.
SPECIAL PACKAGING
Aerosols: an integral ready to use packages in corporating a valve and product which is dispensed by preferred pressure in a controlled manner when the valve is operated.
Type of pressurized packages: aerosols to dispense a large number of products in containers commonly ranging from 3ml to just under a litre. Liquid sprays are the most common but there are solid-liquid dispensers for special purpose and to triggerated type valves for dispensing. Tooth paste about 80 to 85% of aerosol product sprays. They can also be used for foams, liquid streams, pastes, liquid powder and sprays and gas powder sprays interning quantities from 0.05 to 5gm are also possible.
Component:
1. Caps: a removable protective cover over the valve actuator, located in such a manner as to prevent an accidental operation of the valve. It can perform two functions. (1) It protect the valve form damage. (2) Caps often have orinfiece of the valve built in together with either a locking device to prevent accidental operation.
2. Valve: a mechanical device, the operation of which permits the controlled emissions of the product from the aerosols in a predetermined manner. It is incorporated into an actuator button and may take a variety of forms. It can consists of a single hole of closely controlled dimension in a plastic molding or molding and machined parts are locked together depressing the button uncover the holes and connects the interior of the container to the atmosphere. The moisturized material inside is thus released.
3. Container: metal, glass and plastic have been used for pressurized container and each has its place. Aluminum cans while more expensive than tin plate cans have the advantage of seamless construction and hence the possibility of cell around decoration.
4. Propellent: a material which provides the power to eject the contents various gases have been used and infact the soda water siphon is an example of a pressurized pack. Compressed gases have the disadvantage that whilst they provide an internal pressure in the containers, this stands to diminish as the container empties. The compressed gases which have been for carbon-dioxide, nitrous oxide, nitrogen. The use of the buttons as propellant is becoming wide spread and blends of theses with propane are made in order to control the vapour pressure.
The selection of a propallents depends upon a no. of factors such as---
a. Spray characteristics.
b. Valve
c. Viscosity of product.
d. Nature of product
e. Cost.
5. Product: anything that can be made up into a liquid or paste form can be dispensed by this method.
BLISTER PACKAGING: Blister means a bubble like form which to save the product in transport, retailing etc. blister pack is a mode of semi rigid. A blister pack is a combined construction of heat from bubble or blister which is usually shaped to follow. The shape of contour of the articles being container, sealed to a suitable backing card which may be either printed or non-printed. In blister packaging the mold is brought into contact with plasticized PVC film and other materials which is used in blister packaging. The PVC films form blister of required sized and shapes by vacuum forming. The product is then but in these blister and stacked to pre-printed, and pre-laminated adhesive coated card or a separate sealing machine.
The blister packs are ideal for point of sale promotion and have tremendous sale appeal as the product can be seen through the blister pack. The blister packs are sale, crush proof and hygienic. They also eliminate moisture absorption and reduce water vapour transmission rate.
These are designed initially as preventive package to combat pilferage in our modern s/s of open store selling. Easy opening, dispensing, re-use and since its card backing offers scope for promotion.
Material used in blister packaging.
1. Polyvinyl chloride.
2. Cellulose acetate.
3. BOPS (bi-axially oriented polystyrene).
4. Cellulose propionate etc.
Blister packs comprise of two principle components.
A formed base web creating the cavity inside which the product fits.
The lidding foil for dispensing the product out the pack.
There are two types of forming the cavity into a base web sheet thermoforming and cold forming.
1. Thermoforming: in case of thermoforming a plastic film or sheet is unwanted from the reel and guided through a pre-heating station on the blister line. (a form fill-seal process means that the blister pack is created from rolls of flute sheet of film, filled with the pharmaeceutical product and closed (sealed) on the same equipment such equipment is called blister-line).
The temperature of the pre-heating plates (appear and lower plates) is such that the plastic will soften and become moldable. The warm plastic will then arrive in a forming station where large pressure (4 to 8 bars) will form the blister cavity into a negative mold. The mold is cooled such that the plastic becomes rigid again and maintains its shape when removed from the mold in case of difficult shapes, the warm film will be physically pushed down partially into the cavity by a plug assist feature.
2. Cold forming: in the case of cold forming an aluminum base laminate film starch, passed into a molecule means of stamp. The aluminum will be alongated and maintain the shape, in the industry these blister are called cold form foil (CCF) blister. The principle advantage of cold form foil blister is that the use of aluminum is offering a near completer barrier for water and oxygen, allowing an extended product expiry date.
The principal disadvantages of CFF blisters are: the slower speed of production compared to thermoforming: the lack of transparency of the package (a therapy compliance disadvantage) and the larger size of the blister card (aluminum cannot be formed with near 90 degree angels).
Advantages:-
a. Greater product production at a reduced cost.
b. Aesthetic appeal and visual identification.
c. Prevent contamination by dust or dirt.
Skin packaging: Skin packaging is a type of packaging where a produce or (product) is placed on a pieces of cardboard, and a thin sheet of plastic is placed over the product and cardboard. The plastic is affixed to exposed cardboard via heat and suction, ensuring a tight molded fix around the product. The skin package piece then may need to be cut into individual units.
The product is arranged manually on the pre-printed or pre-laminated adhesive coated and perforated card-board. The PVC film of suitable guage is heated up by electric element and brought in contact with product thereof, when the vacuum forming takes place of suction. The PVC film sticks to the laminated chip board and the product is skin packed according to its size and shape and the product does not move.
a. When a skin packaging you can be sure the packing is airtight and hygienic and the product has improved dust & moisture protection.
b. To transit damage is much reduce because shifting of the product is prevented.
c. It makes your product look attractive.
Shrink wrapping: Shrink wrapping involves enclosing the package content is shrink film (flat or tabular film) neat sealing any unsealed portions and separating the package from the film web of covering the package contents with a shrink cover. Depending upon the shape and weight of the package content, the shrink material used should be PE or plasticized PVC film of a thickness of 0.01 to 0.02mm, with PE film being particularly suitable for heavy items. The film is heated from the outside in a shrink oven or with hand-held heat gum so releasing the “frozen in” tension in the film. Shrink films are produced in forms which are oriented either monoartially, in a single direction or bi-axially (in two directions). As the film cools down, it shrinks around the package content, applying a very slight pressure per unit area. The tear strength of shrink films is 1.8 to 3.2 NM/mm2 in machine direction and 1.6 to 2.5NM/mm2 in transverse direction.
Advancement in food packaging tetra packaging:
Vacuum packaging: vacuum packaging refers to packaging in container (rigid or flexible) from which substantially all air has been removed prior to final sealing of the container. This method packaging is actually a form of “modified atmosphere” since normal room air it is removed from the package.
The complete remove all of oxygen from a pack ensure longer preservation for food packaging against microbial deterioration the packaging in oxygen. But sometimes change the color however it is virtually impossible to remove all the oxygen as small quantity will be trapped with the food. When fresh meat is vacuum packaging in CO2, the growth or organism is in habit thus extending shelf life of the meat, same rises, it increases the PH produces H2S etc. suitable materials for vacuum packaging of meat must then combine a high resistance to gases and water vapour with perfect sales and good mechanical strength.
Modified atmosphere packaging (MAP) is a process by which the shelf life of a fresh product is increased significantly by enclosing. It is an atmosphere which slower down degradation process such as growth of microbial organism. Whilst enhancing some beneficial process. Depending upon the product and type of packaging a variety of different combination of gases (oxygen, nitrogen, CO2) are required. The gases an also bacterial growth and oxidation, so it is important to balance the positive effects against the negative effects.
a. Self-service.
b. Super market packaging.
c. Increased shelf-life
d. Product information.
e. Hygiene.
f. Attractive packaging, attract the customer.
g. Reduces moisture loss and freezer turn.
Role of color in sales promotion:
a. High appeal.
b. Gives an idea of content quality.
c. Attracts customer.
Gas packaging: Gas packaging can be defined as the alteration of the proportional volume of the gases which comprise a normal atmosphere. This type of packaging general falls into two categories.
a. Controlled atmosphere (C.A.P): refers to a controlled system where by gases are added or removed to maintain a desired balance. In this case the bulk in or storage vessel is virtually impermeable.
b. Modified atmosphere (M.A.P): refers to enclosing a product in some type of barrier and modifying the atmosphere either by drawing a vacuum of filling with a gas mix. During storage the level of these gases will change due to respiration of the product and permeability of the film.
a. Allows meat to bloom: if the oxygenated red meat color is desired, a blend incorporating oxygen can be sued to controlled color.
b. Extended shelf-life: controls oxidation by displacing the oxygen with carbon dioxide are nitrogen, inhibits bacterial growth of aerobic spoilage organism.
Prevent crushing of soft products.
c. Retains moisture: prevent moisture from getting out of the product if helps sustain enough water mal is helpful to perpetuate the life of the product.
Stretch packaging: In this type of packaging, one or more flat films are placed under mechanical tension & wound helically around the product conductivity & economically. It is designed as a displacement for bulky & costly packaging method such as tapes, co-effing, shrinking, corrugated cartons, metal & plastic, strapping, plastic foams & plastic toys.
Depending upon the shape of weight of the package content. The stretch material used should be PE or plasticized PVC film of a thickness of 0.01 to 0.05. The ends of film web are heat sealed or coded.
It is divided into five categories:
a. Compression: tightly bind product together forming. (Furniture, textiles & foam product).
b. Suspension: secure heavy product or any shape. (Heavy mechanical components).
c. Protection: protect from dirt, moisture, stretches. (Furniture, electronics & window assemblies).
d. Stabilization: transported short distances (local delivery).
e. Utilization: it bundles many loose items together into a single unit load. (Seeds, bottle beverages, corrugated boxes).
a. Saves time.
b. Saves material & reduces packaging expenses.
c. Less worker.
d. Worker becomes more efficient.
e. Better load sensation.
Type of packaging
a. Flexible packaging: these packaging are more popular for food packaging because they provide superior flavor retention and longer shelf-life. Also it is impervious to tight, air, water and most other gases and liquid. It protect package from harmful oxygen, sunlight and bacteria. Flexible packaging application is pouch making (from fill seal pouch).
b. Rigid packaging: they are rigid in natural to assist transportation safety etc. the seal create consumer confidence and product quality. These package are easy to open, close and reuse without destroying the package. Mostly these are made from recycled fibres in addition they provide lasting reuse, features, products identity is rugged strength.
c. Semi-rigid packaging: semi-rigid packaging are formed by folding cartons and collapsible tubes, as opposed to flexible packaging that conform to the shape of product semi-rigid packaging have a shape of their own. They can be their performed from their original shape either while they are emptied on before they are filled. Aluminum foil, containers sheets are used in semi-rigid packaging as they provide protection, barrier to permeation, cooling handling and temperature variation.
Rigid box manufacturing procedure four stage:
a. Cut and score blanks (cutting by cutting machine according required shape).
b. Corner cut (one flat sheet are corner cut for make a box).
c. Corner stay (corner sealing by gum, tapes, adhesive).
d. Cover with paper (last the paper cover for attractive look).