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TRANSCRIPT
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