“Develop success from failures. Discouragement and failure are two of the surest stepping stones to success.”
Introduction to 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:
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).
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.
Graphic Design Element
Shape
Size
Colour
Font (Typography)
Texture
Lines
Balance & Unity
Symmetry & Harmony
UNIT-3
PACKAGING MATERIAL
1. Paper and paperboard:
a. It is cheaper and easily available.
b. They provide attractive look of the product.
c. Easily printable.
d. Recyclable and biodegradable.
e. Light and bulky.
f. Cheap.
g. Easily deformable/ die-cutting.
h. Printable (any process can be adopted).
Limitation:
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
Paper and board are widely used in packaging due to their lightweight, versatility, printability, and recyclability. They are employed in primary, secondary, and tertiary packaging across industries like food, pharmaceuticals, cosmetics, and consumer goods.
Packaging Type
Material
Key Uses
Folding Cartons
Paperboard
Cosmetics, medicines, consumer goods
Set-up Boxes
Thick Board
Luxury items, gifts, jewelry
Corrugated Boxes
Corrugated Board
Shipping, storage, heavy items
Multiwall Paper Sacks
Multi-layer Kraft Paper
Cement, grains, chemicals
Plastic Woven Sacks
Woven Polypropylene
Bulk materials, reusable sacks
Paper Bags
Paper (coated/laminated)
Shopping, groceries, food
UNIT-4
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.
1. 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.
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.
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.
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.
1. 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.
Wood is one of the oldest and most widely used materials for packaging, especially for heavy, bulky, or fragile goods. Wooden packaging provides strength, durability, and protection during storage and transportation.
Property
Significance
Density
Determines strength and weight of container
Hardness
Resistance to surface wear and indentation
Toughness
Resistance to impact and shock
Elasticity
Ability to bend without breaking
Moisture Content
Affects durability, shrinkage, and warping
Strength
Compression, tension, and shear strength critical for load-bearing