Packaging
How does an extruder for injection molding differ from an extrusion profile extruder?
An injection mold extruder must have a provision for ejecting a certain amount of melted material while an extrusion profile extruder has a continuous flow of melted material.
Define Vibration
An oscillation or motion about a fixed reference point
What is a collapsing core?
Core has 2 halves that can collapse around a center component, Knock-out pins eject part from core and the thread is interrupted
Define the following Paperboard Packaging Classifications.
Folding Cartons: -Largest group in paperboard packaging. Made as flat blanks or pre-glued forms flattened for shipping. Classified as tube or tray styles Setup Boxes: -Rigid cartons delivered erected (set-up) and ready for filling Tubes: -Paperboard formed into round or square tubes with paper end seals (ice-cream 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 really is.
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.
Cellulose fiber can be separated from the wood mass by several means. Name the two main methods, and list the advantages and disadvantages of each method.
Mechanically cutting/grinding -the fastest and cheapest method, but it breaks the fibers and reduces their effective length. Chemical -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 very expensive.
Define: Sprue, Runner, Gate, Under cut, Knock out Pins, Sink Marks.
Sprue -main channel through which molten plastic flows into a mold Runners - channels that distribute molten plastic to cavities Gate -small opening through which molten plastic enters the cavity Under cut -A configuration that prevents the straight opening of a mold Knock out pins -Move forward when mold opens to eject the parts form the core Sink Marks -Plastic shrinkage where wall thickness is uneven
Describe the Gravure Printing Process.
The graphics are engraved onto a gravure cylinder. The gravure cylinder passes through an ink fountain and is doctor bladed to remove the surface ink and leave engraved wells filled with ink. The substrate passes between the gravure cylinder and an impression roll. Ink transfers from the gravure cylinder to the substrate.
Describe the Offset Lithographic Printing Process.
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.
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.
Name two products each that are horizontally and vertically filled, and describe why horizontal cartoning machines are more complicated than vertical cartoning machines.
Vertical filling is easier, and is a universally preferred loading method, because it is assisted by gravity. Many products, such as granular or powdered products are load this way, and the process does not require additional machinery to achieve the end goal. However, horizontally filled products (such a frozen pizzas and cakes) require extra care, as they are to be pushed gently into the carton.
What is the difference between a two-phase and a three-phase aerosol?
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 where propellant and product are not mutually soluble and remain separated in the can.
Name 5 properties of using Aluminum foil in flexible packaging.
-Appearance: Bright and reflective -Barrier Properties: at 0.0007" thick, 100% barrier to all gases, pin holing can occur as thickness is reduced -Dead-fold: superior fold property -Friability: unsupported AI is easily punctured -Hygienic: easily sterilized -Conductivity: easily conducts heat and electricity -Formability: ductile material, can be molded into trays and cups, drawn into cans, impact-extruded into tubes and aerosol cans
What are the elements of the European Single-use Plastic Directive passed in May 2019?
-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 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
What are five of the advantages of glass as a packaging material?
-Inert to most chemicals -Foods do not attack glass or leach out materials that might alter taste -Impermeability provides long term storage benefits against volatile loss or oxidation from atmospheric oxygen -Clarity allows visibility -Upscale image -Rigidity prevents deformation -Stability at high temperatures allow hot filling
What does Extended Producer Responsibility mean?
-Producers responsibility at post-consumer 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 the 5 Principal Packaging Functions?
1: Contain 2: Protect/Preserve the product 3: Transport 4: Inform/Sell 5: End of Life
What are the 7 plastic recycling codes?
1: PETE 2: HDPE 3: V 4: LDPE 5: PP 6: PS 7: Other
What are the four main principles encompassed by the phrase "packaging law"
1: Packaging law is a labeling law 2: Packaging law is environmental law 3: Packaging law is structural requirements 4: Packaging law is intellectual property law
What are 4 methods to extend normal biological shelf life of food?
1: Reduced Temperature 2: Thermal Processing 3: Water Reduction 4: Modified Atmosphere 5: Chemical Preservation 6: Irradiation
How many colors can the human eye see? What are they
3 Red, Green, Blue
What is the most common size for a pallet?
48x40 inches
Describe the Letter Printing Process.
A chanbered doctor blade fountain applies ink to an engraved anilox roll. The doctor blade removes the ink from the surface leaving the 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 impression cylinder.
What is Packaging?
A coordinated system for preparing goods for: Transportation, Distribution, Storage, Retailing, Use A package can not exist without a product Packaging functions are both technical and marketing oriented
What is a good first step to consider when approaching labeling requirements?
A good first step in approaching laebling requirements for a package is to determin which governmental agency has the authority over the product.
What is the Ellen MacArthur Foundation (EMF) definition of successful recycling?
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
To mold plastic into a useful shape, it must first be heated and softened. What is the name of the machine that does this? Describe the process.
A plasticating extruder- a barrel with rotating screw. As the screw drives the plastic pellets forward, an increaseng screw diameter causes the pellets to compress, heat, and melt
A) In what order does a consumer notice the following aspects of a package? Shape, Graphics/Text, Color B) What type of response does color evoke? C) What is more pleasing to look at, a rectangle or a square? D) Are long, unfamiliar words easier to read in uppercase or lowercase?
A) 1: Color A) 2: Shape A) 3: Graphics/Text B) Emotional response C) A rectangle D) Lowercase
What is the difference between addition and condensation polymerization
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.
List three advantages and three disadvantages of Injection Blow Molding.
Advantages -No regrind generated -Better material distribution -High precision neck finish Disadvantages -Requires two mold sets -Handle ware difficult -Limited size containers
List three advantages and three disadvantages of Extrusion Blow Molding.
Advantages -Requires single mold -Large containers possible -Handle-ware readily produce Disadvantages -Limited Precision -Cold weld is a weak area -Wide mouth jars awkward
What two things have to considered when choosing the type of steel for a steel can, and what is an example of each?
Alloy and temper, Alloy: M,L,D. Temper: Work Hardened, Double Reduced
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
How is Polyethylene Terephthalate (PET) made and what are its main properties?
An ester produced by reaction of organic acid with an organic base Ethylene glycol + Terephthalic acid -> PET 249C is highest melting point of common packaging plastics When injection, stretch blown, it has superior barrier properties Can not be extruded, not enough melt strength to support an extruded parison PETG is a copolymer with other glycol molecules; has good melt strength; can be extruded Polyesters must be molded dry to prevent hydrolysis 70% of PET is used for beverage bottles
What is annealing, and why is it necessary?
Annealing raises the temperature of a newly blown bottle and slowly cools it to room temperature. The process reduces the stresses in the container wall caused by inside to outside temperature variation.
Complete the following sentences:
As the molecular weight increases, the melting point INCREASES. As the degree of branching increases, density DECREASES A plastic that has two monomers in its molecular structure is called a DIMER A polymer in which the chains are highly ordered is said to be CRYSTALLINE A polymer in which the chain arrangement is essentially random is AMORPHOUS The stiffer HDPE is the one with a molecular weight that is HIGHER
What are the two methods of molding glass bottles? What type is made by each method?
Blow - blow is used for narrow neck containers Press-blow is used for wide mouth containers
What are the three disadvantages of glass as a packaging material?
Break-ability High Density Energy Intensive
Name and describe the four properties used to characterize paper.
Caliper (thickness) and Weight -One thousands of an inch = 0.001" = 1 point -Basis Weight = lb./1000 sq. feet -Fine paper - lb./ream (500 sheets) (3000 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 23C and 50% RH Viscoelasticity -Properties depend on rate load is applied -KDF cartons can take a set and be harder to break-open
Most polymers are based on which atom?
Carbon Atoms because they have the ability to form 4 bonds with other atoms and also have the ability to bond to itself and make long chains
Why is it a good idea to erect and fill folding cartons soon after they have been produced?
Cartons are best run within 90 days of manufacture. The folding carton can take a set and not erect properly in the cartoning machine.
There are two ways of manufacturing plastic film. What are they?
Cast film and blown film
Describe the packaging history in the period "Rome to Renaissance"
Cities established, trade expanded, 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 co-extrusion, and what advantages does co-extrusion offer?
Co-extrusion occurs when more than one extruder feeds material to a sheet to make layers into one sheet. This method is used to combine the performance advantages of different materials. An advantage of extrusion blow molding is that is can readily produce co-extruded bottles.
What is the difference between cohesive failure and an adhesive failure?
Cohesive- indicative of low internal strength in the adhesive Adhesive- indicative of a high internal strength of the adhesive that it exceeds the interfacial bond of adhesive to the substrate
Where did the term "Branding" come from?
Comes from the identifying marks imprinted on early packages like barrels to identify the manufacturer
What is the effect of increased packaging costs on damage?
Damage will decrease
Define demographics, and give three examples of demographic information. What are some sources of demographic information?
Demographics is 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.
Describe the Draw and Iron process for 2 piece cans. What are the advantages and disadvantages of this type of can?
Draw and Iron Process (D&!) -Cut blank and draw cup -Cup redrawn to finished diameter and pushed through series of ironing rings, each of slightly smaller diameter -Rings "iron" the metal into a thinner sheet than the original thickness -Bottom of can has original blank thickness; side walls are considerably reduced in thickness; overall metal area of the final can is greater than the original blank -Necking operation reduces the end-piece diameter -Thin wall cans not suitable for thermal processing; primary use is carbonated beverage cans
You want a transparent package with a high oxygen barrier. What two polymeric materials are candidates for adding barrier properties to the laminate structure? If the package did not need transparency, what other options might you consider?
EVOH and OPP. EVOH is used as a high-oxygen barrier. However, EVOH absorbs water and must be sandwiched between materials that will keep moisture away from it. Oriented polypropylene's (OPP) combination of excellent base properties at an economical cost make it one of the most popular materials for wraps and laminates having sparkling clarity. Foil and metallized film are other non-transparent options.
Why can't the same mold be used to shape all plastic materials?
Each plastic being molded has a unique expansion coefficient and temperature at which the molding takes place. Using the same mold for different plastics would produce parts with slightly different dimensions.
Describe the Extrusion Blow Mold (EBM) Process.
Extrude hollow plastic tube (parison) Parison captured in molten state by two mating halves of blow mold and pulled away. The extrusion continues. Air blown into parison to expand it to conform to the mod walls. Bottle held in mold while plastic cools enough to become rigid and retain shape. Bottle removed form mole; base pinch off and neck finish flashing is trimmed.
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- Increases Value Tear Strength - Reduces Value Burst Strength - Reduces Value Tensile Strength - Reduces Value
With the creation of retail stores and storekeepers' lack of knowledge about all the products what two things did the package have to be able to do?
Had to be able to inform the purchaser and sell the product
Describe the history of Primitive Packaging
Hunter gatherers followed the food source and needed carrying devises: Leaves, animal skins, shells of nuts or gourds, hollow wood, fire carriers 5000 B.C. with some domestication & larger social groups. Storage and transport needed; Sacks, baskets, bags, wooden boxes, clay containers 2500-1500 B.C. Glass discovered Egyptians create core formed glass containers
On a bottle finish, what are the I, T, E, H, and S dimensions?
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 top of the finish to the start of the threads
What are the 9 steps of Environmental Packaging Procedure?
Identify environmental goals Identify the destination of the package (end-of-life) 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 Injection Blow Molding (IBM) process.
Injection Mold parison and partially cool More control of material distribution Multiple cavitation, faster process Ideal for small bottles; mascara Parison retained on core pin and transfer to blow mold station. Air blows parison into final shape Finished bottle transfers to ejection station
What are five of the general properties of glass?
Inorganic Substance, fused at high temperatures Cooled quickly, solidifies in a vitreous or non-crystalline condition Molecular structure of solid glass is the same as liquid glass Glass has no distinct melting point Many metal oxides can be formed into a "glassy" condition Commercial glass is based on silica Beach sand is not suitable for commercial glass making since it has too many impurities; however, there are deposits of pure silica sand in various parts of the world (Recyclable)
Name 4 types of closure seals.
Inserted Liner Flowed-in plastisol liner Linerless plastic closure Valve-type plastic closure
What compounds can be added to glass to change the color?
Iron and sulfur - Amber Chrome oxides - Emerald Cobalt oxides - Blue
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
List five factors to consider when selecting an adhesive for an application.
Nature of the surface to be bonded Method of application Open time Temperature of application end-use chemical resistances
A typical food can might be described as being a "202 x 406." What does this mean?
Nominal can dimensions are given as the overall diameter by the overall height Each dimension is given in three digits. The first digit is in whole inches, and the following two digits represent 16ths of an inch. a 202 x 406 can is 2-2/16 in. diameter and 4-6/16 in. height.
Some cartons are printed with an extra panel. Name 2 uses for the extra panel and why it is necessary.
One use for an extra panel is for additional surface are for graphics and information for consumers. This is done by the pegboard hanger style. The board is twice the thickness, so durability increases. The second use for an extra panel is to act as a cover for the opening of the packaging.
Describe the 4 color printing process.
Original are is separated into 4 screened printing plates, each a different color (CMYK). Superimposing the 4 printing passes will reproduce the original art in the minds eye. Colors are printed at different angles to prevent formation of wavy pattern.
What is pad printing and how does it work?
Pad printing is used to decorate irregularly shaped objects. The pad is first pressed against the inked gravure plate and then moved over and pressed against the object to be printed.
Define Paper. Name 5 sources of the raw material
Paper is defined as a matted or felted sheet usually composed of plat fiber. Paper has been made from: Rags (linen) Bagasse (sugar cane) Cotton Straw Cellulose fiber (derived from wood)
What advantage is gained by metallizing plastic films?
Plastic film being metallized does not need to be sealed, smoothed, or dried as a paper substrate does, in addition to adding decorative appeal, metallizing a plastic film significant improve barrier to all gases.
Describe the 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 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 far as long as possible, through a more efficient and increased recyclability.
What is polarity?
Polarity is the unequal sharing of electrons which causes electrons to spend more time on one end of a molecule.
Define Primary package, secondary package, 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.
What do induction inner-seals do?
Provide a hermetic (air tight) seal Creates a barrier that is tamper proof
What paper properties does refinement affect? Name an application where low refinement is desirable and an application where high refinement is desirable.
Refinement affect tear strength, absorbency, burst strength, and tensile strength. Low Refinement -Higher Tear Strength -Stronger Packaging High Refinement -Decreased absorbency -Wet and Frozen Foods
What are the two ways vibration can damage goods?
Relative motion and vibration resonance
Name and describe the three thread styles.
Rounded style: Rounded profile L style: 30 degree angle on top and bottom of thread M style: Modified Buttress thread, 45 degree angle on top of thread, 10 degree angle on bottom of thread
What is a Hot Runner Mold?
Runnerless or Hot Runner Molds are designed with material feed runners and gate systems that are insulated from the cooled mold cavity and core. Auxiliary heaters are often incorporated in the runner system to insure that the plastic is kept in a hot, fluid state.
List and describe the three types of Corrugated Boards.
Single Face- Consists of one layer of liner and one layer of medium. Can be deformed to wrap packaging Single Wall- Consists of two layers of liners wrapped around a layer of medium. I-beam shape. Has bending stiffness. Flutes gives support to strengthen flat crush. Also gives support to strengthen edge crush. Double Wall- Consists of a liner being wrapped in two layers of medium that is wrapped in two layers of liner. Increases stiffness and edge crush
What is a slit lock?
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 dust flaps, securely locking the flap in place.
What are the three principal constituents of glass?
Soda, Lime, Silica Silica sand Limestone Soda Ash
What are the major applications of the following adhesive classes: starch adhesive, casein adhesive, and cold-seal adhesives? Why are they chosen for these applications?
Starch adhesive for corrugated, for their low cost Casein adhesive for refillable beverage bottles, because of their cold-water resistance Cold-seal adhesive for chocolate bar wrapping, for no-heat, high-speed applications
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 three plastic properties?
Tensile Strength, Tear Strength, Impact Strength, Heat-Seal Strength, Coefficient of Friction, Haze and Gloss, Water-Vapor transmission, Gas Permeability, Grease and Oil Barrier, Dimensional Stability, Environmental Stress Crack Resistance, Chemical Properties.
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.
Discuss the benefits and problems of post-consumer waste paper as a fiber source for paper making.
The benefits of post-consumer waste paper as a fiber source are that it is plentiful and also reduces the cost of papermaking. 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 paper board.
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 in uneven and the color of the kraft will distort the printing ink color.
What is the first step in preparing a packaging design?
The first step in preparing a packaging design is to consider the nature of the product and the kind of packaging needed to contain the product. These considerations include the product's physical form, nature, and use.
What is the objective of any package design? What are the 2 components of a packaging design, and which 4 principal packaging functions does each component satisfy?
The objective is to realize the strategic objectives that will sell the product. The 2 components are the structural component and graphic component. The structural component's primary functions are to Contain, Protect/Preserve, and Transport. The graphical component is to Inform/Sell the product to the consumer.
Why is a reverse tuck carton more economical than a straight tuck carton of the same dimensions?
The reverse-tuck carton has the best board utilization when on the press sheet.
Why is a soldered can not suitable for foods?
The soldered edge comes in contact with the contents of the can, thus tainting it and making it not safe for consumption.
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. 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.
How is a reflective gold surface developed on a plastic film using metallizing technology?
Transparent lacquers and varnishes allow the brilliant reflective metallic sheen to show through. A transparent yellow lacquer would give the appearance of gold.
List the methods of creating a body seam on a three-piece steel can. What are the advantages and limitations of each?
Welded Side-Seam Cans -Exclusively steal; Aluminum can not be welded and is therefore not used for 3-piece cans -Lithography must stop before 6mm/.25in. before welding seam Mechanical Clinching -Only for dry products where a hermetic seal is not needed Adhesive Bonding -Can can not be subject to thermal processing -Full wrap-around lithography is possible (frozen juice concentrate, paint cans) Soldered Side-Seam Cans -Engaging hooks like mechanical clinching; molten solder flows into seam -Lead extraction is a problem for foods; band in US for foods
Define yield point. What is its practical significance?
Yield point is measured up to the point of permanent material deformation. The significance is that a package needs to be strong enough to hold the items you are planning to package. Example, retail bad for groceries and hardware
