ChE El 15: Fundamentals of Packaging

Packaging is best described as a coordinated system of preparing goods for transport, distribution, storage, retailing, and use. It is a complex, dynamic, scientific, artistic, and controversial business function, which in its most fundamental form contains, protects/ preserves, transports, and informs/sells. Packaging is a service function that cannot exist by itself; it needs a product. If there is no product, there is no need for a package.Packaging also is the technology of enclosing or protecting products for distribution, storage, sale, and use. It refers to the process of design, evaluation, and production packages. All products made of any materials of any nature to be used for the containment, protection, handling, delivery and preservation of goods from the producer to the user or consumer.The importance of packaging can be summarized as follows. If adequately packaged, the shelf-life of local surpluses of food may be extended, and this allows the food to be distributed to other areas. In doing so, consumers are given more choice in terms of food available, food resources can be more equitably distributed, and rural producers may be able to generate income from surplus produce. Correct packaging prevents any wastage (such as leakage or deterioration) which may occur during transportation and distribution. Good packaging and presentation encourages consumers to buy products.Packaging should provide the correct environmental conditions for food starting from the time food is packed through to its consumption. A good package should therefore perform the following functional purposes:it should provide a barrier against dirt and other contaminants thus keeping the product cleanit should prevent losses. For example, packages should be securely closed to prevent leakageit should protect food against physical and chemical damage. For example the harmful effects of air, light, insects, and rodents. Each product will have its own needsthe package design should provide protection and convenience in handling and transport during distribution and marketingit should help the customers to identify the food and instruct them how to use it correctlyit should persuade the consumer to purchase the food.

HISTORY OF PACKAGINGPackaging as we know today is the result of a long development process. The very first people to roam the earth, back in depths of prehistory, sought to conserve the surplus food collected during hunting, fishing and food-gathering for the longest possible time, to be prepares for any future food shortages. In the middles age, wooden barrels became the most frequently used way of preserving goods. They were used for storing all kinds of solids and liquids, protecting them from light, heat and dampness.EARLIEST PACKAGING TINNING The use of tinplate for packaging dates back to the 18th century The manufacture of tinplate was long a monopoly of Bohemia 1667 Andrew Yarranton, an English Engineer, & Ambros Crowley brought the method to England where it was improved by ironmasters including Philip Foley 1697 John Hanbury had a rolling mill at Pontypool for making Pontypoole Plates. The method of rolling iron plates by means of cylinders pioneered there, enabled more uniform black plates to be produced than was possible with the old plan of hammering. 1725 Tinplate boxes first began to be sold from ports in the Bristol Channel. The tinplate was shipped from Newport, Monmouthshire. 1805 80,000 boxes were made and 50,000 exported. Tobacconists in London began packaging snuff in metal-plated canisters. CANNING 1810 discovery of the importance of air tight containers for food preservation by French inventor Nicholas Appert, the tin canning process was patented by British merchant Peter Durand. 1812 Durand sold his patent to two other Englishmen, Bryan Donkin and John Hall, who refined the process and product, and set up the worlds first commercial canning factory on Southwark Park Road, London. 1813 they were producing the first canned goods for the Royal Navy 1855 invention of the can openerRobert Yeates, a cutlery and surgical instrument maker of Trafalgar Place West, Hackney Road, Middlesex, UK, devised a claw ended can opener with a hand-operated too that haggled its way around the top of metal cans. 1858 - another lever-type opener of a more complex shape was patented in the United States by Ezra Warner of Waterbury, Connecticut. PAPER-BASED PACKAGING 16th century Set-up boxes were first used 1839 modern folding cartons 1817 first corrugated box was produced commercially in England Corrugated (also called pleated) paper received a British patent and was used as a liner for tall hats. 1890 the Scottish-born Robert Gairinvented the pre-cutpaperboardbox - flat pieces manufactured in bulk that folded into boxes Gair's invention came about as a result of an accident: as a Brooklyn printer and paper-bag maker during the 1870s, he was once printing an order of seed bags, and the metal ruler, normally used to crease bags, shifted in position and cut them. Gair discovered that by cutting and creasing in one operation he could make pre-fabricated paperboard boxes 1844 - Commercial paper bags were first manufactured in Bristol, England 1852 - AmericanFrancis Wollepatented a machine for automated bag-making 20th CENTURY PACKAGING Packaging advancements in the early 20th century includedBakeliteclosures onbottles, transparentcellophaneoverwraps and panels oncartons, increased processing efficiency and improvedfood safety. As additional materials such as aluminum and several types of plastic were developed, they were incorporated into packages to improve performance and functionality 1952 Michigan State University became the first university in the world to offer a degree in Packaging Engineering. 1920 - Invention of transparent cellophane marked the beginning of the era of plastic. Polyethylene was the first plastic used for packaging and was discovered in 1933 by mistake. Aluminium foil made it possible to effectively seal medications and other sensitive products. 1940 - packaging was developed for frozen foods 1952 - aerosol came into the market. Cans, available from the 1960s, heralded the expansion of the soft drinks market. 1961 - Aseptic cartons were invented and used for preserving long-life milkINDUSTRIAL REVOLUTION Began in England in the late 17th century The shift from individual crafts at home or in small groups to mass production in factories brought large-scale migration of workers and their families to towns and cities. Foods and basic commodities previously produced and readily available at home, now had to be transported to shop in the cities to be brought by the workers using their hard-earned wages. This increased the demand for barrels, boxes and bags to bring in supplies on a larger scale and it also brought a need to supply goods in small quantities now demanded by the workers. Goods were often measured out into the purchasers own container, but gradually this was changed to the shopkeeper pre-packing items such as medicines, cosmetics and tea, and having them available for sale in measured quantities, thus offering the buyer some assurance as to the quality and quantity of the goods. Eventually this pre-packing moved back a further stage from the buyer, to the situation where most goods are packed at the point of production rather than sale. 19th century - started the rise of the brand name used as a mark of quality by producers who wanted to make sure the buyer knew which product they were buying and were not misled by inferior goods. Some of the oldest brand names:Schweppes (1972)Perrier (1863)Quaker (1901)MODERN PACKAGING The move from packing goods at the point of sale to packing at the point of production brought about a shift from bulk to consumer packs, which had to survive the journey not just from the shop to home, but, more importantly, from factory to shop. It also gave producers the opportunity to develop their own style of packs to promote their own products, and this has brought us the modern-day pack. Now, having a range of goods to choose from, packaging helps the consumers differentiate between the options available from various companies. Now, consumers expect products to be free from damage, and in the case of foodstuffs, wholesome and safe through packaging. Brand owners now expend their resources in developing packs which attract the attention of the would-be purchaser and at the same time provide the product with the protection needed.LIFESTYLE CHANGES AND THEIR IMPACT ON PACKAGING Reduction in the size of the family unit, due to decreased birth rates, increased number of one-parent families and increased longevity. This means a requirement for smaller packs, thus more packaging per kilogram of goods. Growth in the number of households in which all adults are in either full-or-part-time work, outside of the home. This means less formal meals where everyone sits down together; meals are required at different times, and with minimum preparation. This brings a higher than ever consumer demand for convenience in terms of portion size and food which can be made ready-to-eat at short notice. Ready meals and packaging formats in which they are presented to make a key contribution to meeting this demand. Growth in ownership of domestics appliances such as the fridge and freezer has allowed consumers to buy larger quantities of fresh goods, which are expected to remain in good condition for prolonged periods of time. The development of a low cost domestic microwave oven brought with it a requirement for microwave-suitable packaging.BUSINESS DEVELOPMENTS: Effects of Globalization and Modern RetailingThe growth of modern supermarket brings a highly competitive retail environment, with different versions of brands of the same product all displayed together. The time-pressed shopper relies on the subliminal cues of the packaging to make a selection, usually based on almost instant recognition of familiar features such as colour, graphics or shape.The globalization of manufacturing, with products being shipped over long distances and through different climatic conditions places strong emphasis on packaging to provide protection against likely hazards.Modern supermarkets demand fast stock replenishment with a minimum manual effort. This has brought the requirement of secondary packs which can double up as shelf ready display packs, with no handling of the individual primary packs. Marks & Spencer first company to introduce this concept in 1970s. The straight-on-tray, as it was then called, was initially used for food, and then extended to other goods such as toiletries.Modern supermarkets also demand rapid service at the checkout, and here the ubiquitous bar code provides a quick and reliable means of identifying the product and its price. Importantly, this data is also used for stock control purposes, often linked to automatic ordering to replenish supplies.PACKAGING MATERIALS: Usage & DevelopmentAround 70% of packaging is used for food and drink, but other sectors such as healthcare, beauty products, chemicals, clothing, electrical and electronic equipment all need packaging to ensure they stay in an acceptable condition from manufacturer to consumer.Todays global packaging industry is valued at over $400 billion, roughly broken down into: 36% - paper and board (corrugated boards) 34% - plastics 17% - metals (steel and aluminum) 10% - glass Others wood and textiles

Glass probably the oldest in its use as a packaging medium dating back to its use for hollow vessels in about 1500 BC. Made by layering molten glass around a sand core and then removing the sand once the glass had cooled and solidified. Glass Blowing started to develop around the first century BC and brought with it the ability to make glass containers of different shapes and sizes, as a formability of molten glass was exploited.Examples: beers, wines and spirits, perfumes and some pharmaceuticals Metal packaging reported to date back to Napoleonic times and the development of metal containers for food has gone hand-in-hand with the introduction and development of food sterilization systems such as those used in canning. Steel continues to be used for heat-sterilized cans for food and drink and for large containers such as drums and immediate bulk containers (IBCs). Aluminum first used for cans in the 1950s and today is widely used for drink cans, especially for carbonated soft drinks. Papermaking date back to China in the second century AD and originally used woven strips of wet papyrus, laid down by hand and then dried.Papermaking machinery developments in the 19th century brought the ability to build up layers of cellulose fibers (initially obtained from rags and from trees) into a continuous web, thus allowing a wide range of materials of different thicknesses and performance to be made. Plastic packaging since 1940s has seen the most significant growth since then, of all the packaging materials, due to the development of low-cost processes and materials with a wide range of different properties and the ability to tailor those properties to suit a range of different needs. plastics have replaced the more traditional materials such as glass and metal in some applications, such as: the change from glass to polyethylene terephthalate (PET) containers for bottled water and soft drinks the change from glass to high-density polyethylene (HDPE) containers for milk the change from metal cans to flexible plastics pouches for pet foods, soups and sauces But still, some notable brands of bottled water retain glass for its high-quality image and the vast majority of canned foods remain in the traditional food can. Advantages of Plastics: Brought reduction in pack weight, often with associated reductions in the total cost of the packed products Another significant packaging development relying on plastics is a reel-formed carton typified by the Tetra Pack and Combibloc containers. Wood - has been used for barrels for bulk products such as butter, and is still used for crates and boxes for fresh produce and for heavy engineering items such as machinery parts. The most significant use of wood in packaging is probably in the form of pallets, still the most common way of moving goods from manufacture to seller Other materials used in packaging include cork (wine bottles, albeit challenged by plastics) and textiles such as jute, used for sacks and bags. Jute sacks are used for agricultural products, due to their breathability, and for commodity food products such as sugar and rice. Jute bags are available as shopping bags and gift bags, often by companies wanting to project a green image by using this natural fibre

SOME EXAMPLES OF PACKAGING INNOVATIONSCOCA COLA1894 - Mississippi shop owner Joseph Biedenharn bottled Coca-Cola in a common glass bottle called a Hutchinson after he was impressed by its sales. 1916 - Birth of the contour bottle so its not easily confused with copycat brands.1923 Six packs were introduced to encourage people to take their drinks home and were a huge hit.1955 Packaging innovations shops started selling Coca cola in various sizes including larger 10, 12 and 26 ounce versions.1960 Trademark no.1 for the contour bottle with the word Coca Cola.2009 With a going green wave Coca Cola launched the innovative plat bottle in the US made of completely recyclable PET with 30% plant material and in 2011 the concept went global

HEINZ-Henry J. Heinz began packing foodstuffs on a small scale at Sharpsburg, Pennsylvania-1869 Henry sold horseradish in a cart from his mothers garden.-Henry Heinz went around selling his ketchup and was the first person to come up with an idea of having cardboard spoon packed in the box.-Heinz in 2013 was worth 23BLN

TYPES OF PACKAGING Consumer Packaging-Designed for consumer convenience and appeal, marketing consideration display. The main emphasis is on marketing.

Industrial Packaging-Focuses on the handling convenience and protection during transportation. The main emphasis is on logistics.

CATEGORIES OF PACKAGING Primary packaging Surrounds the product and features labelling Primary or sales packaging forms a sales unit for the user or final consumer It includes also the packaging which surrounds the product when the consumer takes it homeExamples:Individual bags, plastic bags, eco-bags, paper bags

Secondary packaging Box or crate into which a number/group packs of primary packages are placed for ease of manual movement of product. Some secondary packaging also used to display productsExamples:Shrinkwrap film, Thermoformed Plastic Trays

Transit/Tertiary packaging The base pallet, strapping or wrapping used to bundle/collate the boxes or crates for transport and distributionExamples:Roll Cages Shipping Containers Transit packaged products are placed in shipping containers for long-distance transportation and distribution.Examples:Cargo Trucks, Closed Vans.

ENVIRONMENTAL PERSPECTIVE: Responsible Use of ResourcesPackaging has attracted criticism as a squanderer of valuable resources and an environmental pollutant.Packaging and waste Every year, more than 10 million tonnes of packaging are used. Many materials used for packaging cannot easily be recycled, and others became contaminated by food residues and cannot be recycled. Bottle manufacturers have redesigned milk bottles to be 65% lighter. This uses less glass and makes the product lighter and less expensive to transport. Manufacturers have redesigned steel cans to be 61% lighter, saving metals and making the product lighter and less expensive to transport.SUSTAINABILITY is the goal of maintaining a human society over time in ways that are fair and just for all people and do not damage the environment and its biodiversity.SUSTAINABLE DEVELOPMENT a plan for the development of communities that balances the importance of a vibrant economy and sustainability the 3 elements of sustainable development the environment, society and the economy are competing interests.SUSTAINABLE COMMUNITIES - places where people lead lines of quality and dignity without damaging the ecological system. UNEP United Nations Environment and Development Programme . Human being is central to its efforts to promote sustainable developmentWEAK SUSTAINABILITY This model accepts that many aspects of development serve the economy, society, or the environment alone. It suggests that technology can be a substitute for a damaged environment.STRONG SUSTAINABILITY The environmental element of sustainable development is viewed as the common ground where the society and the economy interact and develop. Development cannot damage the environment; a healthy environment is fundamental to a just and fair society and a vibrant economy now and in the future.OUR PART AS ENGINEERSEngineers play a crucial role in improving living standards throughout the world. As a result, engineers can have a significant impact on progress towards sustainable development World Federation of Engineering Organization (2002)We cant solve problems by using the same kind of thinking we used when we created them Albert Einstein

ONE PLANET LIVING10 principles for one planet living that designers can use to plan places and products that promote sustainable development:1. Zero CarbonThe activity must produce net zero carbon dioxide emissions. Net zero means that the activity produces no carbon dioxide, or takes measures to remove the carbon dioxide it produces.2. Zero WasteAll materials must be used cleanly and recycled cleanly in a continuous cycle; or they must be composted to re-enter ecological cycles.3. Sustainable TransportThe movement of materials and products must be done in ways that are good for people and the environment.4. Local & Sustainable MaterialsMeet consumer demands by using materials that are locally sourced and use locally available technologies for recycling and reuse.5. Local & Sustainable FoodPromote and consumes foods that support regional agriculture and food industries, and minimize their use of non-renewable natural resources in the form of fossil fuels used for transport and fertilizers.6. Sustainable WaterWater use that promote human health and prevents water pollution, depletion of fresh water, and harm o aquatic and marine ecosystems.7. Natural Habitats and WildlifeThe harvesting or mining of natural resources, and the construction of transport routes, factories, warehouses and retail centers should not damage or degrade natural habitats or harm wildlife.8. Culture & HeritageEconomic activities should honor and protect the culture and heritage of the communities they affect, and local knowledge should be used to make decisions.9. Equity & Trade FairEveryone involved in the development, distribution, sales and recycling of products must be treated and paid fairly and have opportunities for a dignified life.10. Health & HappinessBeyond the consumption of goods and services to meet basic human needs, there is no correlation between consumption (wealth) and happiness.

DESIGNING FOR SUSTAINABILITY Designing for Weak Sustainability Consider the economic, social and environmental strengths and weaknesses of their designs, but compromise to minimize potential environmental harm. Designing for Strong SustainabilityConsider the economic, social and environmental strengths and weaknesses of their designs, but do not compromise and achieve environmental protection as a design priority.CYCLIC SOLAR-SAFE DESIGN CRITERIAPractical design criteria for judging the strengths and weaknesses of a designs sustainability were developed by Edwin Datschefski in 1998.1. CYCLIC the product must be made from organic materials that can be recycled or composted repeatedly.2. SOLAR the product must use solar or other renewable energy throughout its development, distribution, use and recycling.3. SAFE the product must be nontoxic to humans and other organisms, and no toxic chemicals can be used in manufacturing or recycling.4. EFFICIENT the production and use of the product should require 90% less material, energy and water compared to similar products manufactured before 1990.5. SOCIAL the product and its development and manufacture must not jeopardize the rights, health or livelihood of individuals or communities.SUSTAINABLE PACKAGINGSustainable packaging is packaging that is functional, cost effective and meets sustainability principles or design criteriaPRECAUTIONARY PRINCIPLEThis is an obligation for designers to prove that a product, through its manufacture, use or disposal poses no negative consequences for people or the environment.STRATEGIES FOR SUSTAINABLE PACKAGING1. Manufacture with renewable and compostable materialsExamples: Bioplastics made from corn, potato, wheat, or dairy polymers Paper and cardboard from sustainable managed forests Cellulose film2. Manufacture with recycled and recyclable materialsExamples: Paper and cardboard made from recycled fiber or moulded pulp Recycled and recyclable plastics like HDPE and PET3. Design for ReuseExamples: Reusable and recyclable crates and pallets Re-sealable plastic containers Return system for customer refills4. Design for recyclingExamples: Packaging made from a single material (including labels and closure system) Packaging made from materials that are commonly collected for recycling Packaging with prominent recycling symbols5. Eliminate inks, paints and adhesives that are toxicExamples: Print with inks that do not contain toxic compounds (volatile organic compounds VOCs) Use paints and inks that do not contain heavy metals or other toxic compounds Use adhesives that do not contain toxic compounds6. Eliminate secondary packagingExample: Use only primary packaging and transit packaging7. Reduce the volume of the materials usedExamples: Inflatable pouches to fill package voids Refills in pouches Lightweight bottles and cans

| Prepared by Engr. Benedict S. Marzan11