Intro to Packaging Final Exam

What is the first thing a consumer notices about a package?

Color

What does corona treatment do?

Corona discharge generates ionized air in contact with the plastic via a high-voltage discharge that increases surface polarity on the treated film.

What term describes the new paradigm for handling consumer packaging waste?

Cradle-to-Cradle

What is the advantage of a HF/F/S machine over a VF/F/S machine?

HF/F/S machines can have many operating stations grouped along the horizontal travel path of the pouch. This allows for multiple filling heads, steam purges and other activities.

Name three features that might make hot melts a favored choice.

High-speed packaging, when there is a need to bridge gaps and when substrates are difficult to bond

A hard metallic sheen can be printed only by what process?

Hot-stamping

How can the basic communication message be delivered to the viewer?

Through color, shape, text and graphics.

Why are liners necessary in metal closures? What is the purpose of the backing material in a lined closure?

To achieve a hermetic seal; through the use of resilient liners inside the closure that conform to the minute irregularities of the container finish. The backing material in a lined closure is combined with appropriate other materials to create the actual barrier and seal.

What is the objective of combining various materials into a laminated packaging material?

To combine the best of all material properties into a single package structure.

What is differential tinplate?

Today, black plate is electrolytically tin-plated, allowing substantial reductions in the amount of tin used, as well as offering the ability to put different thicknesses of tin on either side of a steel sheet. The tin layer is extraordinarily thin, about 0.38 micrometers (0 .000015 in.). Manufacturers identify differential tinplate, as to both the amount of tinplating and the side having the thicker tin content, by embossing an identifying pattern onto one side of the sheet. The heavier tin deposit goes to the inside of the container where greater protection is needed.

What is the "flute" of a corrugated box?

"Flute" is the term that describes the wavy medium between the two faces of linerboard that make up corrugated. Flutes range from A, the thickest / tallest to E, the thinnest or even F or Micro, which have hardly any "wave" to them.

What is static coefficient of friction (COF), and how does it differ from dynamic COF?

"Static slip" or "static COF" defines the force required to start the film moving (slipping) over another surface. "Kinetic" or "dynamic COF" defines the film's friction as it is moving over other surfaces.

What is the actual material used to make a "tin" can?

"Tin can" is not strictly correct terminology, since low carbon steel is the predominant canmaking material.

How thick is a 150-gauge film in thousandths of an in.? How many mils is that?

.0015 inches or 1.5 mils

What is a 20-point board?

0.020-in. board.

About what proportion of municipal waste is classified as packaging?

29.6% by weight or 31.6% by volume.

What are a blanket cylinder, an anilox roll and an impression cylinder?

A blanket cylinder accepts ink from the plates and transfers it to the substrate (lithography). An anilox roll accepts ink and transfers it to the printing plate (flexography). An impression cylinder puts pressure on the backside of a substrate so ink can be transferred from the blanket or plate cylinder (lithography, flexography and gravure).

Which is easier to make, a fin seal or a lap seal? Why?

A fin-style vertical seal is easier to make because it brings together two inside heatseal-coated surfaces.

A total package design consists of two separate components. What are they, and what primary roles does each component play?

A structural component and a graphics component. The structural component's primary role is to fulfill the package's technical and physical requirements. The graphic component attracts and informs the consumer and motivates a purchase decision.

What is the difference between addition polymers and condensation polymers?

Addition polymerization involves monomers adding onto themselves like links in a chain. Condensation polymerization occurs when two reactive monomers join together with the release of a molecule of water.

How can you recognize the process by which a bottle was made?

An extrusion blown molded bottle has a pinch-offline across the bottom where the parison was cut and sealed, as well as faint parting lines up the sides where the mold halves came together. An injection blow molded bottle has no pinch-off marks, but it does have a gate point "bull's-eye" where the material was first injected. Faint parting lines are evident on the sides.

How does an extruder for injection molding differ from an extrusion profile extruder?

An injection mold extruder must have a provision for injjecting a certain amount of melted material while an extrusion profile extruder has a continuous flow of melted materials.

Define application torque, removal torque and stripping torque.

Application torque: A measure of the tightness to which the capping machine turns the closure. Removal Torque: The force necessary to loosen and remove the closure. Stripping torque: Torque level that will cause the closure or bottle finish to distort to the point of loose caps or no seal.

What are the predominant flutes used in box making?

B and C flutes and BC doublewall comprise the bulk of corrugated boxes.

Why should the common term "tamper proof" not be used?

Because no practical package can stop someone determined to tamper.

What is the difference between a Beers tray and a Brightwood tray?

Beer trays are knocked down for shipping. Brightwood trays are nonflattening once erected.

What are bioplastics?

Bioplastics are developed from renewable resources, such as cellulose and starches. They may not be all biodegradable, but they are recyclable.

What two colors provide the greatest contrast to the human eye?

Black and yellow

Can boxes be made "waterproof"?

Boxes can be made moisture resistant and water resistant but not fully waterproof.

What MAP gas can act as a bacteriostat?

Carbon Dioxide

What is the difference between chemical compatibility and stress-crack resistance?

Chemical compatibility implies that no significant chemical activity will take place between the product and the chosen polymer. Environmental Stress Cracking (ESC) is a surface-initiated physical phenomenon resulting from the operation of biaxial stresses (loads) in the presence of an external agent that produces no other discernible effect on the plastic. Chemical degradation is not involved.

What is the difference between a cohesive failure and an adhesive failure?

Cohesive failure is indicative of low internal strength in the adhesive. Adhesive failure is indicative of a high internal strength of the adhesive that exceeds the interfacial bond of the adhesive to the substrate.

What is implied by the "cradle-to-cradle" model?

Cradle-to-cradle refers to instances in which the objective is to recover used packaging material and return it into the manufacturing cycle to be manufactured into new packaging.

A special decorating process variation is used to decorate draw-and-iron cans. What is it called, and why is it necessary?

D&I and other round containers have no natural register point and must be printed by offset letterpress, also called dry offset. All of the inks are printed onto a rubber blanket and transferred in one action onto the can surface.

Define demographics, and give 2 examples of demographic information.

Demographics are numerical information about consumers in specific, easily quantifiable classifications. Examples are gender, age, education level, family size, ethnic background and religious beliefs. Demographic information can be obtained through the U.S. Census and surveys.

What is double gluing, and where would you specify it?

Double gluing is the gluing of both the inner closure panels and the outer closure panels to provide a complete sift-proof seal. It is specified for a product that requires sift proofing.

What are the four processes used to make two-piece cans?

Draw, draw and redraw (DRD), draw and iron (D&I) and impact extrusion.

How are bottle surfaces made to look frosted?

Either by acid etching or sandblasting

Name four basic ways of forming plastics into semi rigid shapes.

Extrusion blow molding, injection molding, profile extrusion and thermoforming.

How can you tell the difference between a can that was drawn and one that was drawn and ironed?

For a can that was drawn, the thickness of the finished can sidewall and bottom remain essentially the same as in the original blank. The bottom of a D&I can has the same thickness as the starting disk; however, the sidewalls are considerably reduced in thickness, and the metal area of the final can is greater than that of the initial disk.

What two packaging materials offer absolute barrier properties?

Glass and metal.

Define: -gob -heel tap -blank mold -choke neck -finish -push-up

Gob-a sheared unit of molten glass. Blank mold-a mold set used to create the container parison. Finish- an opening of the bottle that accepts the closure. Heel tap-an excess wall thickness at the base. Choke neck-an excessive thickness just below the finish. Push-up- a concave area at the bottom of the bottle.

On a bottle finish, what are the I, T, E, H, and S dimensions? What are the corresponding dimensions on a closure?

I= diameter at smallest opening inside finish; T =thread diameter measured across the threads; E = thread root diameter; H =top of finish to top of bead or to intersection with bottle shoulder on headless designs; S =the vertical distance from the top of the finish to the start of the thread. Corresponding closure dimensions are S, H, T and E.

To comply with the "Green Guides," list the five claims that must be substantiated.

Impact reduction strategy, biodegradability, recycled content, recyclability and "green-washing."

A PVA emulsion adhesive will form an initial adhesive bond much faster than a dextrin adhesive with the same solids content. Why?

In PVA emulsions, the suspension of the colloids will break as soon as the water is reduced beyond a critical point and the individual polymer units coagulate to create an adhesive film with adequate bond strength. This series of events enables faster application speeds than with dextrin adhesives, which require more time for water evaporation to set.

What is the difference between a twophase and a threephase aersol?

In the simplest two phase system, such as glass cleaners and room air fresheners, the propellant dissolves in the product. Three phase systems are those which propellant and product are not mutually soluble and remain separate in the can.

Name two places where you would not use a hot melt.

In thermal processing operations, or in packaging applications for heat sensitive food products.

Describe the flow characteristics of a thixotropic fluid.

In thixotropic fluids, the resistance to movement changes with the shear rate of the fluid, i.e., stirring a viscous thixotropic fluid will result in a decreased viscosity

Explain how an induction innerseal works. What container or closure body materials would interfere with the creation of a seal?

Induction heat-sealing heads have sealing coils powered by generators running at SO to 500 kilohertz; they produce energy that couples with the aluminum foil that is part of the innerseal. The foil's temperature rises and transfers heat to the heat-seal coating, which then bonds with the container's land area. 10b) Rigid glass containers and metal closures do not change or deform under normal stress.

What is meant by a printing process described as being "offset?"

Ink is not applied directly to the substrate from the plates.

Why is a transfer bead (neck ring) a part of every glass bottle design?

It is essential to transfer the hot glass parison from the blank mold to the blow mold.

What is meant by the "persona" of a package?

It is the "personality" of a package

A 25-micrometer-thick plastic film has a moisture permeability that is 840 mg/100 square in./24 hours. What is the likely permeability if we go to a 12.5 micrometer film of the same material?

It will increase to 1680 mg/100 sq in/24 hrs.

What are MD and CD? Why it is important for a carton designer to know them?

MD=machine direction. CD=cross direction. The properties of paper differ in MD and CD.

List the methods of creating a body seam on a three-piece steel can. What are the advantages and limitations of each?

Mechanical side-seaming, or clinching, is used for containers intended for dry product, where a hermetic seal is not important. Adhesive bonding is an attractive body-assembly method for applications where the can will not be subjected to thermal processing. Unlike welded cans, adhesive-bonded constructions can have full wraparound lithography. The welded seam line is about 30% thicker than the two base metal sheets. Cans shorter than 75 mm (3 in.) are too short to be welded individually, and are made by welding a body twice the required length and cutting it into two cans. Soldered food cans are no longer permitted in North America. Some soldering is still done for nonfood applications. All solders have eliminated lead content.

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 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.

From what raw material source are most packaging plastics made?

Most packaging plastics are made from petrochemicals.

What material are the majority of plastic closures made from? By what process are they made?

Most plastic closures are made from polypropylene. Thermoplastic closures can be either injection molded or compression molded.

Most dairy tubs are injection molded from polypropylene except for ice cream. What material is ice cream tubs made of and why?

PE or a copolymer. PP is subject to cold fracture when frozen and therefore is unacceptable for ice cream tubs.

What is PLA made from and what is its main attribute?

PLA is derived from corn starch rather than petrochemical feedstocks, and it is compostable.

Define "packaging."

Packaging is a coordinated system of preparing goods for transport, distribution, storage, retailing and use.

What paper would you specify for an ice cream box?

Paperboard coated with polyethylene or wax.

How long have paper making and box making been around?

Papermaking has existed for centuries. Paper box making has existed for a little more than 100 years.

What are plasticizers used for in packaging.

Plasticizers impart flexibility or softness and assist in processing,

In thermoforming, cavity molds are preferred over plug molds. Why?

Plug molds have poor material distribution and limited draw. Cavity molds have better material distribution with the use of plug assist.

Which two common packaging plastics are predominantly nonpolar?

Polyethylene and polypropylene are predominantly nonpolar.

Define psychographies, and give examples of psychographic information.

Psychographies studies how groups of people are motivated and how they behave. Psychographies is not as precise as demographics. Examples of groups that could be studied are baby boomers, yuppies and football fans.

What three colors does the human eye detect?

Red, green and blue.

Name the six ways of extending the natural shelf life of foods. For each method, briefly note the mechanisms by which the keeping quality of a food product is increased.

Reduce temperature-(freezing) slow chemical activity and reduce/stop biological activity. Thermal processing-(hot fill, sterile, sealed cans) control microorganisms. Water reduction-(drying) manages moisture content to control microorganisms. Chemical preservation-(acids, carbon dioxide, curing/smoking, antioxidants). Modified atmosphere packaging-(vacuum packaging). Irradiation-(ionization).

"The four R's are used as the guiding principles for managing the waste problem. What are the four R's, in the correct order?"

Reduce, Reuse, Recycle and Recover.

What is the difference between a web press and a sheet-fed press? Which printing processes are most typically web-fed and which are most typically sheet-fed?

Sheet-fed presses run cut blanks of substrate; web-fed presses run the material directly off a roll. Gravure is always web-fed, but litho and flexo can be either one.

What are the three principal constituents of glass?

Soda, lime, silica.

What are: a sprue, a runner, flash, a gate and a parison?

Sprue- the main channel through which molten plastic enters to the mold. Runner- a channel that distributes molten plastic to various cavities in a multicavity mold. Flash- when a machine's clamping force is insufficient to keep the mold halves together, plastic flows to the parting line; it is called flash. Gate- a small opening through which the molten plastic enters the mold cavity. Parison- a hollow plastic tube used in bottle making.

What prompted the paradigm shift that caused producers to change from a "Cradle to Grave" to a "Cradle to Cradle" responsibility?

Sustainability in packaging.

Define "sustainability."

Sustainability is the concept of meeting present needs without compromising the ability of future generations to meet their needs.

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.

What are Tg and Tm? Describe the difference in transition temperature patterns (Tg and Tm) for amorphous and crystalline polymers.

Tg is the glass transition temperature at which a polymeric material changes from a rigid solid state to a soft, rubbery or elastic state. Tmis the melt transition point where the plastic enters a melt phase. Amorphous polymers tend to have a more prominent transition at Tg while crystalline polymers have a more prominent transition at Tm.

A paperboard specimen can be peeled apart into seven layers. What does this tell you?

That it was produced on a cylinder papermaking machine.

What is the Box Makers Certificate?

The Box Makers Certificate is a stamp printed on the box that tells the end user and shipper-freight carrier that the box meets or exceeds requirements for the rules (tariffs) for that particular box. "Standard" BMCs exist for regular boxes and rectangular BMCs are for boxes that have special requirements. Some boxes, particularly hazardous material boxes, require special markings. These markings supercede or even replace the regular BMC. UN-marked boxes have very stringent regulations and penalties for failure to comply with regulations. Failure to comply with a standard BMC rule may result in a freight carrier refusing to accept a shipment.

Explain the two theories of adhesion.

The Mechanical Adhesion Theory proposes that fluid adhesives mechanically interlock into the surface cavities of the substrate and they cannot be pulled away without destroying the surface of the substrate. The Specific Adhesion Theory is based on the bonding that takes place when regions of positive and negative charges are brought into intimate contact to mutually attract each other. The surface charges are expressed as polarity and occur at molecular distances.

What are some tests associated with the regulations and requirements?

The Mullen Test determines the burst strength of a box, ECT determines the stacking strength. The Cobb test determines the ability of boxes and boxboard to resist moisture and water absorption. The Pin Adhesion Test determines the quality of the corrugated board. In addition, performance criteria have been developed by multiple agencies, especially the UN for Haz-Mat that require cyclic impact (vibration), drop and stacking strength testing. Some packages must be manufactured to the exact requirements specified and tested for verification of the box's quality.

Discuss the importance of fiber length on paper properties.

The longer the fiber, the better the fiber entanglement and the stronger the resulting paper. However, the long, coarse fibers produce a rougher surface texture.

What "joint" most commonly makes a flat blank into a box?

The predominant boxmaker's joint today is glue. It is quick and can be automated into the flexo folder gluer, and tests have shown that with the proper dimensions, glue joints are stronger than either stitches (staples) or tape, both of which are slower and have less desirable characteristics.

Why is the bottom of a glass bottle usually stippled?

The stipples reduce the surface contact area and accept the inevitable scratches that occur during handling and use that would weaken the bottle.

What causes loss of torque in a plastic closure application?

Thermoplastic closures on thermoplastic containers can suffer from considerable torque loss after closure application because of the viscoelastic flow (cold flow or creep) properties associated with the materials.

What is the difference between type 1, type 2 and type 3 glass? Where are they used?

These three glass types are used in the pharmaceutical industry for vials and ampules. Type 1- a borosilicate glass that has the most stringent extractable standard. Type 2-a soda-lime glass that has been treated in the annealing oven with sulfur to reduce alkalai solubility. Type 3- a conventional soda-lime glass that has been tested and shown to have a specified extractives level.

How does the manufacturing process for vials and ampules differ from the process for larger glass bottles?

They are made from preformed tubing stock rather than the blowing methods used for glass bottles. The container is cut and formed into shape without the use of a mold, so there are no visible parting lines.

What advantage is gained by metallizing paper?

Vacuum-metallized paper gains the aesthetic appeal of a reflective aluminum surface.

Name four product characteristics that will have a major impact on board selection.

Weight, is product wet, is product greasy/oily, will product tear or burst package

Describe the difference between dry-bond laminating and wet-bond laminating.

Wet bonding requires that at least one substrate be porous enough to allow adhesive solvent or water to escape. Almost invariably, this substrate is paper. Adhesive is applied to one substrate, the two substrates are nipped together and the whole sent through an oven to set the adhesive. In dry bonding, adhesive is applied to the substrate and then dried of solvents. The resinous adhesive is either tacky or can be activated and set by heat. The second substrate is joined by a heated nip against the first to create the bond.

White light is beamed onto a surface that absorbs the blue wavelength. What color does the eye see?

Yellow.

Name the commodity packaging plastic that: a. Does not burn (self-extinguishes). b. Is used mostly for thermoforming. c. Is an exceptionally high all-around gas barrier. d. Is strongest and stiffest. e. Has the lowest melting point. f. Has the highest melting point. g. Is used most often for closures. h. Is used most often for detergent and oil bottles. i. Forms the best "live hinge." j. Is used for thermoformed film when packaging luncheon meat. k. Is lowest in cost. I. Is made into soda bottles. m. Is an exceptionally high oxygen barrier but is water soluble. n. Is an exceptionally high oxygen barrier. o. Is used for most hot-filled bottles. p. Would be used to make a squeezable bottle.

a. PVC. b. PVC. c. PVDC. d. PC. e. LDPE/LLDPE. f. PC. g. PP. h. HDPE. i. PP. j. PA (unoriented nylon 6). k. PE. I. PET. m. PVAL. n. PVDC. o. PP. p. LDPE.