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Lecture 2-

Packaging I

UGSCCS – Autumn 2013

Section 1 Role of Packaging

Section 2 Categories of Packaging

Section 3 Packaging Materials

PACKAGING I

LECTURE STRUCTURE

ROLE OF PACKAGING

PACKAGING OPTIONS - COFFEE

Coffee

granule jar

Single serving sachets

Refills packs

Ground

coffee bags

Coffee bean

jute sack

Provide protection

Promote sales

Allow transportation

Provide information

Prevent / minimise theft

Provide convenience

ROLE OF PACKAGING

WHY DO WE PACKAGE GOODS?

The art of and the operations involved in the preparation of articles or commodities for carriage, storage and delivering to the consumer

British Standards Institution

Packaging is not itself a product, but is a means of delivering a product to a customer in good condition

INCPEN (the Industry Council for Packaging & the Environment)

Packaging is a coordinated system of preparing goods for safe, secure, efficient and effective handling, transport, distribution, storage, retailing, consumption and recovery, reuse or disposal combined with maximizing consumer value, sales and hence profit

Saghir, 2002

ROLE OF PACKAGING

DEFINITION

To enclose or surround

Influenced by

Product characteristics

What is being sold

ROLE OF PACKAGING

CONTAINMENT

Aid preparation and serving

Portioning (meals for one, slimming aids)

Convenience (microwave meals)

ROLE OF PACKAGING

CONTAINMENT - PORTIONS

Facilitate handling

Protect goods

ROLE OF PACKAGING

CONTAINMENT – HANDLING UNITS

Handling

Transport

Storage

ROLE OF PACKAGING

PROTECTION

Defined as “the material or the amount of material that is

spoiled or wasted”

Factors causing spoilage

Light

Gases

Water / moisture

Strong flavours and aromas

ROLE OF PACKAGING

PROTECTION – SPOILAGE

Defined as “to prepare food (or any perishable substance) so as to resist decomposition

or fermentation”

Increase shelf life

ROLE OF PACKAGING

PROTECTION - PRESERVE

Theft

Tampering

ROLE OF PACKAGING

PROTECTION – THEFT

About the product

Manufacturer details

Legal requirments

ROLE OF PACKAGING

INFORMATION

Includes legal requirements

ROLE OF PACKAGING

INFORMATION - IDENTIFICATION

Per item

Per serving

% Daily intake

ROLE OF PACKAGING

INFORMATION – NUTRITIONAL

Product preparation

Assembly instructions

ROLE OF PACKAGING

INFORMATION – PRODUCT USE

Location

Temperature

ROLE OF PACKAGING

INFORMATION - STORAGE

Safety warnings

ROLE OF PACKAGING

INFORMATION - SAFETY

Contact information

Queries

Returns

Spares & replacement

Complaints

May be a legal requirement

ROLE OF PACKAGING

INFORMATION - CONTACT

Part of end of life management

Reduce landfill

ROLE OF PACKAGING

INFORMATION - RECYCLING

ROLE OF PACKAGING

LANDFILL

Brand

Promotional offers / sales message

ROLE OF PACKAGING

PROMOTION

The personality that identifies a product, service or company

Origin in cattle branding

ROLE OF PACKAGING

PROMOTION – BRANDING

The outward expression of a brand – including its name, trademark, communications,

and visual appearance

Brand identity elements include

Name

Logo

Tagline or Catchphrase

Graphics

Shapes

Colours

Sounds

Scents

Tastes

Movements

ROLE OF PACKAGING

PROMOTION – BRAND IDENTITY

Interbrand – Best Global Brands 2011Brand messaging should be led first by packaging and then reinforced by all other

communications

Packaging has become the leading vehicle for differentiation when it comes to

sustainability and corporate citizenship

ROLE OF PACKAGING

PROMOTION – BRANDING

Promotional items

Advertising

ROLE OF PACKAGING

PROMOTION – SALES MESSAGES

The art of and the operations involved in the preparation of articles or commodities for carriage, storage and delivering to the consumer

British Standards Institution

ROLE OF PACKAGING

SUMMARY

Contain

Protect

Promote

Inform

Section 1 Role of Packaging

Section 2 Categories of Packaging

Section 3 Packaging Materials

PACKAGING I

LECTURE STRUCTURE

CATEGORIES OF PACKAGING

THREE LEVELS

Depends on its function

Primary

Secondary

Tertiary

CATEGORIES OF PACKAGING

THREE KEY TYPES

PRIMARY

SECONDARY

TERTIARY

Also known as

Sales packaging

Consumer packaging

The packaging

The individual product unit

Which is in contact with the product

That the consumer usually takes home

CATEGORIES OF PACKAGING

PRIMARY PACKAGING

Groups product units into a convenient package

For replenishment of stock items / shelves

For multiple unit sales

It can be removed without affecting the product

CATEGORIES OF PACKAGING

SECONDARY PACKAGING

Used for transport of the products (logistics unit)

Outer case

Pallet, crates

Roll cage

Designed to ensure the damage free handling and transport

Protect goods

Ease of handling

Storage

Loading on transport mode

Excludes road, rail, maritime or air (ULD) containers

CATEGORIES OF PACKAGING

TERTIARY PACKAGING

Also called

Transit packaging

Transport packaging

Industrial packaging

Distribution packaging

Includes

Pallet

Dunnage

Shrink wrap

CATEGORIES OF PACKAGING

TERTIARY PACKAGING

Display packaging

Retail packaging

Used packaging

CATEGORIES OF PACKAGING

ADDITIONAL TERMS

Unit loads (pallets)

Uniformity of shape

Standard size

Ability to stack

Mechanical handling

Limited goods protection

Unit loads of transport

Protection from damage in shipping

Goods in steel container / road trailer

Reduce the handling of the goods

Reduction in packaging

CATEGORIES OF PACKAGING

INTEGRAL PART OF UNIT LOADS

Higher product value

Greater protection of the product

More crisps on a pallet

Reduction in transport costs / unit

CATEGORIES OF PACKAGING

PRODUCT DESIGN & PACKAGING

Number of units in a carton

Number of cartons on a pallet

Number of pallets in a trailer …

CATEGORIES OF PACKAGING

PACKAGING SHAPE & TRANSPORT

Maximum weight limits imposed to

Prevent overloading

Prevent damage to the goods

Ensure safety of those handling goods

The maximum amount of cargo (weight) carried is affected by

Weight of the vehicle / ship / pallet when empty

Weight of the cargo PLUS

Weight of

Primary packaging

Secondary packaging

Tertiary packaging

CATEGORIES OF PACKAGING

PACKAGING WEIGHT & TRANSPORT

Tare Weight – the weight of a truck when empty

Gross Weight – the weight of a truck and the cargo

Net Weight = Gross Weight –Tare Weight

Increase in number of bottles shipped in every container

Maximising weight capacity

More wine shipped

Less packaging (weight)

Reduces shipping cost of wine

CATEGORIES OF PACKAGING

REDUCING PACKAGING WEIGHT

CATEGORIES OF PACKAGING

PACKAGING COST TRADE-OFF

Source: Saghir, M (2004), The concept of packaging logistics (After Lambert et al., 1998)

Logistics activity Trade-offs

Transportation Decreases Increases

Increased packaging information • Shipment delays

• Tracking of lost

shipments

Increased packaging protection • Damage & theft in

transit

• Package weight &

transport costs

Increased standardisation • Handling costs

• Vehicle weighting time

• Need for specialised

transport equipment

• Modal choice for

shipper

Inventory Decreases Increases

Increased product protection • Theft, damage and

insurance

• Product availability

• Holding costs

CATEGORIES OF PACKAGING

PACKAGING COST TRADE-OFF

Source: Saghir, M (2004), The concept of packaging logistics (After Lambert et al., 1998)

Logistics activity Trade-offs

Warehousing Decreases Increases

Increased package information • Order filling time

• Labour costs

Increased product protection • Cube utilisation by

increasing product

dimensions

• Cube utilisation

(stacking)

Increased standardisation • Material handling costs

Information Decreases Increases

Increased packaging information • Communications related

to lost shipments

Categories of packaging

Primary

Secondary

Tertiary

Relationship between

Packaging and handling costs

Packaging and transport costs

Type of unit load used

Characteristics of packaging materials used

Cost

Size

Shape

Strength

Type

Recyclability

Material

CATEGORIES OF PACKAGING

TRADE-OFF

Section 1 Role of Packaging

Section 2 Categories of Packaging

Section 3 Packaging Materials

PACKAGING I

LECTURE STRUCTURE

Physical state

What is being packed

Gas

Liquid (fluid, viscous)

Solid (powder, paste, granules, tablets, capsules)

Size of product

Shape

Weight

Properties of the product

Hazardous (corrosive, toxic, volatile, corrodible)

Fragile (perishable, easily damaged)

Other (odorous, sticky, abrasive)

Strengths

To withstand loads or pressures

Weaknesses

Of product or component parts

Break , bend, move, become loose

Scratch, abrade, corrode

PACKAGING MATERIALS

FACTORS INFLUENCING MATERIALS

PACKAGING MATERIALS

AVAILABLE TYPES

Plastic (oil based)

Glass Metal

Paper & board

Wood

Other

The market is estimated to reach $696 billion in 2011

PACKAGING MATERIALS

WORLD PACKAGING (US$m)

Manufactured from woodpulp

Highly versatile

Paper bags, food wrappings, sacks

Envelopes

Waterproof paper, baking cases

Treated / coated to improve performance

Clay coating – improved printing surface

Polyethylene –moisture resistance and heat proof

Waxing – moisture barrier

Laminating (plastic, foils) – to act as barrier or decorative

PACKAGING MATERIALS

PAPER

Manufactured from woodpulp

Also known as cardboard, paperboard

> 150g/m squared

Two main types

Carton board

For retail packaging - comprised of several layers of paper

Corrugated board

Cheap adaptable, light weight, strong, resistance to pressure

Layers of paper with a central fluted layer

PACKAGING MATERIALS

BOARD

Renewable raw materials

Easily recycled

Can compete with plastic alternatives

Suited to folding cartons

PACKAGING MATERIALS

PAPER & BOARD - ADVANTAGES

First developments in mid-1800s

Manufactured primarily from petroleum oil

Chemical processes and science used to produce

plastics with specific characteristics and properties

Two types

Thermoset

Thermoplastic

Suited to primary and secondary packaging

PACKAGING MATERIALS

PLASTICS

PACKAGING MATERIALS

PLASTICS - TYPES

Plastic Applications

High density

polyethylene

HDPE Relatively rigid with high glossy finish

Uses include crates, drums, bottles and oil containers

May be used for frozen foods 30oC, also milk

Low density

polyethylene

LDPE Flexible plastic used for thin films – plastic bags, shrink wrap and food

protection

Most common form of plastic packaging

May be used for frozen foods 30oC

Polypropylene PP Can be stretched as a clear film or injection mounded for containers

Can be filled at high temperature120oC

May be used for frozen foods 30oC, biscuits / crisp wrappers, sauce bottles

Polyvinylchloride PVC Widely used (juices and mineral water). Flexible, heat resistant,

impermeable to gas and water and resistant to chemicals and acids.

Food safety concerns re use of plasticisers.

Polystyrene Typically used for cushioning and protection

Excellent heat insulation properties (containers for frozen food)

Polyethylene

Terephthalate

PET Similar to PP. Ideal for food and drink applications and possesses some of

the barrier and clarity properties of glass. High processing melting point –

makes it ideal for microwave applications.

Polyurethane Mainly used for packaging, cushioning and protection

Relatively cheap

Extremely versatile & readily available

Different processing methods permit a huge range of forms

Highly competitive against other materials

Extremely lightweight

1 litre glass bottle 700g vs. plastic 70g

Readily coloured for branding purposes

Excellent for protection of food

PACKAGING MATERIALS

PLASTICS - ADVANTAGES

Modified-Atmosphere Packaging Extends the shelf life by delaying bacterial growth

Air inside plastic containers is replaced with one or mix of following

Oxygen

Retain the colour of food

Carbon dioxide

Slow growth of bacteria

Nitrogen

To slow down oxidation

Uses

Packaging of food products

Meat

Vegetables

Part-baked breads

Packaging of fruit prior to shipping to

prevent ripening

Bananas and mangoes

PACKAGING MATERIALS

PLASTICS - MAP

Physical / chemical deterioration

Predominately petro-chemical based

Impact on landfill volumes

Poor recyclability

PACKAGING MATERIALS

PLASTICS - DISADVANTAGES

Developed ~ 1800 to provide fresh food to troops in the Napoleonic war

PACKAGING MATERIALS

METAL

Widely used for food and beverages

Tin cans / foil containers

Aerosols

Tubes

Technological change

Reduce number of seams (leakages)

Reduce materials (cost)

PACKAGING MATERIALS

METAL

Tinplate

Thin steel sheet (0.17mm – 0.31mm)

Very thin coating of tin on the surface

Blackplate

Steel sheet with no tin coating

Limited applications as liable to rust

Stynthetic laquers may be applied

Tin-free steel

Steel sheet with alternative chromium coating

Cheaper alternative to tin coating

Aluminum

Commonly used for food and beverages

The whole of the can can be recycled

90 – 100 micron thickness

PACKAGING MATERIALS

METAL - OPTIONS

Rust

Steel requires coating to prevent rusting

Not suited to microwave cooking

Plastic alternatives

PACKAGING MATERIALS

METAL - DISADVANTAGES

Thinner walls to reduce weight / cost

Increased likelihood of damage

Potential of leakage

Potential contamination of contents

PACKAGING MATERIALS

METAL - DISADVANTAGES

Used for thousands of years

Accepted form of packaging for many items

Food stuffs

Chemicals

Pharmaceuticals

Cosmetics

Components

Silica 73%,

Lime 11%,

Soda 14% and

Alumina 1%

Raw materials are cheap and readily

available

Relatively high manufacturing costs

Manufacture

Raw materials melted

Formed / blown into shape

Cooled

PACKAGING MATERIALS

GLASS

Chemical inertness

Barrier

Clarity

Rigidity

Resistant to internal pressure

Hear resistance

Flexibility of moulding

Recyclable

PACKAGING MATERIALS

GLASS - ADVANTAGES

Fragility

Broken or chipped

Weight

Trade-off against strength

Competition from alternative materials

Plastic

Paper

Danger

Cuts / damage due to broken glass

Product recall…

PACKAGING MATERIALS

GLASS - DISADVANTAGES

Traditional form of packaging

Soft wood – pine

Hard wood - oak

Forms include

Primary – barrels, drums, coffins

Secondary – presentation boxes

Tertiary – boxes, crates, pallets, skids

Transport packaging - dunnage

Suited to liquid and solid materials

Processed forms include

Plywood

Wood wool

PACKAGING MATERIALS

WOOD

Renewable

Recyclable

Reusuable

Flexible

May be used for maturing goods

Over a long period of time

Impart flavour to the contents - whiskey

PACKAGING MATERIALS

WOOD - ADVANTAGES

Environmental concerns due to use

Natural material

May damage product if broken

Integrated Pollution Prevention and Control (IPPC) treaty

International treaty

To secure action and prevent the spread and production / introduction of pests of

plants and plant products

Promote measures for their control

IPSM15 (International Standards for Phytosanitary Measures Guidelines for

Regulating Wood Packaging Material in International Trade)

Treatment of wood products

PACKAGING MATERIALS

WOOD - DISADVANTAGES

Traditional natural material – ideal for handling

Used for sacks

Largely replaced by plastic alternatives

New uses for jute

PACKAGING MATERIALS

OTHER - JUTE

Renewable

Made from biomass

Corn, sweet potato, caster oil plant

Recyclable / compostable

Take less time to break down

Easier to recycle

Are not toxic as they degrade

Require less energy to produce

Reduce dependence on oil

PACKAGING MATERIALS

OTHER – BIO-PLASTICS

Tetrapak aseptic packaging

Light weight

Composed of layers of plastic, aluminium & paper

Provides long term storage

Without refrigeration

Without preservatives

Storage for up to 1 year

Widely used in food and drink industry

PACKAGING MATERIALS

COMPOSITE MATERIALS

PACKAGING MATERIALS

PROPERTIES SUMMARY

Material Advantages Disadvantages Uses

Glass• Reusable, visual, heat-resistant,

recyclable, keeps shape, low cost

• Fragile, safety

issues, heavy

• Baby foods, salad

cream, pickles

Metal

• Ring pulls (for easy opening),

recyclable, lightweight,

impermeable, withstands heat

processing

• May react with

food

• Soup cans, take-

away dishes, bottle

tops

Card/paper

• Easy to print on, cheap to

produce, biodegradable,

recyclable, can be moulded to a

variety of shapes, can be coated,

lightweight

• Not water-

resistant, may not

protect product

from damage

• Fruit-juice cartons,

egg boxes

Heat-proof

paperboard

• Hygienic, withstands low and high

heat (- 40 °C to + 230 °C)• N/A • Microwave meals