Packaging technology. Fundamentals, materials and processes. Edited by. Anne Emblem and Henry Emblem WOODHEAD PUBLISHING

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1 Packaging technology Fundamentals, materials and processes Edited by Anne Emblem and Henry Emblem Recommended by the IOM3 Training Academy and endorsed by The Packaging Society WP WOODHEAD PUBLISHING i Oxford Cambridge Philadelphia New Delhi

2 Contents Contributor contact details Note about the editors Preface xiii xvii xix Part 1 Packaging fundamentals 1 1 Packaging and society 3 A. Emblem, London College of Fashion, UK 1.1 Introduction: packaging from a historical perspective Social developments: the changing patterns of consumption and their impact on packaging Business developments: the effects of globalisation and modern retailing The different levels of packaging: primary, secondary and tertiary Packaging materials usage and development The environmental perspective: responsible use of resources 9 2 The packaging supply chain 10 G. R. Inns, PEC Partnership Limited, UK 2.1 Introduction Development, structure and inter-dependence of the segments of the global packaging supply chain Packaging as a means of delivering cost effective solutions Challenges of the supply chain The importance of training Sources of further information and advice Bibliography 23 3 Packaging functions 24 A. Emblem, London College of Fashion, UK 3.1 Introduction Containment Protection 26 Woodhead Publishing Limited, 2012

3 vi Contents 3.4 Preservation Using packaging to provide convenience Packaging as the source of product information Packaging to sell the product Conclusion Sources of further information and advice References 49 4 Packaging legislation 50 G. Crompton, The Packaging Society, UK 4.1 Introduction Legislation relevant to packaging Legislation relating to product quality and safety during manufacture, distribution, storage and use Legislation concerning honesty in trade Legislation concerning protection of the environment Legal considerations in international trading Sources of further information The role of trade associations What is legally required and what is good practice? Methods of enabling consistency of compliance The consequences of failure to comply with legislation Sources of further information and advice Disclaimer 64 5 Packaging and environmental sustainability 65 H. J. Emblem, Environmental Packaging Solutions, UK 5.1 Introduction: why bother? Key definitions Waste Compliance with the law Packaging re-use and recovery Environmentally responsible packaging Compliance with voluntary agreements Climate disruption Sources of further information and advice 85 6 Packaging and marketing 87 N. Farmer, Neil Farmer Associates, UK 6.1 Introduction Defining marketing The role of marketing Branding and the impact of packaging on product promotion and advertising 93

4 Contents vii 6.5 Branding and the marketing mix Promoting the brand The importance of consistency of communication Use of market research tools and techniques to identify customer needs Sources of further information and advice 105 Part II Packaging materials and components Glass packaging 109 P. Grayhurst, British Glass, UK 7.1 Introduction Advantages and disadvantages of glass as a packaging material Glass manufacture Forming glass containers Annealing Surface coating Inspection Tolerances Container design Decoration and labelling of glass containers Other glass-making processes Sources of further information and advice Rigid metal packaging 122 B. Page, Packaging Consultant, UK 8.1 Introduction to metal packaging Raw materials Manufacture of rigid metal containers Metal closures Cost/performance comparison: raw materials and forming processes Container specifications Decorating processes Environmental overview References and further reading Aluminium foil packaging 163 J. Kerry, University College Cork, Ireland 9.1 Introduction Aluminium processing Refining Smelting 167

5 viii Contents 9.5 Production of aluminium foil Foil finishes, coatings and lacquers Printing and embossing Using aluminium foil as a laminate Aluminium metallised films Conclusion Acknowledgements Sources of further information and advice Paper and paperboard packaging 178 A. Riley, Arthur Riley Packaging Consultant International, UK 10.1 Introduction Properties of paper and paperboard Raw materials The pulping process Post-pulping treatment of fibres to improve performance The manufacture of paper and paperboard Conversion processes for paper (<250 gsm) Conversion processes for paperboard (>250 gsm) Sources of further information and advice Corrugated board packaging 240 T. Watkins, UK 11.1 Introduction Materials for corrugated board Manufacturing processes for corrugated board Different types of corrugated board container design Decoration and printing of corrugated 11.6 Special board containers 253 board treatments Testing corrugated board materials and containers Sources of further information and advice Basics of polymer chemistry for packaging materials 262 A. Riley, Arthur Riley Packaging Consultant International, UK 12.1 Introduction The basic principles of polymerisation Addition (chain growth or coordination) polymerisation of polymers Condensation (step) polymerisation Copolymerisation and crosslinking polymerisation Factors affecting the characteristics of polymers Sources of further information and advice 286

6 Contents ix 13 Plastics properties for packaging materials 287 A. Emblem, London College of Fashion, UK 13.1 Introduction Market overview Key properties for packaging applications The common packaging plastics Specialist polymers used in packaging Bio-based polymers Conclusion Sources of further information and advice Plastics manufacturing processes for packaging materials 310 A. Riley, Arthur Riley Packaging Consultant International, UK 14.1 Introduction The plasticating extruder Sheet and film extrusion Film treatments after forming Thermoforming process for making plastic packaging Injection moulding Multi-injection moulding Comparing injection moulding and thermoforming Blow moulding Environmental considerations in plastic packaging Sources of further information and advice Packaging closures 361 A. Emblem, London College of Fashion, UK 15.1 Introduction: the role of packaging closures Types of packaging closure Push-fit closures Screw-threaded closures Lug closures Crimped crown cork closures Peelable seal lids Tamper evidence Child-resistance Dispensing and metering closures Testing closure performance Bibliography and sources of further information Adhesives for packaging 381 A. Emblem, London College of Fashion, UK and M. Hardwidge, MHA Marketing Communications, UK 16.1 Introduction Adhesives in packaging 381

7 X Contents 16.3 Theories of adhesion Adhesive types Selecting the right adhesive Adhesive application methods Evaluating adhesive performance Troubleshooting adhesive problems Common adhesive terminology Sources of further information and advice Labels for packaging 395 A. R. White, AWA Consulting, UK 17.1 Introduction Trends in label types Self-adhesive (pressure sensitive) labels How a label manufacturer approaches a job Wet glue (gummed labels) In-mould labels Sleeves The choice of printing process Label specifications What can go wrong? The label market The digital revolution Conclusion and future trends Sources of further information and advice 406 Part III Packaging processes Packaging design and development 411 B. Stewart, Sheffield Hallam University, UK 18.1 Introduction Research Conceptual design Case study: yoghurt for children Conclusion Sources of further information and advice References Printing for packaging 441 R. Mumby, Chesapeake Pharmaceutical and Healthcare Packaging, UK 19.1 Introduction Light and colour The description of colour Colour vision 443 Woodhead Publishing Limited, 2012

8 Contents xi 19.5 Additive and subtractive colour mixing Other factors affecting colour Colour printing Graphic design, reprographics and pre-press Proofing options and approval processes Technological aspects of printing processes Other processing techniques Quality control in packaging References Packaging machinery and line operations 490 G. Crompton, The Packaging Society, UK 20.1 Introduction The packaging line Unscramblers Fillers and filling Closing and sealing of containers Labelling Cartonning Form, fill and seal (FFS) packaging operations Direct product shrink-wrapping and stretch-wrapping Modified atmosphere packaging Miscellaneous wrappers Coding systems End-of-line equipment Quality and efficiency aspects of packaging operations Problem-solving on the packaging line Sources of further information and advice Hazard and risk management in packaging 538 M. Ewart, Authenta Consulting, UK 21.1 Introduction Packaging life-cycles in the supply chain Prerequisite systems and controls Hazard identification and risk assessment Industry technical standards References 559 Index 560

fast-moving consumer goods (FMCG)

Woodhead Publishing Series in Food Science, Technology and Nutrition: Number 244 Trends in packaging of food, beverages fast-moving consumer goods (FMCG) and other Markets, materials and technologies Edited