Rosnita Binti A Talib PDF

PACKAGING TECHNOLOGY
KAZAKH NATIONAL AGRARIAN UNIVERSITY

ALMATY, KAZAKHSTAN
19 - 30 OCT. 2015
by
ROSNITA A. TALIB
BSc (Food Sc & Tech), MSc. (Packaging Engineering) UPM
PhD (Materials Engineering) Sheffield, UK.
Department of Process and Food Engineering
Faculty of Engineering
43400 UPM Serdang, Selangor
Universiti Putra Malaysia
Email: [email protected]
Course Outcomes
Students are able to :
1. To describe the functions, basic packaging design elements and
concepts
2. To analyse various types of packaging materials for use on
appropriate food
3. To differentiate standard test methods for packaging quality
control
4. Describe various types of packaging equipment in food industry
References/Textbooks
1. Soroka, W. (2009) Fundamentals of Packaging Technology.

Naperville. Instituue of Packaging Professionals.
2. Klimchuk, M.R. and Krasovec, S.A. (2006) Packaging Design
Successful Product Branding from Concept to Shelf. Hoboken.
John Wileys & Sons
3. Morris, S.A. (2010). Food Packaging Engineering. Iowa:
Blackwell Publishing Professional.
4. Robertson, G.L. (2006). Food Packaging - Principles and
Practice (2nd Edition). Boca Raton: CRC Press.
5. Kelsey, R.J. (2004). Handbook of Package Engineering (4th
Edition). Boca Raton: CRC Press.
Package vs Packaging
- Simple examples of package: boxes on the

grocer's shelf and wrapper on a candy bar.
- The crate around a machine or a bulk

container for chemicals.
- Generically, package is any containment

form.
- Package (noun) is an object. A physical form

that is intended to contain, protect/preserve;
aid in safe, efficient transport and distribution;
and finally act to inform and motivate a
purchase decision on the part of a consumer.
Package vs Packaging
Packaging is
Packaging
also
- Packaging is a verb, reflecting
the ever-changing nature of the The development and production of
medium. packages (filling, closing, labelling)
by trained professionals or operators
- The act of creating or producing employing methods & equipment
a package. designed for specific product lines
and types of packages.
- Packaging - a coordinated Packaging machines e.g. fillers,

system of preparing goods for counters, cappers, labelers, wrapping
transport, distribution, storage, equipment, cartoners, case loaders &
retailing & use. sealers....
Glossary of Packaging Terms
Soroka, W. Fundamentals of Packaging Technology
PI & PMMI, USA.
Quiz 1: Egg and egg
carton
Quiz 1:
Which one is a package?
Which one is a packaging?
123rf.com
Packaging FUNCTIONS
Packaging functions range from those that are technical in nature to those
marketing oriented.
Technical functions Marketing functions
contain measure communicate promote

protect dispense display sell
preserve transport inform motivate
Technical Marketing
managers need a basic
packaging packaging
understanding of both
professionals professionals
marketing & technical needs,
need science & need artistic &
mixed with good business
engineering motivational
sense.
skills. understanding.
The Packaging Cycle
- A material life cycle: Tracing a
flow materials from raw resources –
finished packaging
- It helps pull together concepts

from different sources & disciplines
to contribute to the final packaged
products.
Elements of the Packaging
Cycle
Raw materials
These include raw inputs into the packaging materials stream
such as metal ores, wood fiber, oil, and energy.
Cycle
Primary & Secondary converters
Primary converters - are the converters that will take raw materials and
convert them into a recognizable single material such as plastic resin
pellets, sheets of paper, or rolls of metal sheet.
Secondary converters are responsible for taking the materials produced

by the primary converters and turning them into finished packages. At this
point, the distinction blurs sometimes, because primary converters may
be producing finished packages as part of their operation. The most visible
example of this is glass manufacturing and molding that is done directly
from raw materials to finished containers, primarily because of the
enormous capital outlay for production systems and the energy-intensive
nature of the material – once molten, it makes little sense to let it cool
until fabrication is finished.
Cycle
Processing, Filling & Sealing Operations

These operations are where the product is processed, after which the
processed product and the package come together to form an interactive
system that must remain safe and saleable until used by the consumer.
Unfortunately, many people (and more than a few companies) consider
this to be the beginning and end of the involvement between packaging
and food processing, and may not fully consider the environmental input
that the package-product system must endure before it is finally used.
Cycle
Distribution & Transportation

- Distribution, inventory storage and management, and transportation
modes and their related hazards are critical considerations in an
industrial food production system.
- They will become even more so as the world’s economy continues to
integrate, with food, consumer items, and all manner of goods being
shipped from one corner of the globe to the other.
- For the packaging cycle to be properly managed for a product, it is
essential to be somewhat conversant with these issues, and
particularly the economics and informatics that are involved in
managing such huge, dynamic systems.
Cycle
Final Product Use

- Final use is where the package-product system is finally evaluated –
the quality of the product and the package’s utility may determine the
physical and financial success of the product.
- An inconvenient, dangerous, or spoiled product (or one with
insufficient information attached) has little chance of fulfilling the
customers’ needs and may be dangerous to the consumer, the
environment, or both, whereas a splendid product that is economically
unfeasible may satisfy the customer but leave the producer somewhat
less pleased.
Cycle
Recycle, Reuse, Refill or Reduce
- This decision, which is usually made by the consumer is also influenced
by regulations and the existing market for recycled material, and by
whether or not the infrastructure exists to return the empty package
into use, either as a raw material or as a refillable container.
- In the absence of these choices, the package becomes part of the
burden on landfills and incinerators that are scarce and expensive in
some areas, due to public reaction, regulatory requirements, and the
necessity of extensive environmental engineering. Because of the
multiple economic incentives in materials use reduction, and better
engineering practices, source-reduction strategies have become more
common in the design of any number of packaged consumer items and
have flattened the per-capita municipal solid waste production in many
industrialized countries.
History of Packaging
PRIMITIVE PACKAGING
FROM ROME TO THE RENAISSANCE
THE INDUSTRIAL REVOLUTION
THE EVOLUTION OF NEW PACKAGING ROLES
PACKAGING IN THE LATE 20TH CENTURY
MODERN PACKAGING
ENVIRONMENTAL & SUSTAINABILITY ISSUES

ENVIRONMENTAL
AND
SUSTAINABILITY ISSUES
The Four Rs Environmental Issues
The guiding principles for designing environmentally responsible
packaging developed in the early 1990s are mbodied in the four Rs
hierarchy & are still valid today:
1. Reduce Packaging design should use the minimum amount of

material consistent with fulfilling their basic function. A reduction in
material use will dimish furthers of reusing, recycling or recovering
other value.
2. Reuse Where practical, containers or packaging components
should be reused.
3. Recycle Where practical, packaging should be collected & the
materials recycled for further use.
4. Recover Finally, before consigning packaging to a landfill, some
thought it should be given to possibly recovering other value from
waste.
The Society of Plastics Industry (SPI) codes identify the main packaging plastic
families. PETE is usually abbreviated PET & V is for PVC. Less commonly used
plastics & mixed-plastic constructions are classified as “others”.
Sustainability Issues
The focus in general press tended to be on Global
Warming (GW) & Green house gases (GHG) emissions,
but this is only part of the picture.
1.Despite replanting, global forest coverage is shrinking every year.

2. Global fisheries are being depleted. E.g. Grand Banks of North
America’s east coast & others have already been essentially fished
out.
3. Changing weather patterns have caused severe water shortages.
4. Arable crop land is being reduced. Food shortage are on the
increase.
5. Air, water & soil pollution are increasing as is global temp.
6. The global economic model is based on continuous growth, while
global resources are fixed.
Sustainability
Environment Consumption Our consumption of

resources has gone
beyond the balance
point at which the envi
can accommodate &
Sustainability is a balancing act generate them.
If global population will

grow by 1.7B people by
Is this sustainable? 2025, are we going
This is not sustainable !!! able to get enough
feed, clothe & shelter?
Sustainability & Packaging
Inputs
Energy Ouputs Final product
Manufacturing
Minerals &
processes Products
Petrochemicals consumption
biomass By-products
Solid waste
End of life
Liquid waste
Airborne waste
Acid rain, ozone depletion, eutrification, smog, human

toxicity, climate change, ecotoxicity.
Life Cycle Analysis (LCA)
fuel fuel energy water
Cultivation
seeding harvesting milling fermenting
energy user distillation Waste

liquor
Animal feed
fertilizer energy
base
Pesticides
chemicals
herbicides
CRADLE TO CRADLE
Cradle to Grave paradigm
Producer is responsible for a
packaging material till it has
been properly disposed of
Cradle to Cradle paradigm

Producer is responsible to
recover used packaging
material & return it into d
manufacturing cycle to be
manufactured into new
packaging.
If fails, producer recover some
other useful values e.g. energy
or composting from the
residues.
THE MODERN PACKAGING INDUSTRY
Metal cans Fillers photography
Glass bottles cartoners marketing
Labels Case packers legal
Paper cartons Date coders Consumer testing
Plastic containers cappers consultants
Raw materials converters machinery services
Suppliers
THE PACKAGING INDUSTRY
Users
consumer industrial institutional

Food Automotive Food
pharmaceutical Machineryl Nonfood
toys Bulk food Military
hardware Chemicals Medical devices
Broad-based Specialised in Other
general- packaging international
interest focus activities
Packaging World Packaging
Institute of Organisation (WPO)
Packaging Machinery
Professionals Manufacturers International
(IoPP) Institute (PMMI) Organisation of
Standards (ISO)
ASTM
Packaging
Flexible Packaging TAPPI
Association of
Association (FPA)
Canada (PAC)
ISTA
LECTURER’S NAME: DR. ROSNITA A. TALIB
COURSE NAME: PACKAGING TECHNOLOGY
INTRODUCTION OF PACKAGING TECHNOLOGY:
Food packaging refers to knowledge of science and technology related to packaging

for food. It also covers the development of producing successful packaging design,
packaging material, packaging quality control and equipment as well as halal
packaging, certification and standard.
IMPORTANCE OF FOOD PACKAGING:
Packaging is now generally regarded as an essential component of our modern life

style. Packaging protects the foods we buy from rapid spoilage and damage. Without
packaging, materials handling would be inefficient and costly, and modern consumer
marketing would be difficult.
The environment will remain a major issue for the packaging industry. The driving
forces are threefold - the consumer, commercial interests, and government
legislation. On the commercial side, supply chain factors will play a key role as
companies in the retail chain respond to the environmental challenge. Recycling,
down-gauging and "simplicity" will remain on the agenda. Commercial reality will
ensure that it will be comparatively rare for a company to package a product
deliberately with more packaging than is necessary thus increasing cost and,
thereby, making the product less competitive. A clear understanding on safety,
environmental aspects related to packaging will produce more responsible
packaging producers and users. It is also important to understand that sustainability
in packaging is a balancing act between environment and consumption. Halal
packaging is also becoming more important as well as it’s certification and standard
due to marketability of products to over 50 million Halal consumers in Europe and
over 1.6 billion worldwide. Thus, this topic will also be discussed in this course.
APPLICATION OF FOOD PACKAGING:
Packaging for food are used widely in packing variety products including fresh
produces such as fruits, vegetables, as well as processed food and pharmaceutical
products.
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REFERENCE BOOKS:
1. Soroka, W. (2009). Fundamentals of Packaging Technology (4th Edition).

Naperville: Institute of Packaging Professionals.
2. Kelsey, R.J. (2004). Handbook of Package Engineering (4th Edition). Boca

Raton: CRC Press.
3. Klimchuk, M.R. & Krasovec, S.A. (2006). Packaging Design: Successful

Product Branding from Concept to Shelf. Hoboken: John Wiley & Sons.
4. Morris, S.A. (2010). Food Packaging Engineering. Iowa: Blackwell Publishing

Professional.
5. Robertson, G.L. (2006). Food Packaging - Principles and Practice (2nd Edition).
Boca Raton: CRC Press.
COURSE TOPICS:
Lecture Topics:
1. Perspective on packaging
2. Environmental and sustainability aspects in packaging
3. Packaging functions
4. Elements of successful packaging
5. Paper and paperboard packaging
6. Glass packaging
7. Metal packaging
8. Plastic packaging
9. Halal packaging, certification and standard
10. Quality control in packaging
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Laboratory topics:
1. Determine packaging contain function – Packaging product analysis

2. Determine packaging protect function – Packaging product analysis
3. Determine packaging preserve function – Packaging product analysis
4. Determine packaging inform function – Packaging product analysis
5. Determine packaging level – Packaging product analysis
6. Identification of Sampling plan in packaging
7. Evaluation of sampling plan
8. Evaluation of flexible package performance – Integrity test analysis
9. Evaluation of transport packaging performance – drop test analysis
10. Categorisation of various packaging equipment
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COURSE : PACKAGING TECHNOLOGY
LECTURER : DR. ROSNITA A. TALIB
PROGRAM : MASTER
DATE : 24 TH OCTOBER 2015 (SATURDAY)
TIME : 14:00-15:00 P.M. (1 HOUR)
VENUE : ROOM 109
NAME : _________________________________________
SIGNATURE : _________________________________________
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1. What are the basic functions of packaging?
i. Contain iii. Protect
ii. Inform iv. Convenient
(A) i, ii and iii

(B) ii, iii and iv
(C) i, ii and iv
(D) i, ii, iii and iv
2. Choose non-basic functions of packaging?

i. Motivate iii. Dispense
ii. Preserve iv. Convenient
(A) i, ii and iii

(B) i, iii and iv
(C) i, ii and iv
3. Which one of the following defines package correctly.

(A) reflecting the ever changing nature of its contain.
(B) the act of creating or producing a package.
(C) a coordinated system of preparing goods for transport.
(D) a physical form that is intended to contain, protect, transport and inform.
4. Which one of the following defines packaging correctly.

(A) a physical form that is intended to contain, protect, transport and inform.
(B) the egg’s shell.
(C) a coordinated system of preparing goods for transport.
(D) non complex and non-dynamic trends.
5. Which one is not technical in nature packaging functions.

(A) measure
(B) protect
(C) promote
(D) dispense
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6. Marketing oriented packaging function communicate to consumers via:
i. Colour iii. Typography style
ii. Texture iv. Symbol
(A) i, ii and iii

(B) ii, iii and iv
(C) i, ii and iii
7. A responsible package designer must understands these two important environmental issues. What are
they?
(A) Labelling requirements
(B) Sustainability and 4Rs concept
(C) Available machineries
(D) Customs and social habits
8. Amongst the elements of 4Rs, which one shall be the first choice of any packaging producer to be
responsible to the environment?
(A) Recycle
(B) Recover
(C) Reuse
(D) Reduce
9. Choose two major packaging plastic families popular for recycling?

i. 1-PETE iii. 3 - PVC
ii. 2- HDPE iv. 4 -LDPE
(A) i and ii
(B) i and iv
(C) ii and iv
(D) ii and iii
10. Irresponsible package designer and user will cause these problems to environment.
i. Acid rain iii. ecotoxicity
ii. Toxicity iv. Clean river
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(A) i, ii and iii
(B) ii, iii and iv
(C) i, ii and iv
11. What is The Packaging Cycle.

(A) A material life cycle
(B) Incomplete cycle
(C) Non cyclic model.
(D) An energy life cycle
12. Which one is not a product of primary converters.

(A) Plastic resin pellets
(B) Roll of metal
(C) Label
(D) Sheet of paper
13. Choose the correct paradigm in sustainable packaging concept.

(A) Grave to Cradle
(B) Grave to Grave
(C) Cradle to Grave
(D) Cradle to Cradle
14. What is sustainability in packaging?

(A) Is a balancing act between environment and environment .
(B) Is a balancing act between environment and consumption.
(C) Is a balancing act between environment and industry.
(D) Is a balancing act between environment and pollution.
15. Packaging industry is a major consumer of materials thus resulted a significant production of waste
materials. What are the possible wastes?
(A) Solid, liquid, airborne wastes.
(B) Solid, chemical, waterborne wastes.
(C) Solid, fluid, waterborne wastes.
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(D) Solid, semi-solid, airborne wastes.
16. Which one is not the Users in modern packaging industry.

(A) Consumer
(B) Institutional
(C) Industrial
(D) Primary converter
17. Modern packaging industry needs the following services to function.

i. Photography iii. Legal
ii. Marketing iv. Consumer testing
(A) i, ii and iii

(B) ii, iii and iv
(C) i, ii and iv
18. Choose correct description about primary packaging.

i. The first wrap or containment iii. Grouping of product for bulk handling
ii. Directly holds product for sale iv. No decorations
(A) i and ii
(B) i and iii
(C) i and iv
(D) ii and iii
19. Arrange different levels of packaging according to the correct ascending order.
i. Breakfast cereal in Aluminium bag iii. Decorated paperboard carton
ii. Corrugated brown carton iv. Unit load
(A) i, iii, ii and iv

(B) i, ii, iii and iv
(C) i, ii, iv and iii
(D) iv, i, ii and iii
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20. Choose correct description for consumer packaging.
i. Directed towards retails and households iii. Small units in large number
ii. Attractive decorations iv. Not appealing to the eyes
(A) i, ii and iv
(B) i, ii, and iii
(C) i, iii and iv
(D) iv only
21. Which one is not the correct packaging type based on physical form.
(A) Flexible
(B) Semi flexible
(C) Rigid
(D) Hard
22. Which one correctly described product’s physical form in a package.

(A) solid and granular material
(B) volatile and odorous
(C) corrosive and toxic
(D) acid or alkaline
23. What the best description for a mineral water?

(A) mobile fluid
(B) viscous fluid
(C) paste
(D) granular material
24. What is the best description for fine sugar?

(A) mobile fluid
(B) viscous fluid
(C) paste
(D) granular material
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25. Choose the problems associated with transport function in packaging.
i. Vibration iii. Mechanical shock
ii. Abrasion iv. Deformation
(A) i, ii and iv
(B) i, ii, and iii
(C) i, ii, iii and iv
(D) iv only
26. Packaging design are planned to reflect _______________________________.

(A) changing in social and economic trends in the world
(B) not appealing to the eyes design
(C) non-functional packaging
(D) not saleable packaging
27. Packaging design objectives encompass two components which are ________________________.
i. structural and material iii. shape
ii. graphic design iv. colour
(A) i and iv only

(B) i and ii only
(C) i and iiii only
(D) iii and iv only
28. Which of the following packaging material-structures provide an appropriate believable pesona.
i. glass-rigid iii. metal-semi-rigid
ii. paperboard-rigid iv. plastic-flexible
(A) i and iv only

(B) i and ii only
(C) i and iiii only
(D) iii and iv only
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29. White space in pharmaceutical packages reflects _______________.
i. purity iii. hygiene
ii. sterility iv. cleanliness
(A) i and iv only

(B) ii, iii and iv only
(C) i and iiii only
30. Successful packaging design must be ______________________.

(A) product’s expression not personal expressions
(B) merely the visual impact
(C) semi-functional packaging
(D) indistinctive
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PACKAGING FUNCTIONS
& PACKAGE DESIGN
14 Elements for Successful
1. SUCCESSFUL
1. SUCCESSFUL
PACKAGE DESIGN
PACKAGE DESIGN Packaging
2. KNOW YOUR PRODUCT
3. COMMUNICATE
4. MARKET ANALYSIS
5. STYLE
6. COPY
7. PRODUCT LIABILITY
8. EXPORT CONSIDERATIONS
9. VENDING
10. MATERIAL SELECTION
11. PRODUCTION REQUIREMENTS
12. SPECIFICATIONS
13. COSTS
14. TESTING
•Connects form, structure, materials, color, imagery, typography & ancillary
design elements with product information to make a product suitable for
Successful marketing.
•Example: consider all 5 senses, not merely the visual impact e.g. the pop
package of a cork, perfumed ink, special texture
Design •Distinctive
•Ability to run on existing equipment at required speed & efficiencies.
•Strength requirements for warehousing etc.
• Among the critical requirements of a package is to maintain its integrity

Know Your under storage conditions, distribution & end use.
• Regulatory requirements.
Product • For dangerous products – package must state nature of hazard & methods
to prevent or offset injuries from such hazards.
• Function as aesthetic means of communicating from all different

Communi backgrounds, interest & experiences – awareness of antrophology,
sociology, physiology, ethnography & linguistics can benefit the design
cate process & the appropriate design choice.
• Product’s expression not personal expressions.
Market •PD serves to visually communicate product differentiation.
Analysis •Think from an appearance standpoint. Example……???
• Besides projecting its content visually, a package also can

Style convey the desired mood of the items..ORIENTAL
feminine EMPHATIC DIGNIFIED
• A promise should be implied in the main panel , to get

Copy attention of the viewer.
• E.g. trademark, description, catchy phrases, quantity
designation & manufacturers name.
Product •Broken glass produces jagged edges.
•Metal cans sometimes have sharp edges.
Liability •Injuries associated with packaging.
• If package is for exporting, hazards of transportation are

Export generally much greater.
considerations • Copy & graphics become more complex
• Color & its combinations should be searched carefully.
Vending • If there is possibility for an item to be used in vending

machines.
• Not to consider only material & labor costs. How about
fixed elements that comprise the overall cost of doing
business.
•Other expenses could be overlooked are:
• control costs for inspection & testing;
Costs •operational cost e.g. sterilisation etc;
•maintenance & supervision;
•anticipated spoilage.
•Promotional materials such as retail display containers
should be charged to the cost of goods or a special
advertising account?
•How about the costs for product launching?
• Not much info on technical information in production
Production line.
Requirements • Lack of various techniques in packaging operations e.g.
cleaning, labeling, wrapping, sealing etc.
• Communicating in precise terms, with purchasing,
manufacturing, QC & all other departments.
Specifications • Properly prepared specifications increase efficiency in all
areas, help prevent errors & should keep costs to a min.
•Based on economical cost, specific properties.
•Paper & paperboard are generally the cheapest, eco-friendly
& sustainable.
Material •Metals have high degree of strength & rigidity.
•Glass may be losing share of market but it is often been
Selection chosen for expensive look & stringent barrier properties.
•How about environmental-friendly issues (as an example)?
The material selection shall be not less crucial than fulfilling
the other important requirements.
• Development of an adequate testing prog.

• Failure of testing prog can be very costly when the effects are
multiplied by the large number of inadequate packages that
Testing might be produced, extra cost of correcting errors, increased
waste rates & loss of consumer satisfaction due to damaged
goods.
Basic/Primary Packaging
Inform/sell Functions
Contain
Provide informations Functions
e.g. how to use, to warn of To hold the pdct
about hazard of misuse, directly.
reveal product content. Packaging
Much of info req.
according to various
laws and regulations. Protect/Preserve
Transport
Against leakage,
To easily & breakage, tampering,
safely move seal out againts
pdct from contaminants (dirt,
manufacturer to moisture, germs, dust
wholesaler to etc) in the
retailer to environment.
consumer.
Packaging types-layer/level
of functions
The basic pckg funcs have diff levels of importance depending on the
particular pckg level.
Primary package Secondary package
-The first wrap or -Any outer wrappings that

containment that help to store, transport,
directly holds/envelops inform, display and protect
product for sale. the product .
-E.g. bottle, can, tube, -E.g. decorated carton or

fiber drum. gift box.
Packaging types-layer/level
of functions
The basic pckg funcs have diff levels of importance depending on the
particular pckg level.
Tertiary package Unit load
- Distribution package -A group of distribution

(shipper). packages assembled
into a single unit for the
Grouping of product for purpose of mechanical
bulk handling, warehouse handling, storage &
storage, transportation & shipping.
shipping.
-E.g. contena.
-E.g. corrugated brown
carton, large pallets of
shrink- wrapped boxes.
Example 1: a breakfast cereal as a packaging product.
Primary package
Is the inner undecorated Al bag.
Main function – to contain & preserve the product, &
to a lesser extent, protect it.
sydlexia.com
Secondary package
Is a paperboard carton, provides physical
protection, informs the consumer &
motivates the purchase decision.
Shipping container
12 cartons are packed into a corrugated shipping
container to protect the product & to facilitate
manual handling & warehousing. The information
printed on the corrugated shipper primarily to
identifies the product for distribution purposes.
Unit load
westfliausa.com Corrugated shippers are assembled into a single unit of unit
load, to facilitate mass handling during distribution.
Quiz 2: Shrink wrap!!!!
Is it Primary ??
Secondary ??
Tertiary package??
Quiz 3: Eggs in the egg carton!!!!
Is it Primary ??
Secondary ??
Tertiary package??
Packaging types-intended
destination/end-users
In addition, packages are often defined by their intended destination or end-
user.
Consumer packaging Industrial packaging
- The package that will ultimately reach -A package for delivering goods from
the consumer as a unit of sale from a manufacturer to manufacturer. It is
merchandising outlet. usually, but not always, contains
- Small units in large number goods or materials for further
processing.
- Attractive decorations
-Larger & heavier units,
- Directed towards retails and -No attempt appealing to the eyes
households - E.g. Fibre drums, gunny bag.
- E.g. Consumable goods – food,
beverages.
Packaging types-commodity
Food packaging
Pharmaceutical packaging
Medical device packaging
Electronic packaging
Cosmetic packaging
Chemical packaging
Hazardous materials packaging
Packaging types- different
physical form
Flexible
e.g. sachets, pouches, Semi-flexible

plastic sacks
e.g. paperboard boxes for
cereal
Rigid
e.g. crates, glass bottles,

metal cans
THE CONTAIN FUNCTION
The product’s physical form :

Mobile fluid viscous fluid solid/fluid mixture
Gas/fluid mixture granular material paste
Free-flowing powder non-free flowing powder solid unit
Discrete items multicomponent mix
The product’s nature :

corrosive corrodible flammable
volatile perishable fragile
aseptic toxic abrasive
Odorous subject to odour transfer easily marked
Sticky hygroscopic under pressure
Irregular shape acidic/alkaline easily melt
THE PROTECT/PRESERVE
FUNCTION
Examples of protective packaging
problems & concerns
Conditions Quantification or Design Requirement
Vibration Determine resonant frquencies

Mechanical shock Determine fragility factor (drop height)
Abrasion Eliminate or isolate relative movement
Deformation Determine safe compressive load
Temperature Determine critical values
Relative humidity Determine critical values
Water Design liquid barrier
Tampering Design appropriate systems
THE PROTECT/PRESERVE
FUNCTION
Typical preservation packaging problems & concerns

Conditions Quantification or Design Requirement
Oxygen Determine required barrier level

Carbon Dioxide Determine required barrier level
Other volatiles Determine nature & barrier level
Light Design opaque package
Spoilage Determine nature/chemistry
Incompatibility Determine material incompatibilities
Biological deterioration Determine nature
Deterioration over time Determine required shelf life
THE TRANSPORT FUNCTION
-Transport function entails the effective movement of goods from the point of
production to the point of final consumption.
-This involves various transport modes, handling techniques & storage conditions.
-In addition to the general physical rigors of distribution, there are number of carrier
rules that will influence the package design.
- A good packaging contributes to the safe, economical & efficient storage of a product.
-Table below provides examples of some of the information required to design

successful distribution packaging
Typical transport, handling & storage information
truck rail aircraft
Cargo ship storage duration storage conditions
Handling methods unitizing method specific shipping unit
Weight considerations stock picking dimension limits
Carrier rules environmentally controlled storage
THE INFORM/SELL FUNCTION
- The communication roles perhaps is the most complex of the packaging functions to
understand, measure & implement because of the many levels at which this
communication must work.
-For example, laws & customs dictate certain messages, without much leeway in their
presentation:
Specific name of the product (what is this?)

Quantity contained
Address of the responsible body
-However, to promote the contained product effectively, a package must appeal to the
potential customer at all levels. The package itself communicates by many channels
such as:
Selected material Predominant typography
Shape & size Recognizable symbols or icons
Illustrations Colour
TRENDS OF PACKAGING
1. health consciousness (nutrient and
additive contents)
2. family size/singles (different portions)
3. economy (various sizes, quality levels)
Past 4. mobility (convenience items)
5. novelty (152 new food and drug items
were introduced in the U.S. in June
Package are 1982)
designed to contain, 6. labeling requirements (contents and
preserve & transport. directions)
7. available equipment (products for the
freezer or microwave)
8. time and convenience to purchase and
Current Trends of Packaging use (various available sizes, complete
meals in a package)
9. consumerism (consumer complaints
Package design are planned have the highest influence on
to reflect the many changing pharmaceutical and health-related
social & economic trends in products)
the world Factors ? 10.customs and social habits (beverage
packaging)
11.environmental concerns (reduced,
PACKAGE DESIGN - objectives
Objectives
Structural & materials component
encompasses the features & characteristics that fulfill
the package’s technical & physical requirements/
configurations: containment, protection/preservation,
convenience & the Q s that facilitate transport &
distribution as well as provide the physical surface on
which the packaging design exists.
A package
design
Graphic component
encompasses the features & characteristics that
attract & inform the consumer & motivate a
purchase decision. E.g. surgace decorations,
although form/ material /shape are equally
important.
Packaging material - structure
Physical shape & choice of material are very important factors in producing a
believable persona.
Paper & Paperboard Plastics
•Corrugated •Rigid or flexible Glass

paperboard bottles, Bottles
•Folding carton tubes, Jars
•Set-up boxes blister packs etc.
•Canisters
•Others Metal
•Cans
•Containers
•Tubes
•Blister Aluminium packs
Basic design elements
Shape
the actual package outline or outline of an illustration or body of text. Length:width
proportions of 2:3 & 3:5 are the most pleasing. Length:width proportions of 2:3 & 3:5
are boring.
Size
How large or small the object or design is. Size can be physical or perceptual.
Colour
Can attract attention & affects the moods or persona of the package. Colour can also
add expense to the package.
Texture
Perceived or real smoothness or roughness. It involves the sense of touch. Consider
the difference between a plastic bag & paper bag. Texture can be created using
graphic patterns or textured substrate.
Basic design elements
Tone
The lightness or darkness. Darker colours appear heavier than lighter ones.
Line
Can be straight or curved, heavy or light, rough or smooth, continuous or broken.
Certain line orientations can create different feelings:
Horizontal: calm Vertical: dignity
Diagonal: vitality Curved: grace
Converging: distance Shadows: volume
Icons
Can attract attention & affects the moods or persona of the package. Colour can also
add expense to the package.
Balance & Unity
In addition, the following considerations contribute to a package’s balance &
unity:
Balance is the convergence of elements or parts to create a design that

makes the appearance of a “whole”.
 Visual balance can be created by symmetrical or formal balance centres

elements geometrically. The elements of one side of the vertical centre
are repeated on the other. Assymetrical or informal balance arranges
elements by optical weight from left to right.
 Weight must be distributed vertically. The bottom is normally given more
weight to avoid a top-heavy look. This can be done optically by having
lighter colours at the top & darker colours at the bottom.
 A theme or mood can create unity. This includes colour, typography,
substrate material & so on.
Balance & Unity
 All elements must tie together in a sense of harmony & belonging. Every
element has to fit so that if one part is removed, it will be missed.
 White space can be a “negative” design element. If there is too much
white space inside the design, it “falls” apart. Use it around the outer
edges. However, white is a common element in pharmaceutical packaging
where it is associated with cleanliness & sterility.
Thank you
HALAL CERTIFICATION
& HALAL PACKAGING
What are the emerging trends & current
issues in Malaysia & Worldwide?
1. Packaging Safety Issues !!!
- Adulteration/migration of hazardous substances to foods.
- E.g. Perfluorinated compounds (PFCs) - widely used in food packaging.

- They are found in teflon cookware, microwave popcorn bags and
stain-resistant carpets.
- These chemicals can weaken the ability of vaccination jabs to
protect young children. It was reported that children exposed to
PFCs in the womb or in the first years of life had lower immunity to
tetanus and diphtheria.
175 Hazardous Chemicals Used in Food Contact Packaging
- Food Packaging Forum (2014) - 175 substances identified are classified

as carcinogenic, mutagenic, or reprotoxic. Others are considered to
interfere with the hormone system, the so-called endocrine disruptors. A
third group of chemicals is considered persistent and bioaccumulative.
Phthalates, which are widely used as plasticizers, are one prominent example
for endocrine-disrupting chemicals that may lead to male infertility, genital
malformations and cancer.
Benzophenones and organotin compounds add to the list of endocrine-

disrupting chemicals used in printing inks and coatings of food contact
materials.
Please refer to attached file that containing the full text article for your
reference.
issues Worldwide?
2. Halal Issues
 Packaging receives Halal certification.
1. In 2009, Titan Chemicals, now known

as Lotte Chemical Titan (formerly
known as) - produces world’s 1st halal
certified polyolefin resins.
 Malaysian Standard on Halal Food

(MS 1500:2009); titled ‘Halal Food:
Production, Preparation, Handling and
Storage – General Guide (MS
1500:2009).
issues Worldwide?
3. Halal Issues-continued.
2. Cardia Bioplastics, an Australian
developer and manufacturer of
sustainable plastics and packaging has
received Halal certification for a new
range of resins. (Food Magazine, 2 July,
2012)
 It has derived its range of Biohybrid

resins from renewable products.
http://www.foodmag.com.au/News/Packaging-receives-Halal-certification
What is HALAL ?
 Halal originates from an Arabic phrase that means allowed or permitted by Islamic Law.
 The opposite of Halal is Haram / non-Halal that means forbidden and prohibited.
 Any food or drink which lies within the grey area and does not fall clearly under the
Halal or non-Halal category is classified as Syubhah’, alternatively called questionable or
dubious. In this category, until the status becomes clear, Muslims should avoid
consuming Syubhah food or drinks.
 The general principle concerning food according to Islamic teachings is that everything
is Halal except impurity (or mixed with impurity), harmful and intoxicant. Therefore, it is
compulsory for Muslims to eat good and healthy food and to avoid all that is forbidden
by Allah.
http://www.halalmalaysia.com.my/halal-certification/
What is HALAL CERTIFICATION ?
 Halal Certification is a process by which a Government-controlled Agency or a credible
Islamic organization certifies (Board) that a company's products can be lawfully consumed
by Muslims. Those who meet the criteria for certification are issued with Halal Certificates
and they may use the Halal symbol on their products and for advertising.
 Halal food certification refers to the examination of food processes in its preparation,
laughtering, cleaning, processing, handling, disinfecting, storing, transportation and
management practices. The application of halal should apply to all stages of processing
"from farm to table".
 Food labeling laws around the world require that claims made on the product label be
certified as true. A "Halal Certified" stamp on a label is often seen by Muslim customers as
a sign of a trustworthy or genuine product. Such a stamp may even be required for the
export of food to certain Muslim countries.
 A Halal certificate is an assurance that a particular product has been thoroughly

investigated and found to conform to the Islamic Shariah Laws and therefore is suitable for
use by Halal consumers. Products certified as Halal by the Board can utilise the registered
trademark Halal logo.
HALAL Logos Around the World
What is HALAL CERTIFICATION ?
In Malaysia
 The Government has, since 2003, streamlined the implementation of the Halal
Certification.
 A Halal certificate is issued by Department of Islamic Development Malaysia (JAKIM).
 JAKIM is responsible for issuing the certificates for halal products for exports and
imports, while the state governments issue halal certificates for local consumption.
While the state governments issue halal certificates for local consumption.
HALAL CERTIFICATION ?
In Malaysia
 A new Halal label was also introduced by JAKIM in 2003 for the purpose of coordinating
the use of a uniformed label at federal as well as state level. Earlier the fifteen different
labels used by the states and JAKIM had caused confusion among applicants and
importers.
 The new label when issued by the state will bear a state code in the label, while the label
issued by JAKIM will not have any code number.
 The new label has been registered under the Trade Mark Act 1976 and the Trade Mark
Regulations 1997. ThisAct that would enable JAKIM (Malaysian Islamic Development
Department) to carry out enforcement on Halal certificate and logo.
Advantages of HALAL CERTIFICATION
 Enhance marketability of products to over 50 million Halal
consumers in Europe & over 1.6 billion worldwide.
 If planning to export products, Halal certificate will help the
company to meet the importing countries requirements.
 If your product is used as an ingredient by your customer, then it
will help your customer to obtain Halal certification & thus
maintain your customers & may also increase sales.
 Halal certified products can be advertised as Halal & can also
display the registered trademark Halal logo on their packaging,
hence making the products readily acceptable by Halal
consumers.
http://www.tmfb.net/halal-certification/halal-certification
HALAL Certification
process
JAKIM’s Halal Certification Flow Chart

Compliance to HALAL Requirements
 With the certification, manufacturers are obliged to act
responsibly to maintain the halal status of the food they produce.
 Manufacturers must ensure during all phases of the production,
the raw materials, equipment, tools and materials used must not
be najs, mixed with any najs material or has been in contact with
najs materials. The product and raw materials used must also be
safe and will not cause harm to the health.
 Ensuring a product is halal is not only limited to the materials and
ingredients used.
 Halal requirements cover all aspects of preparation, processing,
packaging, distribution and all related processes. Any equipment
found to be in contact or contaminated with non halal materials
must be cleansed according to the Syariah requirements.
Compliance to HALAL Requirements
 In Halal food, cleanliness and hygiene is very closely related to
food safety.
 This is an important prerequisite halal certification and the
requirement covers personal hygiene, attire, equipment and
working environment.
Employees’ Understanding
on Halal requirements
 All employees required to be trained to understand the halal
concept, as well as their roles and responsibilities in ensuring the
products are handled accordingly.
 Manufacturers are encouraged to establish a quality assurance
unit to monitor all requirements of halal are complied with at all
time, especially in critical areas such as procurement. The unit
should also ensure that any non-compliance is immediately
rectified.
What is HALAL FOOD ?
Malaysia has defined Halal food through its MS1500:2009: Halal Food –
Production, Preparation, Handling & Storage – General Guideline (Second
Revision) as food permitted under Shari’ah and fulfills the following conditions:
• Does not contain any parts or products of animals that are non-Halal to Muslims or
products of animals which are not slaughtered according to Shari’ah law,
• Does not contain any ingredients that are Najs according to Shari’ah law,
• Is safe and not harmful,
• Is not prepared, processed or manufactured using equipment that is contaminated
with things that are Najs (filth or unclean) according to Shari’ah law,
• The food or its ingredients do not contain any human parts or its derivatives that
are not permitted by Shari’ah law,
• And during its preparation, processing, packaging, storage or transportation, the
food is physically separated from any other food that does not meet the
requirements stated in any above items, or any other things that have been
decreed as Najs (filth or unclean) by Shari’ah law.
What is HALAL FOOD ?
Malaysia has defined Halal food through its MS1500:2009: Halal Food –
Production, Preparation, Handling & Storage – General Guideline (Second
Revision) as food permitted under Shari’ah and fulfills the following conditions:
• Does not contain any parts or products of animals that are non-Halal to Muslims or
products of animals which are not slaughtered according to Shari’ah law,
• Does not contain any ingredients that are Najs according to Shari’ah law,
• Is safe and not harmful,
• Is not prepared, processed or manufactured using equipment that is contaminated
with things that are Najs (filth or unclean) according to Shari’ah law,
• The food or its ingredients do not contain any human parts or its derivatives that
are not permitted by Shari’ah law,
• And during its preparation, processing, packaging, storage or transportation, the
food is physically separated from any other food that does not meet the
requirements stated in any above items, or any other things that have been
decreed as Najs (filth or unclean) by Shari’ah law.
What is HALAL in PACKAGING ?
According to MS 1500:2009
3.7 Packaging, labelling and advertising
3.7.1 Halal food shall be suitably packed. Packaging materials shall be halal in nature and
shall fulfill the following requirements:
a) the packaging materials shall not be made from any raw materials that are decreed as
najs by Shariah law;
b) it is not prepared, processed or manufactured using equipment that is contaminated
with things that are najs as decreed by Shariah law;
c) during its preparation, processing, storage or transportation, it shall be physically
separated from any other food that does not meet the requirements stated in item a) or
b) or any other things that have been decreed as najs by Shariah law;
d) the packaging material does not have any toxic effect on the ha/al food; and
e) packaging design, sign, symbol, logo, name and picture shall not be misleading and/or
contravening the principles of Shariah law.
3.7 Packaging, labelling and advertising
3.7.2 Packing process shall be carried out in a clean and hygienic manner and in sound
sanitary conditions.
3.7.3 Labelling material used in direct contact with the product shall be non-hazardous and
halal.
3.7.4 Halal food and halal artificial flavour shall not be named or synonymously named after
non halal products such as ham, bak kut teh, bacon, beer, rum and others that might create
confusion.
3.7.5 Each container shall be marked legibly and indelibly or a label shall be attached to the
container, with the following information:
a) name of the product;
b) nett content expressed in metric system (SI units);
c) name and address of the manufacturer, importer and/or distributor and trademark;
d) list of ingredients;
e) code number identifying date and/or batch number of manufacture and expiry date; and
f) country of origin.
3.7.6 For primary meat products, the label or mark shall also include the following
information:
a) date of slaughter; and
b) date of processing.
3.7.7 Advertising shall not contravene with the principles of Shariah law and shall not
display indecent elements which are against Shariah law.
Thank you
PAPER
AND
PAPERBOARD
Sources & Preparation of Fiber
1. SUCCESSFUL PACKAGE DESIGN
Paper – defined as a matted or felted sheet usually composed of plant fiber.
Raw material - wood fibers derived from logs, wood chips etc.
(fiber sources) - recovered wastepaper
- non wood fibers e.g. straw, hemp, cotton, flax, bast (e.g. linen,
cotton) & other materials are used to some extent domestically.
paper Thickness basis 0.012 in. (308 m)

Papers < 0.012 in. (308 m)
Heavier paper stock (card stock) 0.006 – 0.12 in. (154 - 308 m)
Paperboard > 0.012 in. (308 m)
Fiber length
The properties of paper & paperboard are dependent on a large number of variables.
Thus, to understand paper products, it is best to know:
1. Fiber source
2. Fiber length
3. How the fiber was extracted & prepared for papermaking
4. The machine on which the paper was made
5. Treatments given on the finished paper
Approximate fiber length of cellulose used in papermaking (Walter, S., 2009)

Fiber Source Typical Fiber Length
Main sources
Hardwood (e.g. poplar, maple) 2 mm/0.08 in
Softwood (e.g. pine, spruce, hemlock) 4 mm/0.16 in
Other Sources
Straw, baggase < 2 mm/0.08 in
Bast (e.g. linen, cotton) > 2 mm/0.08 in
Recycled paper Varies depending on source
The most important characteristic for papermaking is fiber length.
Shorter Longer
fiber length Tensile strength fiber length
Burst strength
Lower Higher
values Tear strength values
Fold endurance
Formation
Good (evenness of fiber distribution)
Wild
formation formation (poorer)
Finer & smoother

paper & also
consistent density
Requirements in paper quality
In designing a package, package designers must compromise between requirements for

achieving important qualities in paper.
Good folding ability,

Good printability
High tensile strength,
(requiring a short fiber but
High burst strength
resulting in a loss of physical
(requiring a long fiber but
strength properties)
resulting in poor formation)
Other Sources of Fiber
Recovered or recycled fiber
- Will have properties inherited from the original fiber source, but with provision that
every repulping process degrades & reduces fiber length.
-Recycled kraft will still have good strength although not as much as virgin kraft.
-Recycled newsprint, already a short fiber, will degraded further.
-Postconsumer waste may contain a variety of extraneous contaminants (many of which

cannot be removed) such as:
- Water-insoluble adhesives these appear in the finished sheet

- Plastic debris as tiny bits of color, “grease” spots &
- Nonremovable printing inks “shiners”.
Structure of Wood
•Cellulose consists of long, straight chains of glucose molecules. It forms the skeleton of
the plant wall and has the most desired properties for making paper. These fibres are
long, strong and translucent.
•Hemicelluloses are short, branched chains of glucose and other sugar molecules. They
fill in space in the plant wall. Hemicelluloses are more soluble in water and are thus often
removed during the pulping process.
•Lignin is a three dimensional phenolic polymer network or natural adhesive that holds
the cellulose fibres together and makes them rigid. It is chemically not stable as cellulose
& discolors readily, and also not water soluble and so can’t be easily removed by simple
water washing. Chemical pulping and bleaching processes selectively remove the lignin
without significantly degrading the cellulose fibres.
•Extractives account for 3(+/-2)% of softwoods. These materials include plant

hormones, resin and fatty acids along with other substances that help the tree grow and
resist disease and pests. These substances are highly toxic to aquatic life and account for
much of the acute toxicity of pulp mill effluent.
Structure of Wood - illustrations
Arrangement of fibrils, microfibrils and

cellulose in plant cell wall.
Structure of Wood - illustrations
Microfibril structure of plant cell walls.

Softwood vs Hardwood
Wood Types
Characteristics of softwood and hardwood fibres
Softwood Hardwood
Cellulose content 42% +/- 2% 45% +/- 2%
Lignin content 28% +/- 3% 20% +/- 4%
Extractives content 3% +/- 2% 5% +/- 3%
Fibre length 2-6 mm 0.6-1.5 mm
Coarseness 15-35 mg/100 mm
Wood Types
Characteristics of softwood and hardwood fibres
Trees can be divided into two general classes - softwoods and hardwoods. Softwood trees are conifers -
e.g., southern pine, Douglas fir, spruce. Hardwood trees lose their leaves every year. Examples include
birch, aspen, red gum.
Softwood fibres with their length and coarseness are generally used to provide strength to a sheet of
paper. Hardwood fibres, being finer and more conformable, give a sheet of paper its smooth printing
surface and opacity. Hardwood fibres are also easier to bleach to high brightness because they have
less lignin.
Paper generally consists of a blend of hardwood and softwood pulps to meet the strength and printing
surface demands of the customer.
Pulping methods
- a process of making pulp.
-In the pulping , water gets b/w lamellae & cause the fibers to swell and then break outer skin, so
that the individual fibrils (small fiber strands) can extend out and interlock with the hairy surface of
other fibers. Individual fibrils will increase as much as 20% in diameter when thoroughly wet, but
only about 3% in length.
-There are 3 processes to make pulp:

1. Mechanical – produces groundwood pulp (GWP)
2. Chemical
1. Soda process [caustic soda (sodium hydroxide + soda ash (sodium carbonate)
2. Sulfate (kraft) process (sodium hydroxide + sodium sulfide)
1. Bleached
2. Unbleached
3. Sulfite process (Ca or Mg bisulfide + sulphurus acid)
3. Combination
1. Thermomechanical
2. Semichemical (caustic soda or neutral sodium sulfite followed by grinding)
Preparing Pulp for Paper Making
-Cellulose bundles separated from the wood mass are refined (beaten) to release small fiber
strands (fibrils).
-Adjusting amout of refining can give an optimum property balance.
-Whiter pulps can be prepared by bleaching the natural pulps with chlorine-containing
compounds or hydrogen peroxide. However, this process reduces the mechanical strength of
the final paper.
Internal Sizing, Additives & Wet-End
Treatment
- There are a variety of sizing agents & additives can be added to the pulp in preparation
for pulp making:
a) Sizing agents: additives to help control water & ink penetration. Hard-sized
papers (high sizing paper) are very water resistant & slack-sized papers are vice
versa.
b) Starches, gums: to improve burst & tensile strength, stiffness & pick resistance.
c) Wet-strength resin: to improve wet tensile strength retention under high

humidity (or damp) conditions.
- Furnish = mixture of fiber, water ( approx. 98%) & additives that fed to the papermaking
machine.
Paper Making Machine
This paper making machine consists of 4 sections: (1)

Wet end section , with Fourdrinier machine; (2) Wet
Press section;(3) dryer section & (4) Calender section.
Fourdrinier machine
Furnish pours out of the headbox of a fourdrinier

machine & onto an endless wire or screen where excess
water can be drained. The fibers remain trapped on the
screen.
(1) Wet-end
-first section.
-Pulp may be delivered to the paper machine in a slurry form (a mixture of 0.5% fiber and 99.5%
water) directly from the pulping process. Alternatively, pulp may be supplied in dried sheets which
are then broken down in water to produce a similar slurry, before being fed to the refiners in the
wet end where the fibers are subjected to high pressure pulses between bars on rotating refiner
discs. This action causes the fibrils of the fibers to partially detach and bloom outward. After
refining the pulp is mixed with some of the following: sizing, fillers, colors, retention aid and waste
paper called broke to a stock, and passed on the headbox. Washing is done in pressurized
screens and hydrocyclones and also deaeration is done.
-The stock then enters the headbox, a unit that disperses the stock and loads it onto a moving
wire mesh conveyor with a jet from an opening called the slice. The streaming in the jet makes
some fibres align. This alignment can partly be taken away by adjusting the speed difference
between the jet and the wire. The wire revolves around the Fourdrinier table, from breast roll
under the headbox over the couch to the forward drive roll, foils under the wire are creating low
pressure pulses that will vibrate and partly deflocculate the fibres while water is removed.
-Later on Suction boxes below the wire gently remove water from the pulp with a slight vacuum
and near the end of the wire section the couch will remove water with higher vacuum.
(1) Wet-end
-The second section, which removes the most water via a system of nips formed by rolls
pressing against each other aided by press felts. This is the most efficient method of dewatering
the sheet as only mechanical pressing is required. Press felts historically were made from
cotton. However, today they are nearly 100% synthetic. They are made up of a polyester woven
fabric with thick batt applied in a specific design to maximise water absorption.
-Presses can be single or double felted. A single felted press has a felt on one side and a
smooth roll on the other. A double felted press has both sides of the sheet in contact with a
press felt. Single felted nips are useful when mated against a smooth top roll, which adds a two-
sidedness—making the top side appear smoother than the bottom. Double felted nips increase
roughness, as generally, press felts.
-Conventional roll presses are configured with one of the press rolls is in a fixed position, with a
mating roll being loaded against this fixed roll. The felts run through the nips of the press rolls
and continues around a felt run, normally consisting of several felt rolls. During the dwell time in
the nip, the moisture from the sheet is transferred to the press felt. When the press felt exits the
nip and continues around, a vacuum box known as an Uhle Box applies vacuum (normally -60
kPa) to the press felt to remove the moisture so that when the felt returns to the nip on the next
cycle, it does not add moisture to the sheet.
(2) Wet Press section
-Pickup roll presses are vacuum assisted rolls loaded against plain press rolls (usually a roll in
a centre position). These are generally found in machines built in the 1970s–1980s. Pickup
roll presses normally have a vacuum box that has two vacuum zones (low vacuum and high
vacuum). These rolls have a large number of drilled holes in the cover to allow the vacuum to
pass from the stationary vacuum box through the rotating roll covering.
-The low vacuum zone picks up the sheet and transfers, while the high vacuum zone attempts
to remove moisture. Unfortunately, centrifugal force usually flings out vacuumed water—
making this less effective for dewatering. Pickup presses also have standard felt runs with
Uhle boxes. However, pickup press design is quite different, as air movement is important for
the pickup and dewatering facets of its role.
-Crown Controlled Rolls (also known as CC Rolls) are usually the mating roll in a press
arrangement. They have hydraulic cylinders in the press rolls that ensure that the roll does not
bow. The cylinders connect to a shoe or multiple shoes to keep the crown on the roll flat, to
counteract the natural "bend" in the roll shape due to applying load to the edges.
(2) Wet Press section
-Extended Nip Presses (or ENP) are a relatively modern alternative to conventional roll
presses. The top roll is usually a standard roll, while the bottom roll is actually a large CC
roll with an extended shoe curved to the shape of the top roll, surrounded by a rotating
rubber belt rather than a standard roll cover. The goal of the ENP is to extend the dwell
time of the sheet between the two rolls thereby maximising the dewatering. Compared to a
standard roll press that achieves up to 35% solids after pressing, an ENP brings this up to
45% and higher—delivering significant steam savings or speed increases.
(3) Dryer section
The dryer section of the paper machine, as its name suggests, dries the pulp by way of a
series of steam-heated rollers that stretch the web somewhat, removing the moisture until
only 4-8% of moisture remains. Additional sizing agents, including resins, glue, or starch, can
be added to the web to alter its characteristics. Sizing improves the paper's water resistance,
decreases its ability to fuzz, reduces abrasiveness, and improves its printing properties and
surface bond strength. Some paper machines also make use of a 'coater' to apply a coating
of fillers such as calcium carbonate or china clay.
(4) Calender (machine finished) section
A calender consists of a number of rolls, where pressure and heat is applied to the passing
paper. Calenders are used to make the paper surface extra smooth and glossy. It also gives
it a more uniform thickness. The pressure applied to the web by the rollers determines the
finish of the paper.
After calendering, the web has a moisture content of about 4-8% (depending on the furnish).
It is wound onto a roll called a tambour, and stored for final cutting and shipping. The roll
hardness should be checked, obtained and adjusted accordingly to insure that the roll
hardness is within the acceptable range for the product.
Cylinder Machines
Rotates a screen drum in a vat of furnish. As the paper pours through the screen,
fiber accumulates on the outside of the screen. This thin layer of matted fiber is
transferred onto a moving felt belt that passes sequentially over further rotating
cylinders, each of which deposits another fiber layer.
Cylinder machines dewater furnish at the cylinder & paste a thin layer of fiber against
the felt. The fiber of subsequent layers is weak.
The dry end- similar to Fourdrinier machine.

Cylinder Machines
A cylinder machine with 6 cylinders

at whict paper layers can be formed.
Cylinder boards are multi-ply boards.

An advantage is that the plies can all
be different.
Vertiformer & twin-wire
formers inject the furnish
between two moving wire
screens.
The advantage is that
dewatering takes place on both
sides of the paper & therefore
fast.
These machines can produce
single & multi-ply sheets with
identical formation at both
faces.
Machine Direction & Cross Direction
MD - the direction in which fibers-and-water

slurry (stock) flows or tends to align in the
direction of travel onto the paper machine
wire.
CD – the direction across the paper making

machine & across the fiber alignment.
The MD can affect paper properties:
Tear strength is higher across MD

Stiffness & Fold endurance are greater
across MD.
Paper Characterisation
Caliper (or thickness) & Weight:

-paper & paperboard are specified in values as caliper or thickness, & a
value in density.
-inch/pound or metric units – used by different mill products.
(A) In inch/pound units:

• Caliper is expressed in thousandths of an inch or in “points”. One
thousandth of an inch is 1 point. For example, a 0.020-in. board would
be 20 points.
• Containerboard for the corrugated board industry & most paperboard
are specified by weight in pounds per 1,000 square feet, the “basis
weight”.
• Fine papers may be specified by the weight in pounds per ream. A
ream is 500 sheets, but the actual sheet size can vary depending on
the product.
Caliper (or thickness) & Weight:
-paper & paperboard are specified in values as caliper or thickness, & a value in
density.
-inch/pound or metric units – used by different mill products.
(B) In metric units:

• Caliper is expressed in micrometres or “µm”. Millimetres are sometimes used,
but µm has advantage of eliminating decimal point.
• Paper mass/unit area relationship is reported as “grammage” = the mass
(weight) of paper in one square metre regardless of the paper type.
The metric conversion factors are:
pounds/1000 sq. ft. x 4.88 = grams/per sq. m

0.001 inc = 25.4 µm (usually rounded to 25 µm)
Therefore, 1 point (0.001 inch) = 25 µm
A 20 points paperboard would be 500 µm (20 x 25)
Brightness
Brightness- measure of the total reflectance of white light.
Values – in scale of 1 to 100, 0 representing black (no light reflection) &

100 (reflection from magnesium oxide).
Paper stock brightness is a specification value for printing paper.

Paper & moisture content

Paper is hygroscopic & absorbs & loses moisture according to the
ambient relative humidityy (RH) & temperature.
Paper at 20% RH will contain 4% moisture, while at 80% RH, it will

contain 15% moisture.
The physical properties of paper vary dramatically with moisture content,

thus all paper testing must be done at a precisely controlled temperature
& humidity. Internationally the standard conditions are specified as 23°C &
50% RH.

Paper is hygroexpansive: when it absorbs moisture, it expands, when it
dries; it shrinks.
Between 0 & 90% RH, the dimensions can change 0.8% in the MD &
1.6% in CD. Such a difference can play havoc with printing & die-cutting
register.
Whenever a paper sheet is laminated to, or coated with, a material that is

not affected by moisture (e.g. plastic film, aluminium foil, heavy print or
varnish), there is a potential of curling when humidity changes.
If paper gain moisture & expands while the surfacing laminate or coating
remains the same, the paper will curl towards the surfacing material.
Quiz 4: What if the paper loses moisture?
When it dries, it will shrink & curl away from the surfacing material.
Paper Types
Newsprint & related grades
Newsprint composed of up to 95% economical mechanical or groundwood pulp.
Newsprint has relatively low brightness, typically 55 to 65, & has low physical strength.
Newspaper inks are primarily oil & carbon, & high oil absorbency is a desirable
characteristic in newsprint.
Book papers
Mostly based on mechanical pulp, but are sized & clay coated to varying degrees to
improve surface appearance & printing qualities.
Commercial papers
Are used for higher-quality journals & books & for general office purposes. Brightness
usually ranges from 73 to 85. Papers used for photocopying are designed to withstand
the heat of photocopying process with a minimum paper curl & distortion. They also
must have controlled electrostatic surface resistance to provide uniform image
transfer.
Paper Types
Greaseproof papers
Are made from a chemical pulps that have been highly refined to break up fiber bundles.
The fine fibers pack densely, providing for a structure that does not readily absorb fluids.
Glassine papers are supercalendered, semitransparent greaseproof paper. Greaseproof
papers used for snack foods, cookies, butter etc.
Natural Kraft papers

Is the strongest of the common packaging papers & is used whenever maximum strength
is needed. The light brown papers are used in industrial bags, in carry-out grocery bags &
as inner plies in multiwall bags.
Tissue papers
“tissue” is generic term for any light paper. In packaging tissue is used for protective
wrapping & as a laminating component.
Paper Types
Label papers
Similar to book papers. Most papers used for label printing are clay coated on one or both
sides. Coated paper can be made in matte, dull, gloss & high-gloss finishes. Cast-coated
paper is made by drying a clay coating in contact with a heated highly polished chromed
drum. The process results in very smooth, extremely glossy surface.
Pouch papers
Are supercalendered virgin kraft papers that have been treated with a plasticiser to make
them more pliable. They are high density, very strong & smooth surface finish. Pouch
papers treated to have alkali resistance are used for soap wrappers.
Containerboards (linerboard & medium)

Containerboard specifically refer to linerboard & medium produced for use in the
manufacture of corrugated board. Linerboard is a solid Kraft board made specifically for the
liners (facings) of corrugated fibreboard.
Medium is used to produce the fluted core of corrugated board. It is the one paper product
where lignin content is an asset; it imparts thermoformability properties to the board.
Paperboard Grades
Chipboard, Cardboard, Newsboard
Chipboard is made from 100% recycled fiber & is the lowest-cost paperboard. Colour
range from light gray to brown. Chipboard is unsuitable for printing & has poor folding
qualities due to its short fiber length. They are used for set-up boxes, partitions etc
where appearance & foldability are not critical.
Food Board
Highly sized solid bleached sulphate (SBS) paperboards are often called food board.
Used for wet foods, frozen food cartons etc where good performance under wet
condition is important.
Thank you
Plastics Processes
& Applications
Selecting Material & Process
- Plastics are synthetic materials
1. SUCCESSFUL with
PACKAGE –
DESIGN
• Common capability of of being flow molded or shaped by application &
removal of heat & pressure.
Thermoplastic:
- Thermoplastic materials are fully polymerized products that when
subjected to sufficient heat, will soften. Pressure makes them flow &
assume new forms, so when they are cooled will form to a useful
shape.
- Scrap or defective shapes can be remelted & reprocessed.
- The easy formability & economic recovery of recycled material make
thermoplastics the material of choice for many packaging applications.
Thermoset:
- Polymers that have not fully completed their polymerization reaction, but
do so when activated, usually by heat, thus resulting cross-linked in
the product.
- It will not be soften again by heat & cannot be reprocessed or reshaped.
- Phenol, urea & melamine formaldehyde – used for specialty closures.
- The proper balance of product protection, containment & appearance

qualities, relative to affordable cost, can be obtained form mechanical
& chemical properties of various polymers.
- One a material is selected, the process or method for converting the
selected polymer resin into a useful form must be determined.
Tooling cost
- Tooling cost- cost of molds & other devices (e.g. cutting tool) to shape the plastic into
the desired form.
- The tooling cost is directly related to the forces that will be required to create the
form.
- Profile extrusion to make continuous solid profiles or tube simply requires a shaped
aperture through which to push the plastic. Tooling cost is low.
- Thermoforming is done with open molds using vacuum & compressed air at moderate
levels. Tooling cost is low to moderate depending on the complexity of the form to be
made.
Manufacturing methods of plastic
products
The most common thermoplastic forming methods for packaging purposes:
 Extrusion (including profile extrusion, extrusion cast film & sheet, blown-film
extrusion & co-extrusion)
 Thermoforming (a secondary forming process using extruded sheet)
 Injection molding
 Extrusion blow molding
 Injection blow molding
 Rotational molding
 Compression molding
-In all thermoplastic shaping methods, the plastic must first be heated to a point
where the material has a plasticity or fluidity appropriate to the intended molding
methods.
Profile extrusion
A plasticating extruder.
Most plastics are colored by
adding color concentrates
along with polymer resin at
the feed hopper. Auxiliary
hoppers are used to meter
in colorants, antistatic
agents & other additives.
-A shape of a constant cross-section (a profile) can be extruded by forcing polymer melt

through a shaped orifice in a die placed at the exit port.
-At it simplest, the die maybe a metal plate with a round hole, in which case the extrusion
is a round rod of approximately the hole’s diameter.
-Tooling cost are low since the process takes place at relatively low pressures.
Profile extrusion - continued
-Placing a suitable torpedo-shaped mandrel at the exit permits extrusion of a hollow pipe or
tube.
A profile extruder. Placing a torpedo-shaped mandrel in the die exit creates a

tube. With other die & mandrel configurations, shapes resembling corrugated
board are produced from the extruder.
Sheet & Film Extrusion
 Sheet extrusion is an application of profile extrusion, but it uses a die with a slot orifice (the
die is also called “coat-hanger” or “T-shape” dies).
 The dies have narrow opening between the die lips through which the plastic melt is
extruded in a thin film.
 The film is immediately cooled & solidified on chill rolls. The dies can be a metre or more
wide.
 Depending on thickness, the end product may be called “film” or “sheet”. This films are
called “cast film”.
 Thicker sheet is used for thermoforming or is die-cut & folded into carton-type constructions
similar to paperboard cartons. Thinner extruded films are used alone or laminated with other
materials in a variety of flexible packaging applications.
Sheet & Film Extrusion
General layout of a cast-film extrusion line.

Blown-film extrusion
Cross-section of a
blown-film die.
- Plastic film can also be manufactured by extruding the polymer through a circular die into a
closed circular bubble & expanding the bubble with air.
-The material is extruded upward, & by pulling the inflated bubble upward & continuously
extruding more plastic, a continuous seamless tube of thin film is created.
-Air flow along the outside of the bubble provides cooling & an air cushion.
-After the film has cooled, it is flattened in a collapsing frame & wound into rolls. The bubble
can be wound up as a seamless tube, or it can be cut to length & sealed at one end to make
seamless plastic bags. Alternatively, it can be slit & rolled into one or several flat film rolls.
-The blown film process is use to make nearly all PE & other films.
Blown-film extrusion -
continued
A blown-film line that produces a tubular film that is slit into two flat sheets.
Co-extrusion
A co-extrusion, slot-orifice cast-film die. Similar

multichannel dies can be made for blown-film extrusion.
-Both cast & blown film extrusion dies can be designed to be fed from more than one
extruder, thus producing a sheet composed of two or more different materials.
-Co-extrusion systems feeding as many as 7 different layers through 1 die block have been
made.
-High polymer viscosity limits the mixing of the extruded layers, so they exist as separate
layers in the finished product.
-Advantage of co-extrusion, the performance of two dissimilar materials can be achieved.
-For example, heat-sealable PE is extruded onto materials that have poor heat-sealing
characteristics, or a high-barrier polymer might be extruded between protective layers of a
less costly low-barrier material.
Injection molding
“Shot” size for an injection-molded part

can be metered either by or by a
reciprocating screw (top) or an extruder
with a separate hydraulic piston
(bottom).
-Injection molding uses a powerful extruder with the capability to inject a precise amount of
resin into a fully enclosed mold.
-Very high hydraulic pressures drive hot, relatively viscous molten material through the
chilled passages of a part mold & fill the cavity before the plastic solidifies.
-The process requires substantial molds that will not flex or move under extreme
temperature & pressure. An 8-cavity mold for margarine tubs may weight upward of a ton.
This required mold mass & the tooling’s complexity makes injection molding the highest in
tooling cost of the plastic forming methods.
Injection molding - continued
- The extruder section of an injection molding machine will ejecting a precise amount,
or “shot”, of polymer melt into the mold.
-Ram-screw-type machines (reciprocating screw) use a melt-conveyance screw
designed to provide reciprocal as well as rotaty motion, combining the function of
screw & piston.
-Disadvantage of this system is that a great deal of power is required to move the
entire screw & its attendant load of plastic resin.
-Screw-plunger or 2-stage machines have a separate chamber & pistonfor injecting
the molten polymer, allowing for faster injection of the plastic into the mold.
-The mold cavity is exactly in the form of desired part. When the part has cooled, the
mold opens & the part is ejected.
Extrusion blow molding
Thermoplastic bottles are made by one of two processes:
 Extrusion blow molding (EBM)- detergent, oil & other
household chemical bottles. Types of polymers including PE,
PP & PVC.
 Injection blow molding (IBM)
EBM processes:
-A hollow plastic tube, or parison, is extruded.
-While in a soft & formable state, the parison is captured between the mating halves of a
bottle mold.
-Air is blown into the hollow parison, stretching the deformable parison to conform to the
mold walls. The newly formed bottle is held in the mold until it cools sufficiently to retain its
shape.
Extrusion blow molding
Typical EBM sequence.

Injection blow molding
IBM process combines
preform molding & a bottle
blowing cycle.
IBM processes:
-IBM combines injection molding & blow molding.
-Instead of extruding a parison, as in EBM, a parison or “preform” is injection molded.
-The injection molding of a preform allows more exact control over material distribution
than available when extruding a parison.
-After the preform injection cycle, the preform, still retained on the core pin, is transferred
to the blow-molding station.
-The final blow molding operation is similar to extrusion blow molding.
-Economics generally confines IBM to higher volume production, since two molds are
required to make a container: the injection mold(s) to produce the preform & the
companion blow mold(s) to blow the container.
Rotational molding
Configuration of a one-step IBM machine. One core rod is shown empty

for illustration purposes.
Injection-Stretch Blow Molding
A major application for injection-

stretch blow molding is the
manufacture of PET carbonated
beverage bottles..
-A variation of IBM, injection-stretch blow molding (ISBM), uses a rod to stretch the preform
during blowing.
-In a typical operation, at the point that the core rod touches the bottom of the preform, a
small amount of air is introduced to start the blowing process.
-When the core rod reaches the bottom of the mold, the full volume of inflating air is
introduced.
-This mechanical stretching orients the polymer molecules & improves stiffness & barrier
properties.
Thermoforming methods
The material is pulled to the
mold shape when a vacuum is
applied between the mold &
sheet interfaces.
Microwave-compatible plastic
tray can be thermoformed PP,
PS or crystallised PET (CPET).
-The core part of the die simply pushes the softened plastic into the matching cavity half.
-Matched dies can be used only for shallow draws. Material distribution is poor.
-Vacuum forming into a cavity mold or over a plug mold is the simplest form of vacuum
molding.
-Vacuum holes are required in the cavity’s lowest point.
-Cavity molds allow for easier part removal, since the hot plastic shrinks away from the
cavity when it cools, whereas the cooled plastic will tend to tighten around a plug mold.
Rotational molding
Configuration of a typical
rotational molding machine.
- Rotational molding does not required an extruder.

-Polymer, usually a finely powdered PE, is placed in a mold that is then heated while being
rotated in two axes.
-The heat eventually melts the PE, which flows & evenly coats the inside surfaces of the
mold.
-While still rotating, the plastic is cooled. The mold is open & the part is removed.
-The advantage of this process is the making of a hollow object with no openings.
-Since rotational molding is not a pressure process, the molds need not be massive.
-Used to make very large bins & bulk container.
Compression molding
-Compression molding is primarily used to mold thermoset plastics. A measured charge of
unpolymerised thermoset plastic is placed into the hot cavity of a mold.
-A mating core is brought down to squeeze the plastic into close conformity with the mold.
The heat from the mold cures the plastic.
Molding thermoplastic part vs thermoset part

 The main difference being that the thermoplastic is melted in an extruder, & a measured
shot is then injected into a chilled mold cavity. Compression molding has been used to
make thermoplastic closures.
 As with the thermosets, the core forces the molten plastic to conform to the mold
profiles.
Thank you
Metal
Cans & Containers
Metal packaging form
Metal packaging form provides sanitary food can. Thermal processing of food
packed into hand-soldered cylindrical metal cans started in the early 1980s & developed
into a major industry.
Advantages:
1. Being relatively inexpensive.
2. Capable of being thermally processed.
3. Rigid.
4. Easy to process on high-speed lines.
5. Readily recyclable.
6. Offer total gas & light barriers.
• Originally, all steels containers were
fabricated from flat sheets that were
cut to size, bent to shape &
mechanically clinched or soldered to
hold the final shape.
-These food cans were of three-piece can
construction –a formed sidewall & a top
and bottom end.
• Now , ways of drawing metal (shaping Three-piece (left) & two-piece (right) can
metal by pushing it through a die) construction.
were developed.
-Shallow drawn containers with friction
or slip covers were used for pastes,
greases & other semisolid products. -
Later, two-piece shallow drawn cans with Two-piece can construction have a body &
double-seamed (folded) bends were bottom in a single piece with a separate
used for sardines. attached end.
Two-piece vs. Three-piece cans
Advantages:
-Two-piece cans reduced material usage,
improved appearance & elimination of a possible
leakage location.
-Three-piece cans can easily be changed in length
& diameter.
Disadvantages:
-Two-piece cans require more elaborate tooling
that is dedicated to one can form.
Common types of metal
Ductile metals such as:
 Low carbon steel-are the most common form of steel, containing approx. 0.05 to
0.15% of carbon.
 Tin (Sn), a chemical element belonging to the carbon family, Group 14 (IVa) of the
periodic table.). Tin is widely used for plating steel cans used as food containers, in
metals used for bearings, and in solder.
 Lead (Pb).
 Aluminium (Al).
Common metal container shapes
The most common metal container shapes include:
 Three-piece steel sanitary food cans.

 Aerosol cans made by two methods: (1) Three-piece sheet cans with a welded body & two
ends, & (2) one-piece, impact extruded aluminium cans necked-in to accept the valve cup.
 Steele or aluminium two-piece, drawned-and-ironed beverage cans.
 Two-piece steel or aluminium cans made by drawing or by draw and redraw. Full opening,
ting pull-top cans are used for fish products, canned meats & dips. Double seamed,
conventional-top cans are used for many canned food products.
Common metal container shapes -
continued
 Canned with hinged lids, usually steel, used for medications, confections, small parts &
novelties.
 Flat round cans of drawn steel or aluminium with slip covers. Used for ointments,
confections, shoe polish & novelties.
 Three-piece steel or aluminium ovals, typically fitted with a dispensing spout & used for
oils.
 Traditional pear-shaped, three-piece steel ham cans.
 Oblong, steel three-piece F-style cans. The “F” name comes from Flit insecticides.
 Oblong, key-opening cans, three-piece steel, used for luncheon meat products.
 Three-piece square-breasted steel cans. Larger design are used for the talcum, bath &
baby powder products. Smaller cans, used for spices & dry condiments.
Can-making steel
- The name “tin can” is not strictly correct, since low-carbon steel is the predominant can-
making material.
-Bare steel corrodes readily when in contact with moisture & other corrosive agents, &
unprotected steel or black plate can be used only for noncorrosive products such as
waxes, oils or greases.
-Normally a coating is needed to protect the steel.
-This was first done by dipping black plate sheets into baths of molten tin.
-Today, black plate is electrolytically tin-plated, allowing substantial reductions in the
amount of tin used, as well as offering the ability to put different thicknesses of tin on
either side of a steel sheet.
-Electrolytic chrome-coated steel (ECCS) use chrome & chrome oxide for corrosion
protection. ECCS is more economical than tinplate. However, the chrome must be
removed to weld the body can. Therefore, ECCS is most often used for can ends or for
drawing, where weldability is not the requirement. ECCS is also known as tin-free steel
(TFS).
Three-piece steel cans
-Steel three-piece can bodies can be mechanically seamed, bonded with adhesives, welded or
soldered.
-Aluminium cannot be soldered or welded economically. Welded sanitary three-piece can
bodies are, therefore, only made on steel.
-Mechanical seaming, or clinching, would be used only for containers intended for dry
products, where hermetic seal is not important.
-Adhesive bonding, or cementing, uses a thermoplastic (or other) adhesive extruded onto a
hot can blank. The blank is shaped into a cylinder on a body former, the hot thermoplastic
adhesive is applied, & the seam is “bumped” & quickly chilled to set the bond.
-To solder a can, engaging hooks are bent into the can blank similar to that for a mechanical
seam. Molten lead lead-or tin-based solder is flowed into the seam. Lead extraction by food
products is always a potential problem. Soldered food cans no longer permitted in North
America, but, some soldering is still done for non-food applications.
Three-piece can production.
-All three-piece can bodies are pressure-tested & have the ends flanged to receive the
can top & bottom ends.
-The can maker plies one can end & sends the other end to the user for double seaming
after the can is filled.
-Sanitary food cans that may be thermally processed in a retort have beads pattern
embossed into the can sidewalls; the pattern improve resistance to collapse because of
external pressure. This prevent paneling during pressure differentials encountered during
retorting & enables the can to withstand an internal vacuum.
Can-end embossing pattern..
-Can ends intended for thermal processing are stamped with a series of circular expansion
panels. This allows the ends to move so that the contents inside the can are able to expand &
contract without bulging or otherwise distorting the can.
-The chich panel is designed to give the proper clearance to the double-seaming chuck used
to seal the can end to the body.
-A vital can-end component is the compound applied around the perimeter curl. It acts as a
sealant when the ends is mated & double-seamed to the can body.
Two-piece drawn cans
There are 3 methods of making steel or aluminium
two-piece cans:
 Draw
 Draw and redraw (D&D)
 Draw and iron (D&I)
Straight lines on a blank (left) become

distorted in different directions when
drawn into a can (right).
Draw process
-A shallow-profile can – is the one whose height is less than its diameter – can
be drawn directly from a circular metal blank.
-The metal blank is stamped or drawn through a die & re-formed into a new
shape.
-The thickness of the finished can sidewall & bottom remain essentially as in the
original blank. The process is sometimes referred to as “shallow draw”.
Draw-and-redraw process
-A single-draw operation is limited in how far the metal can be reshaped.
-cans having a height equal to or greater than the can’s diameter will usually
require a second draw, is called the “draw-and-redraw” process .
-The first draw produces a shallow cup. The second reduces the diameter as the
can is deepened.
-Cans having a height significantly greater than the can diameter would require
a third draw.
-If the container is to be thermally processed, sidewall beads are rolled into the
walls in a separate step. Body flanges for engaging the can end are rolled on in a
manner similar to that used in three-piece can manufacturing.
The manufacturing sequence for a

necked D&I can.
Draw-and-iron (D&I) process

-Carbonated beverage cans are made by D&I process.
-a blank disc is first drawn into a wide cup (step 2).
-in a separate operation (step 3), the cup is redrawn to the finished can diameter & pushed
through a series of ironing rings, each minutely smaller in diameter than the previous one.
The rings “iron”, or spread, the metal into a thinner sheet than the original disk.
Draw-and-iron (D&I) process - continued
-The bottom of a D&I can has the same thickness
as the starting disc; however, the sidewalls are
considerably reduced in thickness & the metal
area of the final can is greater than that of the
initial disk.
-Necking operations reduce the diameter of the
can top, thereby reducing the end-piece
diameter. This results in significant metal savings,
In the D&I process, the second draw &
since the end piece is much thicker than the
ironing stages occur in one continuous
sidewalls. movement. The punch finishes its stroke
-The thin walls of D&I can restrict its use to against the bottoming tool.
applications where it will not be thermally
processed & that will lend support to the walls.
Carbonated beverage cans, where the internal
pressure of the carbon dioxide keeps the walls
from denting, is the primary application.
-Noncarbonated juice cans rely on internal
pressure created by inert nitrogen gas introduced
into the container.
Impact extrusion
Impact extrusion sequence.
-Impact extrusion forms ductile metals into seamless tubes.

-Most impact extrusions are made from aluminium. Example of product is collapsible
toothpaste tubes.
-In impact extrusion, a metal slug is located on a shaped striking surface. A punch strikes
the slug with great force. Under the enormous impact pressure, the metal flows like a
liquid straight up along the outside of the striking punch, forming a round cylindrical
shape.
-Tube height can be up to 7times its diameter.
-The tube’s shoulders & tip are formed as part of the process. Tube with a dispensing hole
will have a hole in the slug, while tubes that need a dispenser with a thin web of metal
over the opening will start with a solid slug. Embossed shoulders are another option.
Tube dimensioning. Examples of impact-extruded tube tips.
Advantages of Metal Tubes vs
Laminate & Plastic Collapsible Tubes
1. They are absolute barriers to all gases & flavors.
2. They have the best dead-fold characteristic (ability to flattened or rolled up). This
feature is particularly important for some pharmaceutical applications, where air
suck-back into the partly empty tube could contaminate the contents or expose the
product to oxygen.
3. They can be decorated in a manner that takes advantage of their metallic character.
4. They have a wide range of internal lining options because of the metal’s ability to
withstand high curing temperatures.
5. By using heavier slugs, strong cylinders can be made by impact extrusion. These
cylinders hold special greases & has a major application for aerosol products.
Thank you
Glass
Containers
Glass Types & General Properties
Glass – refers to an inorganic substance fused at high temperatures & cooled quickly so
that it solidifies in a vitreous or noncrystalline condition. That is, the molecular structure
of the solid glass is practically the same as liquid glass, but the cooled glass is so viscous
that the mass has become rigid.
Glass has no distinct melting or solidifying temperatures. There is gradual softening with
heat & gradual solidifying with cooling.
Most commercial glass or soda-
lime-silica or simply soda-lime
glass containers are made from
abundant raw materials:
1. Silica sand ( silicone oxide)

2. Soda ash (sodium carbonate)
3. Limestone (calcium carbonate)
4. Alumina (aluminium oxide)
Other source of material:

1. Cullet ( broken glass recovered
from plant operations or post-
consumer waste).
Silica sand fused with sodium
compounds (usually carbonate)
produces sodium silicate or
“water glass”, a water-soluble
glasslike form.
Insolubility is imparted by adding
calcium compounds.
Advantages of glass as packaging
material
1. Pure
 It is chemically inert to most chemical.

 the preferred packaging for consumer health and the environment.
 consumers prefer glass packaging:
 for maintaining the purity of food and beverages (78 percent),
 preserving a product’s taste or flavor (75 percent),
 and maintaining the integrity or healthiness of foods and beverages (82 percent)
 Glass is the only packaging material rated “GRAS” or “generally regarded as safe” by
the U.S. FDA.
material
2. Premium Image
• perceived as having an upscale image.

•no other packaging material matches the shelf impact of glass.
•tranparent/clarity, shape, and feel of glass containers contribute to
the premium image of products ranging from fine perfumes to
liquor to gourmet foods and beverages.
material
3. Stable at high temperature
a) Suitable for Microwave oven

•convenience because can serve at the table without the content
being transferred to another receptacles.
•tranparent to microwave energy.
b) Suitable for hot-fill & retortable products.
material
4. Sustainable
-Recycling glass reduces consumption of raw materials, extends the life of plant
equipment, such as furnaces, and saves energy.
-Energy costs drop about 2-3% for every 10% recycled glass used in the glass making
process. Recycling one glass bottle saves enough energy to power a 60-watt bulb for four
hours, a computer for 30 minutes or a television for 20 minutes.
-Every 10% increase in recycled glass =
• 10% decrease in sulfur dioxide (SO2)
• 6% decrease in nitrogen oxide (NOx)
• 17% reduction in carbon dioxide (CO2)
• 2.5% reduction in electricity and natural gas
• 6 oC reduction in furnace temperature
• 9.5% reduction in raw materials
material
5. Rigidity
• the container shapes & volumes do not change under vacuum or

under pressure.
material
6. 100% Recyclable
• 100% recyclable and can be recycled endlessly with no loss in

quality or purity.
• Glass recycling is a closed loop system, creating no additional

waste or by-products.
• It is a mono-material, meaning it is not made up of several

different materials.
Disadvantages of glass as
packaging material
1. Heavy
Because high density.
1. Brittle/Breakability
2. Energy intensive
Glass manufacturing is energy intensive & high energy costs will affect the
cost of glass.
Commercial glass manufacturing
-Commercial glass is made in gas-fired melting or
furnaces lined with high temperature refractory
materials.
-Premixed raw materials are continuously fed into
one end of the furnace while gas-fired heating
flames are directed over the glass surface from the
firing ports located along the furnace sides.
-The raw materials fuse into glass at about 1510°C (2750°F), accompanied by the release of carbon
dioxide gas from the decomposition of carbonate ingredients.
-The released gases & convection currents serve to mix the glass. This process also produced non-
environmentally nitrogen oxides. Newer furnaces are using oxygen instead of air, eliminating possible
pollution source, while also reducing the overall energy requirement by up to one-third.
-The hot flue gases are passed through some form of heat exchanger that is used to heat incoming cold
air or oxygen.
-Cullet (as much as 80% of the batch charge) is added to enhance melting rate & significantly reduce the
energy requirements.
-The surface level of the molten glass at the furnace draw-off orifice is about 4 metres above the bottle-
manufacturing floor level. Molten glass is gravity-fed through spouts/chutes to bottle-forming
machines.
Commercial glass manufacturing
-The forehearth brings the glass temperature down to about 1300°C (2300°F).
-A furnace maybe equipped with several forehearths, each feeding a separate bottle-making machine
on the floor below.
-Coloring agent may be added at either either to the melt furnace along with other ingredients, or they
can be added at the forehearth.
-for standard furnace glasses, they are restricted to 3 colors:.
1. Flint-basic clear glass. Used for majority of packaging application.
2. Amber-brown glass, filter out critical UV region (300-400 nm). Used for UV-sensitive products e.g.
beer & some pharmaceuticals.
3. Emerald-bright green glass used mostly for wines &lime or lemon flavoured soft drinks.
-For non-standard colors:
• Blue, green & opaque glasses also available.
• Georgia green, champagne & dead-leaf green popular for wine industry.
• Blue glass makes white products look whiter.
• Opaque white glass adds prestigious appearance to toiletries & cosmetics.
-A ceramic-lined draw-off orifice at the bottom end of each forehearth allows the glass to extrude
downwards in a controlled manner.
-Just after the extrusion die, a large shear-knife cuts the glass flow into individual gob; each gob being
the exact quantity glass needed for 1 bottle.
Colored glass
Molds
Molds
Molds
Molds
Body halves of the blank mold with parison (left) & blow
mold with bottom plate and blown bottle (right).
Blow-and-blow process
Blow-and-blow bottle manufacturing.

Blowing the Bottle or Jar
Blow-and-blow process
1. The gob is dropped onto the blank mold through a funnel-shape guide. Note that the blank mold is
upside down. The gob temperature is about 985°C (1800°F).
2. The guide is replaced by a parison bottomer, & air is blown into the mold (called the “settle blow”)
to force the glass into the finish section. The bottle finish is complete.
3. The parison bottomer is replaced by a solid bottom plate, & air is forced through the bottom finish
(called the “counter-blow”) to expand the glass upward & form the parison.
4. The parison is removed from the blank mold, using the neck ring (transfer bead) as a gripping
fixture, & rotated to the right-side-up orientation for placement into the blow mold. The parison is
supported in the blow mold by the neck ring.
5. Air forces the glass to conform to the shape of the blow mold. The bottle is cooled so that it can
stand without becoming distorted & is then placed on conveyors that take it to the annealing oven.
Press-and-blow process
1. In the press-and-blow process, gob delivery& settle-blow steps are similar to blow-and-blow
forming.
2. However, in press-and-blow, the parison is pressed into shape with a metal plunger rather than by
being blown into shape.
3. The final blowing step in a separate blow mold is identical to that in the blow-and-blow process.
The blow-and-blow process is used for narrow-necked bottles.
The press-and-blow process, for making wide-mouthed jars.
6. The blown bottle is removed from the blow mold with takeout tongs & placed on a deadplate to air
cool for a few moments before transfer to a conveyor that will transport the container to the
annealing oven &/or surface coatings.
Inspection & Packing
-visual inspection has been replaced by mechanical & electronic

means.
1. squeeze testers pass the containers between 2 rollers that
subject the container walls to a compressive force.
2. plug gauges check height, perpendicularity, and inside & outside
finish diameters.
3. optical devices inspect for stones, blisters, checks, spikes, bird
swings & other blemishes or irregularities by rotating the
container past a bank of photocell.
-examples of physical defects are shown in the figure on the right -flat bottles are prone to develop
side. “bird swings” & “spikes”. Spikes
-other surface or cosmetic defects are: are glass projections inside the
 a blister is a bubble in the glass not greater than 1.5 mm. bottle; a bird swing is a glass
 a seed is a contaminating grain or grit less than 1.5 mm. thread joining the 2 walls. Heel
taps & choke naps are excessive
 a check is a small crack on the glass surface. thicknesses of glass. An overpress
 a stone is a particle of unmelted material in the glass. is a ridge of glass around the
bottle opening.
Glass bottle nomenclature
Thank you
Purposes of testing
- There are 3 major reasons for conducting tests on

packages, containers or packaging materials:
1. To predict performance in practice.
2. To control quality.
3. To obtain information to modify, improve or
reduce the package cost.
To predict performance in practice
- To predict performance a measure of correlation is needed b/ween
the tests carried out in the lab & the behaviour of package, a
container, a component or a material in practice.
- 3 or 4 correlations are required:
1. between the field performance of the package & a lab transport
test.
2. between lab transport test on the filled package & tests on the
empty container & on any fittings or components.
3. between the strength & other properties of various materials
used in the container making & the tests on the empty
container.
4. For materials e.g. paper, film, foil & plastics, a 4th correlation
should be established b/ween the properties of the packaging
material & its manufacturing variables.
To control quality
- Tests are used to predict the performance of a complete package need
only to be applied once.
- After it has been proved that a package will be satisfactory in practice,
it is necessary to control the package quality of that package for future
distribution to ensure these are up to standards.
- The tests needed for this purpose are different in many respects from
qualification tests.
- Important criteria of these tests:
1. Relatively simple.
2. Fairly rapidly.
3. Capable to provide numerical result.
- These considerations will apply whether quality control of a
package, a container, a component or a material is involved.
To obtain information to modify,
improve or reduce the package cost
- The testing methods that may be applied to

packages, containers, components or materials
to obtain information about their strength &
weakness when subjected to specific hazards
(e.g. climatic hazards, transport & distribution
hazards) can be very sophisticated.
How to test?
- 3 ways of obtaining information about any particular package,
container or component:
1. Comparative testing: The simplest, to compare a known
package, container or component with the unknown one.
This comparison can be determined not only whether the
2nd is better than the 1st, but in some cases it measures the
degree of difference.
2. Assessment testing: An attempt will be made to reproduce
the events experienced by the package or material in use &
to deduce from the results of what may happen in practice.
3. Investigational testing: One can ignore the required
performance & devise a means of determining where the
strength & weakness in the package lie.
Assessment testing
- Generally only necessary to determine whether the
pack passes or fails.
- Or will be YES or NO.
- Scoring – may not be necessary.
- Indeed, to carry out a complete evaluation of the
package, the use of a sequence of tests may make a
scoring inappropriate.
- The pass/fail test, the event of failure, may be used as
a starting point for package improvement or
investigation into the cause of failure & its
prevention. H/ever w/out adequate inspection during
testing, the requirement of the 2 objectives are often
incompatible.
Comparative & Investigational testing
- A scoring system is essential so that the progress
can be measured or differences quantified.
- The emphasis will be on certain aspects of the
package which have been found to limit its
performance & the test will be intended to assess
these aspects only.
- A sequence of different tests on the same package
is inappropriate & a single type of test will be
applied.
- It may be necessary to provide ‘pre-conditioning’
tests (e.g. climatic storage, vibration).
Scoring
- To score the result in order to compare one package with
another.
- Scoring is either quantitave i.e. a record of drop height
causing failure or based on a grading system (not more than
4 classes of damage e.g. ‘damaged beyond hope of sale’ or
‘damaged but still saleable’ or ‘perfect’).
- In a mixed sequence of tests, the package & the contents
are usually scored at the end of a test sequence or at some
pre-determined, fixed intermediate point during the test.
- In single tests, the test may proceed at repeated constant
level until a fixed damade score has taken place.
- E.g. length of tears in a case, number of glass jar broken
etc.
Scoring
- At the end of the test, the score is finally taken.
- Where the damage is scored for a single non-repetitive
test, it is a measure of the effect of both the case & its
content.
- In an increasing level test (level at which a certain effects
occur on the package), e.g. the load to produce collapse
in compression strength test, is the score of damage.
- Where damage to the content is concerned, except for
breakage e.g. occurs with bottles or jars, scoring must be
carried out at a pre-determined point during a sequence.
- Where case damage is concerned, the damage after each
cycle can be assessed visually.
SPC & Acceptance Sampling
- Statistical Process Control (SPC) involves
inspecting a random sample of the output from
the process and deciding whether the process
producing products with characteristics that fall
within a predetermined range.
- Sampling refers to observation of a population or
lot for the purpose of obtaining information.
- Acceptance Sampling is defined as sampling
inspection to make decision whether to accept or
reject products or services. A conclusion can be
reached regarding acceptability of lot.
Application of SPC and
Control Charts
Process capable of Production process is stable &
1st
Next
producing product reliably produce quality parts.
within required -machine is stable & running
specifications. at a steady state, the
Q cannot be measured attributes of
“inspected in”, Q samples removed periodically
must be produced. for QA will fall w/in
boundaries of established SD.
Of established st
- Data o/side SD will occur
only when some changes
occurred that will take
production o/side established
steady state.
Histogram
- Bar chart arranged by frequency of an event
occuring.
- Focus on the most frequent occurances.
Pareto Charts
- Bar chart arranged by the relative importance of an number
of events that occur.
- Focus on the incidents/factors that are the most serious.
Pareto Charts
- In QC, it may represents the most common sources of
defects or the highest occurring type of defect.
SPC control charts
& Acceptance Sampling
- To become aware of changes that might be taking

place, this requires keeping a continuous record
of the product characteristics using SPC control
charts.
- Sampling is done at predetermined times based
on the product’s nature & the production speed.
- Most usually, a group of 3 or more specimens are
drawn, the measurements made & their average
is plotted on the control charts.
Acceptance Sampling
- Advantages:
1. Eliminates or rectifies poor lots & improve
overall product’s quality.
2. Reduce inspection costs & risk.
3. In inspection of sample of greater care will be
taken so that the results will be more accurate.
4. A rejected lot is frequently a signal to the
manufacturer that the process should be
improved
Control chart
- A control chart (process chart or quality control

chart) is a graph that shows whether a sample of
data falls within the common or normal range of
variation.
- It has upper & lower limits that separate common
from assignable causes of variation.
- The common range of variation is defined by the
used of control chart limits.
- “out of control” when a plot of control data
reveals that one or more samples falls outside the
control limits.
Control charts
- Control chart shows sample data plotted on a

graph with Centre Line (CL), Upper Control Limit
(UCL) & Lower Control Limit (LCL).
Control charts
- Control chart for variables – used to monitor

characteristics that can be measured.
- For example: weight, length, diameter, time
etc.
- Control chart for attributes – used to monitor
characteristics that have discrete values & can
be counted.
- For example: %defective, number of flaws in
a bottle , number of broken eggs in an egg
tray, etc.
Control charts
- Control chart for variables – used to monitor

characteristics that can be measured.
- For example: weight, length, diameter, time
etc.
- Control chart for attributes – used to monitor
characteristics that have discrete values & can
be counted.
- For example: %defective, number of flaws in
a bottle , number of broken eggs in an egg
tray, etc.
Control Charts for Variables
- Mean (X-bar) chart

- Track the central tendency the average value
observed) over time
- Range (R) chart
- Track the spread of the distribution over time
(estimates the observed variation)
X-bar chart & R chart
The R- chart is
used when the 
for the process
distribution is not
known.
X-bar chart
- Suppose 20 packages are removed from a filling
line & the following weights in grams recorded.
w1 w2 w3 w4 w5
Observation 1 95 97 105 103 98
Observation 2 96 104 102 99 100
Observation 3 100 99 98 101 102
Observation 4 99 100 101 101 100

X-bar chart
- 1. Calculate the means of each sample
- 2. Calculate the SD of the Sample Mean
w1 w2 w3 w4 w5
Observation 1 95 97 105 103 98
Observation 2 96 104 102 99 100
Observation 3 100 99 98 101 102
Observation 4 99 100 101 101 100
Sample means 100g (target weight)

(X-bar)
SD () 2.53 g
X-bar chart
- The client has called for a minimum fill weight of 94 g.
- Figure (left) below, shows that the filling process is not capable of
meeting the client's fill requirements.
- Furthermore, at the other end, anything over 100 g is a costly
give-away.
The left curve

shows the gram
weights at each
standard deviation.
The right curve
shows the change
when a more
accurate weighing
system is installed.
X-bar chart
• By installing a more accurate weigh cell, the lowest and highest fill
weights are eliminated. Now the 20 fill weights are:
w1 w2 w3 w4 w5
Observation 1 100 97 100 103 98
Observation 2 97 103 102 99 100
Observation 3 100 99 98 101 102
Observation 4 99 100 101 101 100
Sample means 100 g (target fill weight)

(X-bar)
SD () 1.7 g
• The new filler is able to easily meet the 94 gram specification
at three sigma, and has reduced the giveaway by 2.5 grams.
X-bar chart
A good understanding of sampling and understanding statistical distributions is a

key factor in not committing the type of errors illustrated in the figure above.
X-bar chart
• 8:00 The operator weighs a box from production and finds it is holding 95.1 g
of product. The lower limit is 95 g so to be safe the operator increases the
machine's fill weight. In actual fact, the machine is properly adjusted; this
particular package happened to be at the lower end of the distribution curve.
• 8:30 The operator hasn't realized it yet, but a fair percentage of product is
over the UCL. At 8:30, the operator weighs another package and discovers it's
considerably overweight. The fill weight is drastically reduced.
• 9:00 Between 8:30 and 9:00, all fills are below LCL. Not knowing what is
going on the operator increases the weight upward a little.
• 9:30 Finally at 9:30 the operator thinks fill weight are finally correct so no
adjustments are made. In actual fact the distribution curve is partly below
the LCL limit and so half the packages are under-tilled.
• 10:00 Now the operator is cursing the machine. It was perfect at 9:30, and
now it's filling below LCL again. Actually the machine hasn't changed at all ...
the distribution curve is in exactly the same place as it was at 9:30. The
operator increases the fill again.
• 10.30 At the end of the day, everyone is wondering what's wrong with the
machine.
X-bar chart
A normal X-bar chart with a random distribution of attribute
points about the mean. A single point outside the standard
distribution would indicate a lack of stability and should be
investigated.
X-bar chart
• A run of seven or more points to one side of the centerline calls for
an investigation.
X-bar chart
• A directional trend is a warning that the machine is drifting out of
control.
X-bar chart
• Cycles are patterns that repeat; a sure sign of instability. In this
example each cycle is preceded by a point beyond the control
limits.
X-bar chart
• Mixtures usually indicate that there are two processes working at
different levels.
X-bar chart
Stratification may happen when improperly calculated control limits
or chart scales are used. It is also possible that the specimens in any
given sample group are constantly averaging out to the median line.
X-bar chart
- Correlations
between the range of
values in the sample
and the deviation are
possible.
- In a positive
correlation the X-bar
and range points
tend to follow each
other up and down.
In a negative
correlation the points
move in opposite
directions.
Cost control through
minimized overfill
Automation.com
- Filling is subject to a large number of influences that can cause

fluctuations in packaged goods weight.
- However, weight fluctuations must not cause the net weight of even a
single package to fall appreciably below stated net weight.
Government regulations generally specify permissible underfill amounts.
- Some manufacturers systematically overfill to eliminate risk of consumer
and legal complaints.
- But such general overfills can be costly and lower the revenue
considerably. Even with the modest output rate of smaller
companies, corresponding product give-away costs are striking.
- Accurate monitoring and quality data management provides better
results. Giving the process closely controlled limits can help reduce
expensive product giveaway.
Summary
- Overfill cost is directly related to raw material costs. But safe-margin
overfills are an effective way to ensure compliance with net content
legislation.
- Overfills are costly, even with the modest output rate of small
companies.
- Calculated, minimized overfilling can be very effective at controlling

giveaway and its resulting expense without increasing personnel
costs.
- Various solutions are available such as static scales with built in SQC
intelligence for random sampling of net content data or inline
CheckWeighers for 100% data checks.
Filling
Equipments
FILLING SYSTEMS
o Selection criteria of filling systems:
 Product categories:
1. Liquid & solid
2. Liquid & dry
FILLING SYSTEMS
o Dry products include:
1. Discrete items e.g. candies, fasteners, pills
& nuts. Often counted for filling.
2. Free flowing powders/granules - powders
having consistent density & pour readily to
form a fairly flat cone when dumped on a
plane surface.
- the flatter angle of repose  more readily
the material will flow & more consistent
density. Easy to measure by a variety of
methods, including free-fall gravity feeder.
Types of dry products
 Free-flowing  Does not flow freely

 Relatively constant  Variable density
density  Equal volumes will vary in
 Can be measured by weight
volume  Must be weighed
FILLING SYSTEMS
1. SUCCESSFUL
3. Non-free powders/granules – do
PACKAGE DESIGN
flowing
not flow readily & have a steep angle of
repose when pour out on a plane surface.
- Frequently bridge & clog passages
- Some have tendency to agglomerate,
pack or entrain air & thus density is not
consistent.
- These materials can’t be fed by gravity
alone, may need to physically moving
them through the filler.
- Since their densities vary, volumetric fills
are inappropriate.
FILLING SYSTEMS
4. Fragile dry products – require gentle

handling.
- Vibratory system & net weighing are
typically used.
- E.g. potato chips, dry cereals & some
granular compositions
FILLING SYSTEMS
o Wet or liquidPACKAGE
1. SUCCESSFUL products
DESIGN range from low-
viscosity free-flowing liquids to viscous
semiliquids to extremely viscous product =
classed as semisolids:
- Liquid-fill characteristics vary widely,
depending on factors:
 temperature
 tendency to entrain air
 surface tension and
 frothing or foaming tendencies
- Carbonated beverages form a class of
their own.
FILLING SYSTEMS
o Some products contain a mixture of ingredient
types. Instant soups may contain noodles, assorted
dried vegetables, dried meat and powdered soup
base.
o It is impossible to premix these and ensure a
consistent fill in proper proportions, since the
ingredients will always separate according to their
densities and geometries.
o Such products need a separate filling station for each
ingredient. Mixed solids and liquids, such as canned
peas or stew, are similarly filled at two stations: one
for the solids and one to top up the fluid portion.
Other Considerations
Rigid glass, metal or heavy plastic containers can be accelerated and decelerated at high rates. They can have significant force applied to the finish during filling or
FILLING SYSTEMS
 Other considerations
o Rigid glass, metal or heavy plastic containers can be
accelerated and decelerated at high rates.
- They can have significant force applied to the finish
during filling or to the sidewalls during conveying.
Vacuum or pressure levels during the fill cycle are not
critical considerations.
FILLING SYSTEMS
o Semirigid containers, typically blow-molded
plastic bottles, cannot withstand the same
stresses.
- This places limitations on the vacuum or
pressure level that can be used during the fill, and
also limits the means of moving the container
from station to station.
FILLING SYSTEMS
o Flexible pouches or bags cannot maintain their
dimensions in all axes, and therefore, must be
retained in a fixture while being filled.
- Since flexible containers cannot be filled to a
specified level, piston volumetric fillers are often
used to push the product into the pouch.
LIQUID FILLING
o Constant-Volume & Constant-Level Fillers
- Liquids can be metered into containers so that
they reach either a constant level or a constant
volume.
- Constant-level filling is used for most low- or
moderate-cost products such as soft drinks, beer
and ketchup, where accurate volume is not as
important as keeping a visually constant-fill level.
- Containers can have slightly inconsistent volumes
due to variations in wall thickness.
LIQUID FILLING
- Liquids can be metered into containers so that
they reach either a constant level or a constant
volume.
- Constant-level filling is used for most low- or
moderate-cost products such as soft drinks, beer
and ketchup, where accurate volume is not as
important as keeping a visually constant-fill level.
- Containers can have slightly inconsistent volumes
due to variations in wall thickness.
LIQUID FILLING
LIQUID FILLING
- Fill height levels will, therefore, vary if the
containers are filled to a constant volume.
- Customer satisfaction demands that all containers
be filled to the same level. Constant-level filling
achieves this regardless of the actual liquid
volume.
LIQUID FILLING
o Constant-Level Fillers
- Constant-level filling can be constructed by using
gravity, vacuum, pressure or combinations of
pressure and vacuum, & level sensing techniques.
- Constant-level liquid fillers enter the container & fill
it to the tip of the filler nozzle with a suck-back
action at the end of the cycle to prevent dropping
or by using electronic or pneumatic controls to
shut off the filling valve.
LIQUID FILLING
o Constant-Level Fillers
- Constant-level fillers also may be the vacuum
type, in which the filling head seals against the
mouth of the container and draws a vacuum.
- This provides the force to bring the liquid from
the storage tank; when the level in the container
reaches the vacuum tube, the excess is
siphoned off and an automatic valve shuts the
flow.
- For faster fills, pressure in the filler bowl maybe
combined with the vacuum in the container.
LIQUID FILLING
o Constant-Volume Fillers
- Volumetric constant fillers fill to an accurate
product volume into the container, usually with
pistons or other accurate metering systems e.g,
timed flow, diapraghm.
- Which can cause displeasing difference of level if
container dimensions are not held to a tight
tolerance.
- But they are fast & accurate.
LIQUID FILLING
- Uses for constant-volume fills:

 Expensive products.
 Products where net weights must be maintained
because the product is sold by weight.
 Products whose end use demands accurate
weight or volume control (such as paint tint
bases).
 Pharmaceuticals or chemicals requiring accurate
dosage rates.
 Non-free-flowing viscous and paste products.
LIQUID FILLING
- These fillers can also be designed for “Top filling”.
- This is done by inserting the filling tube into the
container's neck to the fill-height level and by either
allowing the product to drop to the bottom or
directing the liquid to the container sides so that it
will run down the sides with a minimum of
turbulence and air entrapment.
LIQUID FILLING
- The more common method, "bottom-up filling," inserts

the filling tube down to the container bottom and allows
it to recede gradually upward as the container fills.
- Bottom-up filling inhibits frothing, minimizes product
aeration, eliminates air pockets in semisolids and avoids
undue vaporization of volatile products.
- Rigid filling-line connections are used when the
containers themselves are raised and lowered. Flexible
connections are used when the filling stems are inserted
into the containers and gradually moved upward. (See
Figure in next page)
Bottom-up filling can be done by lowering the tube into the
fixed container and gradually withdrawing it as filling
proceeds, as illustrated above, or by putting the container on a
stage that can be elevated and then gradually lowered as the
container fills.
LIQUID FILLING
- Filling carbonated beverages requires a special
approach to eliminate foaming and ensure
retention of desired carbonation levels. Product is
supplied to the filling heads from a chilled supply
bowl that is pressurized with carbon dioxide.
- The container is brought up against the filling-head
seal, and a multiposition valving system opens to
the supply-bowl headspace.
LIQUID FILLING
- When the pressure inside the container is at about
the same elevated pressure as the supply bowl,
the valve repositions to allow product to flow from
the supply bowl into the container.
- When the liquid level reaches the bottom of the
vent tube, a check valve stops the filling process. A
vent then opens to the atmosphere while sealing
off the pressure equalization tube.
- This allows the container pressure to come down
to atmospheric levels. The process is virtually
foam-free.
Carbonated beverages are filled cold and under pressure to
ensure minimum loss of carbonation. Rotary carbonated-
beverage fillers can have 100 or more filling heads.
LIQUID FILLING
o Vacuum Fillers
- "Vacuum fillers" operate by lowering the stem,
consisting of the filling tube and a vacuum line, into
the container neck and sealing the stem into place
with a seal ring.
- Air is drawn from the container so that air pressure on
the product in the supply tank forces product into the
container.
- When the product reaches the vacuum inlet, suction
draws it into the overflow tank, preventing it from rising
above the fill-height level. Excess product drops to the
bottom of the overflow tank, and air is sucked through
the tank outlet tube through the vacuum pump.
LIQUID FILLING
o Vacuum Fillers
- Vacuum-fill systems are used for putting free-
flowing liquids into glass containers. They are
fast, flexible and relatively low in cost.
- However, they are limited to rigid containers and
the constant-level method. They are not used
with products that are affected by agitation.
LIQUID FILLING
o Gravity Fillers
- "Gravity fillers" have a filling stem with a spring-
loaded outer tube and a rubber seal that fits over
the bottle finish.
- The outer tube is raised by the bottle to open the
filling valve. This eliminates drip before and after
filling.
- Gravity filling is slower than vacuum filling, and for
this reason, it is used primarily for some foaming
products, since agitation is minimal.
LIQUID FILLING
o Gravity Fillers
- Very foamy products demand bottom-up filling.

- Flow rate is controlled by the height of the product
in the supply tank above the filling tubes.
- Gravity filling cannot be used with slow-flowing
products.
- Few products are filled by gravity alone.
LIQUID FILLING
o Pressure Fillers
- "Pressure filling," which is similar to gravity
filling, uses a pump to provide the force to move
the product.
- This makes an elevated supply tank
unnecessary and results in a faster product flow.
- Pressure filling is ideal for viscous products
requiring minimum agitation.
LIQUID FILLING
o Pressure Fillers
- Pressure-and-vacuum combinations are used to
dispense viscous foaming products into plastic
containers.
- The pressure gives faster product flow, and the
vacuum draws off overflow.
- The system prevents containers from bulging
under the filling seal, which would create an overfill
or overflow condition when the seal was removed.
LIQUID FILLING
Pressure-and-vacuum fill system.

LIQUID FILLING
- Liquid fillers can be either in-line or rotary in action
with the in-line somewhat limited in the number of
nozzles they can spread out and fore the number of
containers that can be filled simultaneously, fillers, on
the other hand, have been built with more than 100
nozzle can attain filling speeds above 2,000 per
minute
Piston Volumetric Fillers
- Simple "piston fillers" consist of a cylinder fitted with a
plunger and a valve. Product is drawn from the supply
tank when the plunger is drawn back and is forced into the
container when the plunger is pushed forward.
- A valve rotates 90° with each cycle. Suction draws the
product through the valve duct and into the cylinder during
the first part of the cycle. Then the valve rotates, shutting
off the supply tank and allowing product to be forced into
the filling spout when the plunger pushes forward.
- Piston fillers usually have a control device that prevents the
valve from rotating if no container is in the filling station.
Product is pushed back into the supply tank without
spillage.
- The amount of product ejected depends on the cylinder's
diameter and the piston stroke length. The stroke is adjustable
while the machine is in operation.
- Piston fillers are available as single, manually actuated
pistons or as fully automatic rotary machines with twelve or
more pistons.
- (See Figure in the next page) Many ingenious valve
arrangements huve been designed for piston fillers.
- Continuous-motion rotary-head piston fillers are used for
high speeds of 500 to 2,000 cpm. They are ideal for viscous
or paste products, such as honey, peanut butter, creams and
jams, as well as for free-flowing liquids such as fruit juices.
Cross-section of a rotary piston filler.

Diaphram Volumetric Fillers
-"Diaphragm fillers" are used to fill a premeasured
volume of fluid rather than for filling to a level. A rolling
diaphragm in a cylindrical chamber moves up to
charge the cylinder with product. Valves then open to
allow discharge into the container when the
diaphragm moves down. Precise volumes are
attained by adjusting diaphragm movement. The use
of a rolling diaphragm eliminates the need for seals
between piston and cylinder, as would be needed on
a piston filler. Such sliding seals can cause abrasion
and particle generation, though.
Diaphram Volumetric Fillers
Metering Pump as Filler
- "Metering pumps" can be used as fillers. These
use positive displacement pumps or constant
output impellers to measure a preset amount of
product.
- To control the amount dispensed, the pump usually
operates for a preset number of revolutions and
then stops.
- Timed pumps are also available, but are said to be
less accurate. Pump fillers are used for aerosol
propellants and single portions of ketchup, mustard
and other liquids.
DRY-PRODUCT FILLING
- The three principal methods of metering dry fills are

by:
 Volume
 Mass or weight
 Count
Volumetric-cup (or Flask) Filling
In its simplest form, a "volumetric-cup" filling machine consists of a
flat, circular plate fitted with open-top cups at regular intervals. As
the plate revolves, the cups fill by passing under a product hopper.
Scrapers or brushes ensure that the cup is even and level. The
cups revolve to a discharge station where the product discharges
to the container.
- The simplest discharge system employs a
stationary disk under open-bottom cups.
- This disk has a single opening at the discharge
station, and the product is contained in the cups by
the disk until the discharge opening is reached.
- The alternative system employs a trap door under
each cup, eliminating the stationary disk.
- The trap doors open at the container-filling station
and close again before the cup-filling station is
reached.
- Volumetric adjustments are made by using
telescoping cups, with the bottom half of the cup
sliding up over the top half. The maximum
adjustment cannot be more than a 2:1 ratio.
- Cup- or flask-filling is used for free-flowing solids of
consistent density. It is advisable to maintain a
constant level in the feed hopper in order to
maintain consistent density and an even flow of the
product into the flasks.
Vacuum-volumetric Filling
- "Vacuum-volumetric filling" is accomplished by
means of a rotating wheel with adjustable
volumetric cups.
- When a cup is in the top position, product is fed
from a feed hopper.
- As the product flows into a cup, a vacuum is drawn
from the center of the wheel, through a very fine
filter.
- The vacuum removes the air from the product,
making it more dense and compact.
Vacuum-volumetric Filling
- The wheel rotates to the discharge station, where
the vacuum is released.
- The slug of product is discharged into the container
either directly or, when a small-mouthed container is
used, through a funnel.
- This filling method proves accurate with products
that are normally light and fluffy and entrain large
quantities of air.
- Talcum powders and cocoa powders are typical
examples.
Auger Fillers
- "Auger filling" is a volumetric form of product
measure. Generally, auger fillers are used for
products that are non-free-flowing in nature.
- This type of filler consists of a supply hopper and
an auger, or "worm," running in an outer sleeve.
- The sidewalls of the hopper are funneled to form
the sleeve in which the auger runs, and the product
is discharged from the end of the tube into the
container.
Auger Fillers
Auger Fillers
- When the machine stops, product is prevented from
falling through by a saucer or disk attached to the
lower end of the auger.
- As the auger spins, the centrifugal force throws
product off the disk. The amount measured from an
auger filler can be controlled either by a time cycle
or by counting its revolutions.
- Accuracy is to a large degree dependent on the
mechanism used to start and stop the auger
rotation.
Auger Fillers
- Product characteristics determine auger

construction.
- A straight auger is most suitable for products that
do not tend to pack in the hopper.
- Tapered augers are used with loose product.
- The larger auger flutes are capable of handling
more product than the smaller flutes running in the
sleeve.
- This also ensures that the auger at the discharge
point has a continuous supply of product.
Auger Fillers
- Auger fillers are commonly used in the spice

industry.
- Although used primarily for dry products, auger
fillers can also be used with many semisolids such
as ointments, thick sauces and patching pastes.
Net Weighing
- "Net weighing" employs weigh cells and tared
weigh buckets to weigh the product accurately
and then transfer it to the container.
- In older systems, product is fed from a hopper,
usually by a vibratory feeder, to a scale bucket. An
electrical contact stops the feed when the required
product weight is in the bucket and trips it to
discharge the product into the container.
- A single-station net-weigh scale cannot work at
speeds much higher than 20 or 22 weighings per
minute.
Net Weighing
- An inherent problem of net weighing is the presence
of product in midair between the feeder and the scale
at the time that the correct weight is reached in the
scale bucket.
- The "bulk-and-dribble" system reduces this problem
by splitting the feed into a fast-flowing bulk stream and
a slow-flowing dribble line.
- Both lines feed the scale bucket until the required
weight is nearly reached. The bulk feed then stops,
and the dribble feed continues until the final weight is
obtained. This minimizes the amount of product
suspended between the feeder and the scale bucket,
but slows the filling process.
Net Weighing
- That amount of product above the declared

weight, or "giveaway," is an important cost factor.
- Product cost and legal requirements justify the
higher price of accurate scale systems rather than
volumetric measure. These considerations have
spurred many improvements to the basic net-
weighing system.
Net Weighing
- Bulk-and-dribble tilling methods have been replaced
by computerized "staged-weighing systems."
- In these systems, final product weight is based on
combining product from several weighing stations to
fill the container. Approximate quantities of product are
distributed among a number of holding buckets.
- The amount dropped in each bucket is usually
between 20 and 33% of the required fill. The product
in each bucket is weighed by a load cell integral to the
bucket.
- Then, a microprocessor selects the three, four or five
buckets that will provide the fill nearest to the declared
weight.
Net Weighing
- In the system illustrated below, product is brought

by vibratory feeders from the main supply hoppers
to the filler's circular dispensing cone, and then
along individual vibratory feed trays to one of a
number of staging buckets. (Most machines have
between nine and fourteen buckets.
- Fillers may be based on a circular-flow dispensing
pattern, as shown in this text, or may have a linear-
flow pattern.)
Net Weighing
Net Weighing
- The vibratory feed trays operate on a demand-

timed cycle, only when a staging bucket is empty.
- The staging buckets empty their contents into their
respective weigh buckets whenever one is
available.
- Load cells determine the weight in each bucket
and enter these data into the filler's
microprocessor memory system.
Net Weighing
- When a package becomes available for filling, the

microprocessor searches through the available
eights and releases a combination of weigh
buckets that is closest to the declared weight but
not under.
- An example of computer-combination weighing is
given in Figure next.
There are 511 possible bucket combinations
on a nine-bucket computer-combination
Net Weighing
weigher. The fifteen combinations closest to
the 100 gram (g) target weight are shown
here. The machine will combine the product in
buckets 2, 4, 7, and 9 to get exactly 100 g.
Net Weighing
- For example, an assortment of chocolate-covered
confections has pieces weighing from 2 to 8 grams
(g).
- With bulk-and-dribble systems, the average
giveaway is about 20 g in a 350 g package (0.7 oz.
in a 12 oz. package).
- Staged-weighing divides the feed stream into ten
holding buckets, each typically holding about 70 to
120 g.
- The computer selects whatever combination of
buckets comes closest to but not under the declared
fill weight. Giveaway is reduced to 0.5 g (0.02 oz.).
Net Weighing
- It is possible to use load cells to check container
tare weight and automatically adjust the gross
weight so that consistent net weights are obtained.
- This system requires two weigh cells. The first cell
weighs the empty container and relays the weight to
a receiver and a memory unit, which adjusts the
reference voltage so that an accurate net weight is
obtained.
- Sophisticated systems record weights continually;
compute averages, deviations and ranges; adjust
fillers through feedback; and eliminate off-weight
packages.
Teaching Plan for Packaging Technology (19th – 30th October 2015)
Date Topic Delivery method/ Contact
hours
Assessment
19th Perspective on Packaging Lecture/Practical 3
October Quiz
20th October Packaging functions Lecture/Practical 3
Quiz
21st Environment and Lecture/Practical 3
Sustainability
October Quiz
22nd Successful Packaging design Lecture/Practical 3
October Quiz
23rd Paper and plastic packaging Lecture/Practical 3
material
October Quiz
26th Metal and glass packaging Lecture/Practical 3
material
October Test
27th Plastic & its applications Lecture/Practical 3
October Oral presentation by student
28th Halal Packaging, Certification Lecture/Practical 3
and Standard
29th Packaging Quality control Lecture/Practical 3
October Final Examination
th
30 Selected packaging Lecture/Practical 3
equipment
Total 30 hours

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PACKAGING TECHNOLOGY

KAZAKH NATIONAL AGRARIAN UNIVERSITY

1. Soroka, W. (2009) Fundamentals of Packaging Technology.

- Simple examples of package: boxes on the

- The crate around a machine or a bulk

- Generically, package is any containment

- Package (noun) is an object. A physical form

- Packaging - a coordinated Packaging machines e.g. fillers,

Which one is a package?

Which one is a packaging?

Technical functions Marketing functions

contain measure communicate promote

- It helps pull together concepts

Secondary converters are responsible for taking the materials produced

Processing, Filling & Sealing Operations

Distribution & Transportation

Final Product Use

FROM ROME TO THE RENAISSANCE

THE INDUSTRIAL REVOLUTION

THE EVOLUTION OF NEW PACKAGING ROLES

PACKAGING IN THE LATE 20TH CENTURY

ENVIRONMENTAL & SUSTAINABILITY ISSUES

1. Reduce Packaging design should use the minimum amount of

1.Despite replanting, global forest coverage is shrinking every year.

Environment Consumption Our consumption of

If global population will

Acid rain, ozone depletion, eutrification, smog, human

energy user distillation Waste

Cradle to Cradle paradigm

Raw materials converters machinery services

THE PACKAGING INDUSTRY

consumer industrial institutional

COURSE NAME: PACKAGING TECHNOLOGY

INTRODUCTION OF PACKAGING TECHNOLOGY:

Food packaging refers to knowledge of science and technology related to packaging

IMPORTANCE OF FOOD PACKAGING:

Packaging is now generally regarded as an essential component of our modern life

APPLICATION OF FOOD PACKAGING:

1. Soroka, W. (2009). Fundamentals of Packaging Technology (4th Edition).

2. Kelsey, R.J. (2004). Handbook of Package Engineering (4th Edition). Boca

3. Klimchuk, M.R. & Krasovec, S.A. (2006). Packaging Design: Successful

4. Morris, S.A. (2010). Food Packaging Engineering. Iowa: Blackwell Publishing

1. Determine packaging contain function – Packaging product analysis

(A) i, ii and iii

2. Choose non-basic functions of packaging?

(A) i, ii and iii

3. Which one of the following defines package correctly.

4. Which one of the following defines packaging correctly.

5. Which one is not technical in nature packaging functions.

(A) i, ii and iii

9. Choose two major packaging plastic families popular for recycling?

11. What is The Packaging Cycle.

12. Which one is not a product of primary converters.

13. Choose the correct paradigm in sustainable packaging concept.

14. What is sustainability in packaging?

16. Which one is not the Users in modern packaging industry.

17. Modern packaging industry needs the following services to function.

(A) i, ii and iii

18. Choose correct description about primary packaging.