(FINAL EXAM) Intro to Packaging Chapter 1-7
Define the following Paperboard Packaging Classifications: Folding cartons Setup boxes Tubs Trays Liquid resistant boxes
Folding Cartons: Largest group in paperboard packaging. Made as flat blanks or preglued forms flattened for shipping. Classified as tube or tray styles Setup Boxes: Rigid cartons delivered erected (set-up) and ready for filling Tubs: Paperboard formed into round or square tubs with paper end seals (icecream containers) Trays: Flat sheets with gusseted corners can be folded to form trays Liquid Resistant boxes: Board coated with wax or polyethylene for wet food applications
Define the term "green washing"
Green washing refers to a provider trying to look more environmentally preferable than it is really is
Cellulose fiber can be separated from the wood mass by several means. Name the two main methods, and lists the advantages and disadvantages of each method.
Mechanically cutting/grinding the wood is the fastest and cheapest method, but it breaks the fibers and reduces their effective length. The least fiber damage occurs when chemicals are used to dissolve the natural lignin binders in wood, leaving the fiber bundles intact and undamaged, but it is expensive.
List the most widely accepted definition of sustainability.
Sustainable development is development that meets the needs of the present without compromising the ability of future generations to meet their own needs.
Describe the Letter Press Printing Process
ink on doctored blade onto anilox roller. Excess is removed and pressed onto printing plate. Substrate goes between printing plate and impression cylinder chambered doctor blade applies ink to anilox roll Doctor blade removes excess ink Anilox roller applies ink to raised portion of printing plate Substrate between impression cylinder and printing plate ----- A chanbered doctorblade fountain applies ink to an engraved anilox roll. The doctor blade removes the ink from the surface leaving ink in the engraved wells of the anilox roller. The Anilox roller applies ink to the raised portions of the printing plate. The printing plate applies the ink to the substrate while it is compressed by the impression cylinder. (a sketch of this process, properly labeled, is acceptable)
Name and describe the four properties used to characterize paper.
*Caliper (thickness) and Weight One Thousandths of an inch = 0.001" = 1 point Basis Weight = lb./1,000 sq. feet Fine paper - Lb./ream (500 sheets)(3,000 sq. feet) *Brightness Reflectance of white light 1 to 100; higher with added TiO2 Packaging papers are usually 78-84 *Moisture Content 20% RH = 4%; 80% RH = 15% Paper testing is done at 23∘C and 50% RH *Viscoelasticity Properties depend on rate load is applied KDF cartons can take a set and be harder to break-open
What are the elements of the European Single-use Plastic Directive passed in May 2019?
-Bans single-use plastic products -Reduce plastic food containers -EPR -Recycling goals for bottles • Bans on certain single-use plastic products that have alternatives • Measures to reduce the use of plastic food and beverage containers • Measures to use specific labeling with waste management options of certain products • Extended Producer Responsibility (EPR) schemes for certain single-use plastic products and fishing gear containing plastics in all Member States • Recycled content targets for PET bottles • Recycling goals for single-use plastic bottles Member States have two years to transpose legislation.
Describe the Gravure Printing Process.
-Graphics engraves on cylinder -Cylinder through ink fountain and extra sink is doctor bladed -substrate between cylinder and impression roll -Direct --------------------------------- The graphics are engraved onto a gravure cylinder. The gravure cylinder passes through an ink fountain -doctor bladed to remove the surface ink and leave the engraved wells The substrate passes between the gravure cylinder and an impression roll. Ink transfers from the gravure cylinder to the substrate. (a sketch of this process, properly labeled, is acceptable)
What are the 4 disadvantages of cut and stacked labels?
-Limited material options -in line gluing is messy -longer set-up and clean lines -potential for label mix-ups
What are the 5 Principal Packaging Functions?
1 Contain. Also deliver or dispense the product 2 Protect/Preserve the product 3 Transport 4 Inform/Sell: Use Instructions; Sales Promotion; Drug Facts 5 End of Life Cradle to Cradle (C2C)
What are the 7 plastic recycling codes (labels)?
1: PETE 2: HDPE 3: V 4: LDPE 5: PP 6: PS 7: Other
What is packaging
A coordinated system for preparing good for -Storage -Use -Transportation -distribution -Retailing A package cannot exist without a product Packaging functions are both technical and marketing oriented
Describe the history of packaging during the Industrial Revolution?
An Industrial Society with World Wide Connections Rural workers migrate to city factories Mass produced goods available, the consumer is born Factory workers need commodities and food Shops and stores open Food needs to be transported to urban areas Impact on Packaging Demand for barrels, boxes, kegs, baskets & bags Mechanize the packaging industry to meet demand Devise ways to preserve food beyond natural biological life
Why is a reverse tuck carton more economical than a straight tuck carton of the same dimensions?
BEST BOARD UTILIZATION WHEN ARRANGED ON PRESS SHEET It best board utilization when arranged on a press sheet The reverse-tuck carton has the best board utilization when arranged on a press sheet.
Why is it a good idea to erect and fill folding cartons soon after they have been produced?
Because the folded carton can take a set and not erect properly in the cartoning machine. (run in 90 days)
Where did the term branding come from
Branding comes from the identifying marks imprinted on early packages like barrrels, casks, pots etc. to identify the manufacturer
Describe the packaging history in the period "Rome to Rensissance".
Cities established, trade expands, armies move Existing packaging practices grow in quality and quantity 50 B.C. - glass blow pipe allows direct formation of hollow glass containers, wood barrel created 105 A.D. - China's Ts'ai Lun makes first paper from the inner bark of the mulberry tree 768 A.D. - wood cut printing traced back to Japan 868 A.D. - oldest existing book, Diamond Sutra, printed in Turkistan
What is the Ellen MacArthur Foundation (EMF) definition of successful recycling?
Definition: when post-consumer collection sorting and recycling works in practice and at scale -30% recycling rate for 400 million inhabitants -over 95% of packaging by weight is recyclable A packaging or packaging component is recyclable if its successful post-consumer collection, sorting and recycling is proven to work in practice and at scale. "In practice and at scale" = 30% post-consumer recycling rate for at least 400 million inhabitants, or on markets where packaging is sold. • Recyclable if over 95% of packaging by weight is recyclable • Minor components compatible with process
Define demographics, and give three examples of demographic information. What are some sources of demographic information?
Demographics: numerical information about consumers in specific, easy classifications. Like [gender, age, education] sourced from the U.S and surveys
What is double gluing, and where would you specify it?
Double gluing: gluing inner and outer closure panels for a complete sift-proof seal. It is specified for a product that requires sift proofing.
Some cartons are printed with an extra panel. Name 2 uses for the extra panel and why it is necessary
Extra panel adds additional surface for graphics Extra panel acts as a cover for the opening of the package One use for the extra panel is for additional surface areas for graphics and information for consumer. this is done by the pegboard hanger style The board is twice the thickness so the durability increases. The second use for an extra panel is to act as a cover for the opening of the packaging. This is done by the _________?
What is the first step in preparing a packaging design?
First step: consider the nature of the product and the kind of packaging it needs -physical form -nature -use
What is the effect of shorter fiber length on the following paper properties? Fold endurance, Formation, Tear Strength, Burst Strength, Tensile Strength
Fold endurance: Reduces value Formation: Improves value Tear Strength: Reduces value Burst Strength: Reduces value Tensile Strength: Reduces value
Describe the Primitive Packaging
Hunter gatherers followed the food source Leaves, animal skins [shells of nuts or gourds, hollow wood, fire carriers] 5000BC: Domestication, sacks, baskets, some clay 2500-1200BC: Egyptians forming glass 5,000 B.C. with some domestication & larger social groups Storage and transport needed: [Sacks, baskets, clay ], bags, wood boxes, clay containers (pottery and ceramic) 2,500 - 1,500 B.C. Glass discovered Egyptians create core formed glass containers
What are the 9 steps of the enviromental packaging procedure
Identify environmental goals, identify the destination of the package (end-oflife), identify applicable regulations, identify mode of shipping, identify company-specific requirements, identify applicable customer requirements, select raw materials, design the package, communicate environmental characterization
Describe the 4 color printing process.
Most complex printing task is reproduction of a full color illustration Mixing inks to match an artist mixing paint colors is not technically possible Using half-tone printing with the 4 process colors (CMYK) allows the eye to mix the individual dots and see the blended color Original art is separated into 4 screened (dot patern) printing plates Superimposing the 4 printing passes will reproduce the original art in the minds eye Colors are printed at different angles to prevent formation of moiré (wavy) pattern (Source: Slide #50, Presentation #3)
What is the objective of any package design? What are 2 components of a package design and whcih of the 4 principal packaging functions does each component satisfy?
Objective: realize the strategic objective that will sell the product. 2 components: the structural and graphical component. The structural component's primary functions are to contain, protect/preserve, and transport. The graphic component is to inform/sell the product to the consumer
With the creation of retail stores and storekeeper's lack of knowledge about all the products what two things did the package have to be able to do
Packages now had to be able to inform the purchaser and sell the product
Define paper. Name 5 sources of the raw material.
Paper: matted or felted sheet usually composed of plant fiber Paper has been made from: -Rags (linen) -Bagasse (sugar cane) -Cotton -Straw -Cellulose fiber (derived from wood)
Describe a circular life cycle.
Plotting the complete material, energy and process flow from raw materials to end of life. Packaging Conversion Manufacturing Distribution Retail Use Recycle Packaging Conversion A Circular Economy model requires a change in our current production and consumption system - packaging and products are designed with a recyclable or reusable end-of-life in mind. The goal is to keep resources circulating for as long as possible, through a more efficient use of production resources, more durable and repairable designs and increased recyclability.
Define primary package, secondary package and distribution/tertiary package.
Primary package is the first containment of product that directly holds the product. Secondary package is the containment for the primary package. Tertiary package is the containment with the foremost purposes of protecting the product during distribution and providing for efficient handling.
Describe the Offset Lithography Printing Process.
Printing plate has oil receptive and water respective areas Oil and water are applied, filling their respective regions Plate transfers ink to blanket cylinder-> substrate between blanket cylinder and impression cylinder ------------------------ The printing plate has oil receptive and water receptive areas. Water is applied to the plate and is absorbed by the water receptive areas. Oil based ink is applied to the plate and is held by the oil receptive area. The printing plate is compressed on to a rubber blanket and the ink transfers to the blanket cylinder. The substrate passes between the Blanket Cylinder and the Impression Cylinder; ink transfers to the substrate. (a sketch of this process, properly labeled, is acceptable)
What is pad printing and how does it work?
Prints on irregularly shaped objects The pad pressed on inked gravure plate and pressed against the object to be printed
What does Extended Producer Responsibility mean?
Producers have responsibility to recycle (not just cities and towns). Including recycling programs, recycling targets and global legislation • Producers responsibility at postconsumer stage. • Responsibility shift: From city and town and private industry → "producers" • Programs contain mandated recycling targets. • Incentive to design for low impact. • Packaging & Products are impacted by other global legislative requirements, such as Design, Labeling, Recycled Content, etc.
What are 4 methods to extend normal biological shelf life of food?
Reduced temp, water reduction, irradiation, chemical preservation 1. reduced temperature 2. thermal processing 3. water reduction 4. modified atmosphere 5. chemical preservation 6. irradiation
What plastic properties does refinement affect? Name an application where low refinement is desirable and an application where high refinement is desirable
Refinement affects -tear strength -absorbency -burst strength -tensile strength Low refinement: high tear strength, stronger packaging High refinement: decreases absorbency, wet foods, frozen foods
What is a slit lock?
Small slits between the tuck flap and top closure panel Slits engage shoulder cuts into dust flaps Slit-lock closures incorporate small slits between the tuck flap and the top closure panel. When the carton is closed, the slits engage shoulders cut into the dust flaps, securely locking the flap into place.
Discuss the benefits and problems of postconsumer wastepaper as a fiber source for papermaking
The benefits of postconsumer waste paper as a fiber source are that itis plentiful and also reduces the cost of paper making. However, every repulping process degrades and reduces the fiber length and some extraneous contaminants may appear as bits of color, 'grease spots" and "shiners" on the paperboard
Why is it difficult to print on natural kraft paper?
The fibrous nature (irregular surface) and color of natural kraft paper does not lend itself to fine printing. Ink transfer on an irregular surface is uneven and the color of the Kraft will distort the printing ink color
How many colors can the human eye see? What are they?
The human eye can see 3 colors. Red, Blue, Green. (The brain processes combinations of these colors to see all other colors.)
Name two products each that are horizontally and vertically filled and describe why horizontal cartoning machines are more complicated than vertical cartoning machines.
Vertical: Granular/powdered products assisted by gravity Horizontal: Frozen pizza and cake: Extra machinery to carefully load products Vertical filling is easier and is a universally preferred loading method because it is adssisted by gravity. Many products such are granular or powdered products are loaded this way, and the process does not require additional machinery to achieve the end goal. However, horizontally filled products (such as frozen pizzas and cakes) require extra care as they are to be gently pushed into the carton
a. In what order does a consumer notice the following aspect of a package? Shape/Graphics/Text,Color b. What type of response does color evoke? c. Which is more pleasing to look at, a rectangle or a square? d. are long, unfamiliar words easier to read in uppercase or lowercase
a. color, shape, graphics b. emotional response c. rectangle d. lowercase
