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unit 1an overview of packaging1lesson 1a historical perspective on packaging11what is packaging?12primitive packaging23from rome to the renaissance34the industrial revolution55the evolution of new packaging roles66packaging in the 20th century87modern packaging97.1changing needs and new roles97.2packaging and the modern industrial society97.3world packaging118waste management and environmental issues129the modern packaging industry16lesson 2basic functions of packaging221introduction222the containment function233the protection/preservation function234food preservation244.1the nature of food244.2meat products264.3fish264.4produce264.5barrier packaging274.6microorganisms285the transport function356the information/sales function36unit 2packaging materials and containers42lesson 3paper and paperboard421introduction422representative papermaking machines422.1fourdrinier machines422.2cylinder machines432.3twinª²wire machines453machine direction and cross direction454surface or dryª²end£¬treatments and coatings465paper chracterization475.1caliper and weight475.2brightness485.3paper and moisture content485.4viscoelasticity496paper types496.1newsprint and related grades496.2book papers496.3commercial papers496.4greaseproof papers506.5natural kraft paper506.6bleached krafts and sulfites506.7tissue paper506.8label paper506.9pouch papers516.10containerboards£¨linerboard and medium£©517paperboard grades517.1chipboard£¬cardboard£¬newsboard517.2bending chipboard517.3lined chipboard517.4single whiteª²lined£¨swl£©paperboard527.5clayª²coated newsback£¨ccnb£©527.6double whiteª²lined£¨dwl£©paperboard527.7solid bleached sulfate£¨sbs£©527.8food board527.9solid unbleached sulfate£¨sus£©52lesson 4corrugated fiberboard boxes571historical perspective572corrugated board582.1construction582.2flutes592.3fiberboard grades602.4corrugating adhesives612.5board manufacture623fiberboard characterization tests633.1mullen burst test£¨tappi t 810£©633.2edgewise compression test£¨tappi t 811£©633.3flat crush test£¨tappi t 808£©.643.4combined weight of facings643.5thickness of corrugated board£¨tappi t 411£©643.6gurley porosity£¨tappi t 460 and t 536£©643.7flexural stiffness£¨tappi t 820£©643.8water takeª²up tests£¨tappi t 441£©643.9puncture test£¨tappi t 803£©643.10pin adhesion£¨tappi t 821£©653.11ply separation£¨tappi t 812£©653.12coefficient of friction£¨tappi t 815 and astm 04521£©654corrugated boxes654.1selecting the correct flute654.2box styles674.3manufacturer¬ðs joint684.4dimensioning685carrier rules685.1application685.2summary of rules for corrugated box construction69lesson 5metal containers751background752common metal container shapes763threeª²piece steel cans774twoª²piece cans794.1draw processes794.2drawª²andª²redraw process794.3drawª²andª²iron process805impact extrusion816aerosols836.1aerosol propellants836.2other pressurized dispensers84lesson 6glass containers891glass types and general properties892bottle manufacture902.1blowing the bottle or jar902.2annealing922.3surface coatings922.4inspection and packing933bottle design features933.1bottle parts and shapes933.2finish and closures943.3neck and shoulder areas943.4sides943.5heel and base953.6stability and machinability953.7vials and ampoules953.8carbonated beverages96lesson 7plastics in packaging981introduction to plastics982thermoplastic and thermoset polymers1003shaping plastics1014plasticating extruders1015extrusion1025.1profile extrusion1025.2sheet and film extrusion1035.3blownª²film extrusion1035.4orientation1045.5coª²extrusion1056injection molding1056.1injection molding machines1056.2coª²injection molding1067extrsion blow molding1068injection blow molding1079thermoforming1099.1principle and applications1099.2thermoforming methods1099.3billow forming11010other forming methods11110.1pressblowing11110.2rotational molding11110.3compression molding11110.4blowª²fillª²seal molding11211recognizing molding methods112lesson 8flexible packaging laminates1161laminates1162aluminum foil 1162.1chemical characteristics1172.2aluminum foil in flexible packaging1172.3foil coatings1183vacuum metallizing1193.1the metallizing process1193.2vacuumª²metallizing paper1203.3vacuumª²metallizing films1204other inorganic coating1214.1silicone oxides1214.2carbon coatings1214.3nanocomposites1215laminate structural and physical properties1215.1coefficient of friction1225.2body and deadª²fold properties1235.3tear properties1235.4 thermoformability1235.5use environments1236flaxible bags£¬pouches and sachets1237sealability1268barrier properties1279laminating processes1299.1bonding methods1299.2laminating machines1299.3coating stations13010specifying laminates132lesson 9closures1381selection considerations1382tamper evident closures1393tamper evident systems1404childª²resistant closures142unit 3packaging dynamics and distribution packaging145lesson 10shock£¬vibration£¬and compression1451shock1451.1shock resulting from drops1451.2shock during rail transport1471.3other shock conditions1471.4quantifying shock fragility1481.5cushioning against shock1512vibration1522.1vibration damage due to relative motion1532.2vibration resonance1532.3stack resonance1542.4isolating vibration1553compression1563.1static and dynamic compression1563.2compression strength and warehouse stack duration1573.3compression strength and humidity1573.4other factors influencing box stack strength1573.5contents’ effect on compression strength1593.6plastic bottle stacking factors1613.7stacking and compression1613.8distribution environment and container performance1623.9estimating required compression strength163lesson 11mechanical shock1691introduction1692the freely falling package1693mechanial shock theory1714shock duration1765shock amplification and the critical element1776horizontal impacts179lesson 12lansmont six step method1841step 1 define the environment1851.1shock environment1851.2vibration environment1872step 2 product fragility analysis1882.1shock£ºdamage boundary1882.2vibration£ºresonance search &dwell1913step 3 product improvement feedback1924step 4 cushion material performance evaluation1924.1shock cushion performance1924.2vibration cushion performance1935step 5 package design1945.1shock£ºpackage design1945.2vibration£ºpackage design1955.3package design considerations1966step 6 test the product£¯package system1966.1shock£ºpackage testing1966.2vibration£ºpackage testing197lesson 13distribution packaging2001short history of distribution packaging in the usa2002functions and goals of distribution packaging2002.1containment2002.2protection2002.3performance2002.4communication2012.5product protection2012.6ease of handling and storage2012.7shipping effectiveness2012.8manufacturing efficiency2012.9ease of identification2012.10customer needs2012.11environmental responsibility2013the cost of packaging2014the package design process2025taking a total system approach to package design2026the protective package concept2037the 10ª²step process of distribution packaging design2057.1identify the physical characteristics of the product2057.2determine marketing and distribution requirements2057.3learn about the environmental hazards your packageswill encounter2057.4consider packaging and unitizing alternatives2057.5design the distribution package2057.6determine quality of protection through performanceª²testing2067.7redesign package£¨and unit load£©until it successfullypasses all tests2067.8redesign the product if indicated and feasible2067.9develop the packaging methods2077.10document all work2078a final check2079the warehouse20710unit loads20810.1pallets20810.2unit load efficiency21010.3stabilizing unit loads211lesson 14test method for product fragility2151shock£ºdamage boundary2151.1conducting a fragility test2172vibration£ºresonance search & dwell219lesson 15stressª²energy method for determining cushion curves2231current practice2232something new2233stressª²energy method2244procedure to find the stressª²energy equation2255using the stressª²energy equation to generate cushion curves2266test procedure2267conclusion228unit 4packaging technology and machinery230lesson 16liquid filling2301introduction2302type of filling machine2303use of filling machines2314rotary and straightª²line fillers2315liquid volumetric filling2315.1introduction2315.2piston volumetric filling2325.3diaphragm volumetric filling2355.4timed flow volumetric filling2365.5rotating metering discs2365.6rotary pumps2375.7augers2386liquid constant level filling2386.1introduction2386.2pure gravity filling2386.3pure vacuum filling2406.4gravity vacuum filling2416.5pure pressure filling2426.6level sensing filling2426.7pressure gravity filling243lesson 17dry product filling2481introduction2482type of dry products2483type of dry filling operations2484product delivery2495dry volumetric filling2495.1introduction2495.2cup or flask fillers2495.3flooding or constant stream fillers2515.4auger fillers2515.5vacuum fillers2526dry filling by weight2536.1introduction2536.2net weight filling2536.3gross weight filling2546.4types of scales2557filling by count2567.1introduction2567.2board or disc counters2567.3slat counters2577.4column counters2587.5electronic counters2597.6maintenance259lesson 18applied packaging£¨i£©2621carded display packages2622blister packages263lesson 19applied packaging£¨ii£©2661carded skin packaging2662pharmaceutical packaging2672.1drug properties2672.2packaging emphases2682.3regulations2692.4manufacturing practice270unit 5packaging development273lesson 20packaging development process2731managing the packaging project2732project scope2743the package development process2753.1an overview of the package development process2753.2generating ideas2763.3the package design brief2773.4the development timetable2803.5development and testing of alternatives2804specifications281glossary 285resources316