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SE2127 Packaging Materials, 7.5 creditsStudy period 3, spring semester 2010

Department of Solid Mechanics in cooperation with Department of

Fibre and Polymer Technology and Innventia AB

Examiner: Sören Östlund

Learning objectivesAfter the course, the student should be able to

describe the components of the packaging value chain, and d t t h th i fl th d i f kdemonstrate how these influences the design of packagesdiscuss important applications in packaging technology using correct terminology from physics, mechanics and chemistryselect suitable material and technology for manufacturing of a particular type of packagingexplain the properties of a packaging material based on the structure and chemistry of the materialrelate the results from mechanical testing of packaging materials to relevant fundamental solid mechanics parameters, anddemonstrate the value of modelling and numerical calculations for design of packages

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Course content• The packaging value chain

– Packaging logistics– Packaging ergonomics

• Solid mechanics and the finite element method for packaging design• Manufacturing of packaging• Optical, printing and closing properties• Plastics

– Design of plastic packagingBarriers– Barriers

• Wood fibre based packaging materials– Converting and end-use properties– Design of paper and paperboard packaging

• Glass and metal packaging

Facts• Credits: 7,5 hp

L l Ad d• Level: Advanced• Grades: A-F• Language: English• Course structure:

– Lectures 36 h, laboratory 12 h, design project• Web pages

– www.kth.se/sci/institutioner/hallf/gru/kurser/SE2127/VT10-1– www-old.hallf.kth.se/kurser/0910/SE2127/SE2127.htm

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InstructorsSören Östlundsoren@kth se

Mikael Hedenqvist (MH)mikaelhe@kth.sesoren@kth.se

tel. 08-790 7542@

tel. 08-790 7645

Chris Dominic (CD)Chris.Dominic@stfi.setel. 08-676 7000

Mikael Magnusson (MM)mima@kth.setel. 08-790 7552

Laboratory• Laboratory 1 is based on the software CAPE PACK for

packaging logistics and will take place in the student p g g g pcomputer room at Solid Mechanics on Thursday, 11 February at 13.15-17.00.

• Laboratory 2 deals with testing of some mechanical properties of paper and paperboard and will take place at Innventia on Thursday, 18 February at 8.15-12.00.

• Laboratory 3 is a half day visit to Ranhammar AB on• Laboratory 3 is a half day visit to Ranhammar AB on Monday, 22 February at 8.00-12.00.

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Design Project• Design, in groups of (2)3 students, a package made from a

paperboard plastic composite materials. This design should include analysis of strength and stiffness, as well as artistic design, printing, manufacturing and cost considerations.

• The design project will be assessed regarding content, analysis, written and oral presentation, and will affect the final grade.

• Well ahead of to the oral presentation, each group should give the examiner a short status report on the project work in order to clarify possible misunderstandings and to check details in the analysis.

Assessment of Design Project• Preliminary design review• Short paper A full text paper is not expected, but the short paper p p p p p , p p

should be written as a complete report. You can write the short paper in English or Swedish at your own choice, but the presentation should be in English.

• Presentation on Friday, March 12. You should preferably present your design using Power Point. A computer and projector will be available. Each group will only have approximately 10 minutes for their presentation.

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Examination

• Written exam (TEN1, 4 credits)Wednesday 17/3, 14-18

• Laboratory (LAB1, 2 credits)• Design project (ÖVN1, 1,5 credits)

• Final grade is given by a combination of TEN1 and ÖVN1.

“Required” reading I• (PBoP) Pocket Book of Packaging, Innventia• (BOA) Paperboard Reference Manual, Iggesund Paperboard AB (1993)• (LJU) Pulp and Paper Chemistry and Technology - Volume 4, Paper ( ) p p y gy , p

Products Physics and Technology, Chapters 1, 2, 3, 4, 9, 10, 11, 12• (LJU66) The Ljungberg Text Book, Chapter 66• (FoPT) Walter Soroka, Fundamentals of packaging technology, 3rd Edition,

Institute of Packaging Professionals, Naperville, Illinois, USA, 2002• (CCC) Twede, D. and Selke, S. E. M., Cartons, Crates and Corrugated

Board – Handbook of Paper and Wood Packaging Technology (Chapters 7 and 16), DEStech Publications, Inc., Lancaster, Pennsylvania, USA, 2005(HPT) R E Mark C C Habeger Jr J Borch and M B Lyne (Editors)• (HPT) R. E. Mark, C. C. Habeger, Jr., J. Borch and M. B. Lyne (Editors), Handbook of Physical Testing of Paper (Chapter 11), 2nd Edition, Marcel Dekker, New York, NY, USA, 2002

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“Required” reading II• (BPM) Barrier packaging materials, M. S. Hedenqvist, Chapter 26, 547-563,

in Environmental Degradation of Materials, Ed. M. Kutz, William Andrew P bl N i h NY (2005)Publ., Norwich, NY (2005)

• (MET) Metal Packaging, Metal Packaging Manufacturers Association, www.mpma.org.uk (2006)

• (LOG) Johansson, K., Olsmats, C., Tiliander, L. and Lorentzon-Karlsson, A., Packaging Logistics, Packforsk, Kista 1997, pages 9-15, 33-45Chris Dominic, Packaging Networks – A Study on Swedish Packaging IndustryChris Dominic, STFI-Packforsk, Emergent structures in Supply/Demand Chain Management.Chris Dominic, STFI-Packforsk, Supply/Demand Chain ManagementChris Dominic, STFI-Packforsk, Summary of published papers

Reading advice• Use the lecture notes as the basis for individual

studiesstudies.• Use the literature to learn more about the topics

covered at the lectures and to get a thorough conceptual understanding.

• Note that the assessment of the course content is focused on conceptual understanding ratheris focused on conceptual understanding rather than repeating facts and knowledge on the underlying fundamentals is important.

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Program – week 4# Time for lecture Instr

uctorTopics Literature

1 M d 25/1 13 SÖ C i d i L1 Monday 25/1, 13-15, Room E34

SÖ Course introduction. Overview of packaging materials and applications. Packaging industry, value chain, primary, secondary and tertiary packaging, trends.

Lecture notesFPT 1 and 2LJU Ch. 10

2 Wednesday 27/1,15-17

SÖ Paper and paperboard based packaging, overview of different types of materials

Lecture notesBOA (p. 11-36, 51-57)different types of materials. 57)LJU Ch. 10

3 Friday 29/1, 15-17 CD Packaging logistics, functional demands, transport testing,

LOG

Program – weeks 5, 64 Monday 1/2, 15-17 SÖ,

CDEnvironmental issues, life cycle analysis, packaging ergonomics.Introduction to DESIGN PROJECT

Lecture notesFPT 1 and 2LJU66LOGPROJECT.

Introduction to CAPE PACK.LOG

5 Wednesday 3/2,15-17

SÖ Paper physics, fundamentals of solid mechanics for paper materials.

Lecture notesLJU Ch. 1 and 2BOA (p. 84-112)

6 Friday 5/2, 10-12 SÖ Paper physics, laminate theory LJU Ch. 2, 11

7 Monday 8/2, 15-17 MH Polymer based materials and packages, overview of different types of materials

Lecture notesFPT Ch. 9-11

types of materials.8 Wednesday 10/2,

15-17MH Barrier materials I Lecture notes

BPM, FPT Ch. 14Thursday 11/2, 13-17 CD Laboratory 1 CAPE PACK

9 Friday 12/2, 8-10 SÖ Manufacturing of paperboard and corrugated board, quality parameters.

Lecture notesFPT 5 and 15BOA (p. 31-44)CCC 7

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Program – weeks 7, 810 Monday 15/2, 15-17 MH Barrier materials II Handed out material

BPM11 Wednesday 17/2,

15-17MH Plastic packaging – Other properties Lecture notes

FPT 13-14Thursday 18/2, 8-17 SÖ Laboratory 2 Experimental Innventia AB, Drottning Kristinas väg 61

pdetermination of some mechanical properties of paper and board.

12 Friday 19/2, 13-15, Room E51

SÖ Manufacturing of paperboard and corrugated board packaging, converting operations: printing, creasing, folding, gluing

Lecture notesLJU Ch. 10BOA (p. 157-225)FPT 4, 6, 15 and 18

Monday 22/2, 8-12 SÖ Laboratory 3 Study visit to Ranhammar AB inRanhammar AB in Bromma.

13 Wednesday 24/2, 15-17 SÖ Design of paper and board packaging: stacking, shocks, climate loading, analytical methods. Company’s software such as Billerud Box Design or Korsnäs Optipack.

Lecture notesLJU Ch 10BOA (p. 119-128)FPT 15HPT 11

14 Friday 26/2, 13-15, Room L21

SÖ Tutorial I Handed out material

Program – weeks 9, 1015 Monday 1/3, 15-17 SÖ Design of paper and board

packaging, advanced concepts, FEM

Lecture notes (partly based on HPT)LJU 2 11 12FEM LJU 2, 11, 12

16 Friday 5/3,10-12

SÖ Tutorial II Handed out material

17 Monday 8/3, 13-15 SÖ Other wood fibre based packaging: sacks, bags and wood packaging. Glass and metal packaging. The future of paper and paperboard

Lecture notesFPT 7 and 8FPT (p. 505-509, 514-516)MET

packaging.18 Friday 12/3, 13-15 SÖ,

MHPresentation of DESIGN PROJECTS

Wednesday 17/3, 14-18, Room D42

Written examination

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After Lecture 1 you should be able to

• describe what packaging is• give examples of efficient packaging systems• give examples of efficient packaging systems• describe how the industrial revolution lead to

modern packaging• discuss the relations between packaging and the

development of a country• describe the two major divisions within thedescribe the two major divisions within the

packaging industry• give examples of packages made from the most

common packaging materials

Literature• Lecture notes

f• Fundamentals of packaging technology –Chapters 1-2

• Pulp and Paper Chemistry and Technology -Volume 4, Paper Products Physics and Technology - Chapter 10

• Pocket book of packaging – Pages 4-43

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Packaging, everybody know what it is?

What is packaging?• A coordinated system of preparing goods for

transport, distribution, storage, retailing and use.transport, distribution, storage, retailing and use.• Packaging is a

– complex– dynamic– scientific– artistic

t i l– controversial

business function• Needs a PRODUCT!

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•Definition Packaging *“Packaging” shall mean all products made of anyPackaging shall mean all products made of any materials of any nature to be used for the containment, protection, handling, delivery and presentation of goods, from raw materials to processed goods, from the producer to the user or the consumer. “Non-returnable” items used for the same purposes shall also be considered to constitute

k ipackaging.

* Directive 94/62/EC on packaging and packaging waste

Packaging functions range from technical to marketing

Technical Functions Marketing FunctionsTechnical Functions• contain• protect• preserve• measure• dispense (sv. dela ut, i.e. medicin)

Marketing Functions• communicate• display• inform• promote• sellp

• transport• store

• motivate

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Typical protect, transport and storage problems

• Vibration• Mechanical shock• Abrasion• Deformation• High/low temperature

R l ti h idit• Relative humidity• Water• Tampering

Packaging- a part of a system -

Product

Packaging

Distributionenvironment

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Functions of packaging systems

1. Product flow - Handling - Transport - Storage

2. Protection - Mechanical - Barrier

3. Runnability - Stiffness - Flatness

4. Environment - Material savings - Environmental concern

5. Communication - Information - Promotion

Different levels of a packaging system

Consumer/Sales packaging – primary packaging

Retail/Group packaging – secondary packaging

Transport packaging – tertiary packaging

Pallet

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Packaging in the distribution chain

RAW MATE

PACKAGING END-

INDUSTRIAL PRODUCTS

CONSUMER PRODUCTSPRODUCER/

WasteDisposal

MATE-RIALS

MANUFAC-TURERS R

ETAILER

USER

WH

OLE-

SALER

PRODUCER/CONVERTER

REUSE MATERIAL RECYCLING

REQUIREMENTS AND DEMANDS

Bur-ningBurning

PACKAGING DESIGN

Different levels along the chain

MANUFACTURER/PACKING

WHOLE-SALERWHOLESALER RETAILER END-USER/

CONSUMER

PRIM

SEK

TERT

Handlingmanual X%

Building up ofpackage system TransportBreaking down of

package system

Filling of primary packagemanual X%

Storage

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The modern packaging industrymetal cansglass bottlespaper cartons

fillerscase packers

photographymarketinglegal

The packaging industry

Suppliers

raw materialsconverters machinery services

paper cartonsplastic containersflexible materials

case packersdate coders

legalconsumer testingconsultants

Usersconsumer industrial Institutional

foodpharmaceuticaltoyshardwarepersonal care

automotivemachinerybulk foodchemicals

foodnon-foodmilitarymedical devices

What is an efficient packaging?

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forenvironmentfor

human

Effective packaging

for

human

for logistics

Packaging & Unit load© IKEA of Sweden AB

Example of packaging logistics

IKEA of Sweden

GlimmaTea lights

Forecast 15,000,000 bags of 100 pack

Mat

tias.

erik

sson

@m

emo.

ikea

.com

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New Glimma - Old Glimma Packaging & Unit load© IKEA of Sweden AB

Mat

tias.

erik

sson

@m

emo.

ikea

.com

Glimma today

Packaging & Unit load© IKEA of Sweden AB

Glimma future

(Photo is of the test prototype)

252 bags of tea lights

Mat

tias.

erik

sson

@m

emo.

ikea

.com

360 bags of tea lights30 % less unit loadsIf one pallet takes 5 min to unpack almost 200 working days in the stores will be saved

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In store• Fast unpacking time

Packaging & Unit load© IKEA of Sweden AB

• Easy to handle• Could be used as

multiple sale solution• More commercial• Less carton board

visiblevisible• Less space/100 pack =

more space for other products

Mat

tias.

erik

sson

@m

emo.

ikea

.com

IKEA

Outbound gods will be reduced ith 300 t k

Packaging & Unit load© IKEA of Sweden AB

with 300 trucks30 % less pallets to store in the distribution chain30 % less pallets to handleReduce costSafe transport

Mat

tias.

erik

sson

@m

emo.

ikea

.com

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History of packagingPrimitive packaging

• We do not know what the first package was– Containment and carrying devices

– Fabricated sacks, baskets and bags made from materials of plant or animal origin

– Hollow glass objects in about 1500 B.C.

– Marking of olive oil amphora in Greece about 250 B.C.g p

From Rome to Renaissance

• Glass blow pipe invented in about 50 B.C.• Paper made in China in about 105 A.D.• Printing from woodcuts in about 700-800

A.D.

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Industrial revolution• Rural agricultural workers migrated into cities

I i d d d b• Inexpensive mass-produced goods became available to a large segment of the population

• Factory workers needed commodities and food• Many new shops and stores opened• Some industries located in non-agricultural g

areas

The evolution of new packaging roles

• RURAL COMMUNITIES – Barrels• CITY DWELLERS – Smaller quantities requiredC S S a e qua t t es equ ed• Shops adapt the bulk delivery system• First pre-packaged products – medicines, cosmetics,

teas, liquors and other expensive products• Individual packaging – quality producers wished to

identify their particular product, for exampleSchweppes (1792)Perrier (1863)Colgate (1873)

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The evolution of new packaging roles

• Early packages or wrappings for higher cost gods applied the evolving printing and g pp g p gdecorating arts

• Plastic packages occur in the early 1900s• Cellulose films (1911)• Cellophane (1927)• In department stores with thousands of products

staff people had little knowledge of the products ⇒– The package had to inform the purchaser– The package had to sell the product

Packaging in the late 20th century

• 1950s– fast food outlets appearfast food outlets appear– convenience and prepared food packages– plastics available as packaging material

• 1970s– child-resistant closures, tamper (sv. manipulera) evident closures,

labelling laws– microwave food, yoghurt, bottled watery g

• Last decades of the 20th century to now– ageing population– smaller families, single person house-holds– convenient and fast for the urban dweller

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Modern packaging• High proliferation (sv. snabb förökning) of goods

– Packaging forced to the role of purchase motivation rather than just presenting the product

– Marketers aimed at features and advantages beyond the product itself

– New concern is removal of debris generated by consumer society and impact on ecologyconsumer society and impact on ecology

– Sustainable development of packages

Packaging and the modern industrial society

• Packages a requirement for everyday enjoyment of hi ll d ll ifi f dgeographically and seasonally specific food

• Central processing allows value recovery of what would normally be waste.– Use of by-products (i.e. chicken feathers used as fill material,

gelatine, animal food)

– Packaging material recycledPackaging material recycled

• Economical manufacture of durable goods requires good packaging, c.f. TV sets, computers, furniture etc.

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Science of packaging is in a continuous state of change

Science of packaging is closely connected with everything we do in society For exampleeverything we do in society. For example …Oil:

1) bulk to service stations into glass jars2) metal cans3) foil/fibre composite cans4) plastic bottles

Milk:1) glass bottles2) plastic bottles3) flexible bags4) aseptic paperboard cartons

World packaging

• Development of the packaging level is an i di t f th lth f th tindicator of the wealth of the country

• Packaging– reduces food prices– preserves, protects and transport food– enables an industry that recovers value from– enables an industry that recovers value from

food by-products

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Value of packaging materials usage in different branches

SEK/billions

Most frequently used packaging materials

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The total turnover of the global packaging market is more than 500 billion dollars

Metals

Glass

PaperBoardCorrugated

Machinery

Others

PlasticsSource:WPO

Usage (percent by weight) of different packaging materials in a typical

shopping basket year 2000

SteelWood

Glass

Aluminum

Paper

Corrugated

Paperboard

Plastics

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Which materials are used for storage of CD discs?

• Stiff plastics• Stiff plastics• Soft plastics• Paperboard• Plastics/paperboard composites• Metal• Wood

Packaging of carbonated drinks

• Glassb ft d i k– beer, soft drinks, champagne

• Plastics– soft drinks, water,

cider, beer

• Metalbeer– beer

• Paperboard– ?

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Milk in plastic bottle or paperboard packaging?

• When asked about drink choices at school 51% of those• When asked about drink choices at school, 51% of those surveyed said that they would choose milk over other beverage options when milk was presented in a plastic bottle. When milk was presented in a paper carton, only 24% of the students said they would choose milk over the other options.

• Students described the milk in plastic bottles as cool, trendy stylish new and fun to drink They described thetrendy, stylish, new and fun to drink. They described the paperboard carton as old fashioned.

• Kids drink more milk when the right package is offered.

Cans• Metal• GlassGlass• Paperboard

– Tetra Recart

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Transport packaging

• Wood• Corrugated board

Paper and Paperboard

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Inherent weaknesses of paper and board in packaging applications

Fail in a brittle mannerFailure load of shopping bags

Paper bag Plastic bagPaper bag Plastic bag

Reference 1000 N 250 N

On wet surface 250 N 250 N

Rapid loading 500 N

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Poor creep properties(particularly in varying moisture climates)

Difficult to form into complex shapes

Past Now Future

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Paper based composites

Plastics

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Plastics based composites

Metals

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Glass

After Lecture 1 you should be able to

• describe what packaging is• give examples of efficient packaging systems• give examples of efficient packaging systems• describe how the industrial revolution lead to

modern packaging• discuss the relations between packaging and the

development of a country• describe the two major divisions within thedescribe the two major divisions within the

packaging industry• give examples of packages made from the most

common packaging materials