HAND BOOK OF PACKAGING TECHNOLOGY(E-BOOK)

Packaging A total concept, Systems Approach to Packaging,  Test Procedure for Packaging Materials & Packaged Products,  Testing Methods for Evaluation of Transport Packages,  Standards , Basic Concepts, Packaging Materials, Rigid and Ancillary Materials and Export Packaging,  Printing,  Surface Design and Sales Appeal,  Graphic/Surface Design,  Eco Friendly Packaging for Exports, Export Packaging, Speciality Papers for Packaging,  Folding Board Cartons and Coated Cartons,  Corrugated Board,  Multi Wall Paper Sacks,  Plastics, PVC in Packaging, Biaxially Oriented Polypropylene Films, Plastic Woven Sacks, Expanded Polystyrene, Expanded Polyethylene,  Flexible Packaging Laminates & Coating Applications, Laminated Tubes,  Co-Extrusion,  Shrink and Stretch Wrapping, Packaging in Glass Containers, Aluminium Foil,  Manufacture of Black Plate and Tin Plate,  G.I. Drums oil Drums, Closures,  Adhesive Tapes,  Wooden Containers,  Systems Packaging,  Aseptic Packaging, Vacuum Packaging,  Strip Packaging, Aerosol Packaging Technology, Form Fill Seal Machine ( Systems), Labels and Labelling,  Thermoforming in Packaging, Packaging of Horticultural Crops,  Packaging of Meat, Fish & Poultry, Packaging of Dairy Products,  Packaging of  Biscuits, Bread and Confectionery, Food Products Processed and Dehydrated,  Packaging of Fruit Juices, Packaging of Ready to Eat Foods,  Packaging of Pharmaceutical Products Orders,  Packaging of Pharmaceutical Products Injectables, Packaging of Cosmetic Products, Packaging of Soaps & Detergents,  Packaging of Hazardous Chemicals, Packaging of Fertilizers, packaging of Pesticides Industry,  Packaging of Handicrafts for Export, Packaging of Textiles. 

HAND BOOK OF PACKAGING TECHNOLOGY


PACKAGING A TOTAL CONCEPT

Definition
Packaging Criteria
Appearance
Protection
Function
Cost
Disposability
Recycling
Non Packaging applications
Conclusion
The Concepts for Packaging

SYSTEMS APPROACH TO PACKAGING

What is packaging
Functions of a package
Primary
Secondary
Types of Packages
Guidelines for Retail Packages
Guidelines for Shipping Containers
Factors Influencing Design/Selection of Package
Product Factors
Kinds of Product
Physical Properties/Characteristics
Vulnerabilities of Contents
Distribution Factors
Marketing Factors
Statute and Regulations
Packaging Operation Factors
Cost Factors

TEST PROCEDURE FOR PACKAGING MATERIALS & PACKAGING PRODUCTS

Introduction
Conditioning of Test Specimen
Physical Tests
Rigidity, Stiffness & Softness
Exudation Test (Staining Test)
Abrasion Loss (Scuff resistance)
Waterproofness
Water penetration
Water Absorptiveness of Paperboard (Cobb Test)
Procedure
Water Vapour Transmission
Water Vapour Permeance
Water Vapour Permeability
Grease Resistance
Chemical Tests
Measure of pH
Estimation of Solvent soluble Matter
Bio-Chemical Test
Procedure
General

TESTING METHODS FOREVALUATION OF TRANSPORT PACKAGES


Functional Requirements
Transit Packaging
Mechanical Tests
Drop Test
Vibration Test
Compression Test (Contour Test)
Rolling Test
Drum Test
Climatic Tests
Rain Test
Sand and Dust Tests
Salt spray test
Fungus Resistance Tests


STANDARDS BASIC CONCEPTS, PACKAGING MATERIALS, RIGID AND ANCILLARY MATERIALS

AND EXPORT PACKAGING

Standardization
BIS Work
Aspects of Standards
Standard Space Diagram
Levels of Standard
Functions of Standards
Advantages of Standardization
Set up of BIS
General
Procedure for Formulation of Standards
International Standards

PRINTING

General Description of Printing
Basic Printing Technology
Platemaking processes
Letterpress
Intaglio
Offset Plate
Printing Processes
Platen Press
Cylindrical Press
Rotary Press
Direct and Indirect Printing
Direct Printing
Indirect Printing
Comparison of Printing Processes
Flexographic Printing
Offset Printing
Gravure Printing
Platemaking
Running Plate
Flexo Plate
Gravure Engraving
Plate Rotogravure
Cylinder
Shaft Mounted Cylinder
Sleeve Type Cylinder
Electroplating
Electronic Photograving
Offset Plate
Photoengraving Process
Classification of Originals
Colour Film
Three Primary Colours
Screen
Printing Ink
Kinds of Printing Ink
Composition of Printing Ink
Printing Machines
Flexo Printer
Offset Printer
Web-Fed Rotogravure Printer
Printing Material and Printing Suitability
Printing on Corrugated Fibreboard
Printing on Folding Cartons
Printing on Flexible Packages
Printing on Metal Surfaces
Printing on Metal Plates
Curved Surface Printing on Metal Containers
Printing on Plastic Bottles
Packaging and Printing

SURFACE DESIGN AND SALES APPEAL

Scope and Purpose of a Package
New Functions of the Package
Objectives of Package Design
Recent Trends in Package Designing
Linking Package Design with Advertising
Guiding Principles for Package Designer
Elements of Good Design
Shape of the package
Influence of Colour on Sales
Pictures on the Package
Brand Name and Trade Mark
Creating a House Style
Typographical Treatments
Fitness to Printing Process
Impact of Supermarket on Surface Design

GRAPHIC/SURFACE DESIGN

The Responsibilities
The Creation
The Formula
The Brand
The Illustration
The Text
The Colours
The Testing

ECO FRIENDLY PACKAGING FOR EXPORTS

Suggestion/Recommendations
Avoidence
Reduction
Reusability
Recyclability
Incineration
Land fill

EXPORT PACKAGING

Do's and Don'ts


SPECIALITY PAPER FOR PACKAGING


Tissue Papers
Printing Paper
High Gloss Papers
Cover Papers
Glassine and Grease Proof Papers
Waxed Paper
Water Proof Papers
Parchment Paper
Functional Papers
Functional Papers
Wet Strength Papers
Mould Resistant Papers
VPI Papers
Laminations


FOLDING BOARD CARTONS AND COATED CARTONS

Introduction
Relevant Properties of Paper/Board forCarton Manufacture
Type of Paper/Board
Grammage
Caliper
Bursting Strength
Shade
Grain Direction
Folding
Moisture Content
Stiffness
Manufacturing Process Sheeting Cutting Trimming  of Board
Lamination
Pre-Printing Process
Printing
Text
Coating/Surface Lamination
Suface Lamination
Die Punching
Make-Ready
Insepction
Stripping, Prefolding and Gluing
Insepection
Finishing, Insepction and Despatch
Developments in Folding Carton Design and Process
Cad Systems for Carton Design, Plate Making and Laser Die cutting
Printing
Offset Printing
Computer Controlled Inking
Damping
Coating and Varnishing
Die cutting Machinery
Waste Seperation and Make Ready Equipment
Gluing Machinery
Collectors
Pre-Feeders
Stack Turner
Automatized Make Ready
Quality Control

CORRUGATED BARD

Outline
The Material
Components of Corrugated Board
Liners
Fluting
Adhesive
Board Manufacture
Box Manufacture
The Joint
Box Styles
Box Dimensions Refer to Internal Dimensions Only
Printing
Closing the Box
Box Design
Flute Selection
Some Other Important Considerations
Recent Developments

MULTI WALL PAPER SACKS

Manufacture
Advantages and uses
Situation in India
Early years
New Requirements for Paper Sacks
Reasons for Slow Development
High Cost of Paper
Paper Sacks for Cement
Paper Sacks for Tea

PLASTICS

Distinction Between Plastics, Fibres and Elastomers
Synthesis of Plastics
Classification of Synthetic Polymers
Techniques of Polymerization
Techniques of Polymerization
Processing of Plastics
Compression Moulding
Injection Moulding
Extrusion
Blow Moulding
Vacuum Forming of Sheet
Straight Vacuum Forming
Drape Forming
Plug Assist Forming
Matched Die Forming

PVC IN PACKAGING

Introduction
Films/Sheets
Applications of PVC Films
Bottles
Conclusion

BIAXIALLY ORIENTED POLYPROPYLENE FILMS

Process of Manufacture
Basic Categories of Film
Yields
Tensile Strength
Elongation at Break
Propensity to Absorb Moisture
Moisture Vapour Transmission Rate (MVTR)
Heat Sealability
Transparency and Gloss
Tear Strength
Applications
Conversion

PLASTIC WOVEN SACKS

Introduction
Plastic Woven Sack Materials
High Density Polyethylene (HDPE)
Polypropylene (PP)
Method of Making Woven Sacks
Flexible Intermediate Bulk Containers (FIBC)
Construction of FIBC
Use of Woven Sacks/FIBC


EXPANDED POLYSTYRENE

Properties of EPS
Biological Properties
Other Properties
Other Properties
Physical Properties
Basic Classification of Cushioning Materials
Advantages of EPS Packaging
Forms of EPS in Packaging
Applications of EPS


EXPANDED POLYETHYLENE

Material
Expanded Polyethylene Properties
Resilience
Compression Set
Rate of Recovery
Cushion Factor
Creep
Damping
Corrosion
Hygroscopicity
Micro-Biological Effect
Dusting
Abrasive Characteristics
Performance at Low Temperature
Density
Chemical Resistance
Applications
Extremely Fragile
Very Delicate
Delicate
Moderately Delicate
Rugged
Vibration
Other Packaging Applications

FLEXIBLE PACKAGING LAMINATES & COATING APPLICATION

Slection of A Laminate
Chemical
Resistance to Grease and Oils (Grease barrier) Performance
Converting Characteristics
Detailed Questionnaire for Design of Laminates
Comparison of Barrier Properties of Some Common Flexible Materials
Laminates Foil Bearing Structures
Aluminium foil Laminates for Food Packaging (Currently Popular in India)
Waxed Wrappers
Toffee Wrappers
Food Ovenwraps
Boil in Bag Pouches
Instant Coffee Pounch
Soft Drink Concentrates
Adhesive for Laminating  Aluminium Foil
Refort Pouches
Advantages of Retort Pouch
Disaster Relief Packages
M.R.E. Package: (Meals Ready to Eat)
Snack Food Packaging
Corn Chips
Cross Laminated Film
Modified Atmosphere Packaging
Fresh Red Meat
Cooked Meat
Fish
Coating Packaging Materials
Common Coating Materials
Coating/Resins/Adhesives
Some Useful Questions
Cold Seal Adhesive for Flexible Packaging
Hot Melt Adhesives
Composition of Various Hot Melts and The Relationship Between Hot Melt Chemistry and Physical

Properties
Hot melt Chemistry and Physical Properties

LAMINATED TUBES

Introduction
The Product
The Manufacturing Process
Shoulder Profection
Insert
Rondelle
Pilfer Evident Closures
Special Tubes
Filling and Sealing
High Frequency (HF)
Ultrasonic
Hot Air Sealing
Hot Jaw Sealing
Market

CO-EXTRUSION


Cast  Film Co-Extrusion
Blow Film Co-Extrusion
General Co-extrusion Problems
Cast Film
Raw Material
Support Materials
Bonding Agents
Barrier Material
Application of Co-Extruded Film
Application of Multilayer Films

SHRINK AND STRETCH WRAPPING

Shrink Packaging
Why Use a Shrink  Wrap System
Stretch Wrapping
Pilfer Proof Packs
Pallet Stretch Wrapping

PACKAGING IN GLASS CONTAINERS

Properties of Glass
Composition
Types of Glass
Manufacture with Automatic Machine
Application
Machines and Equipment
Advantages of Glass Packaging
Standards
Testing
Annealing
Thermal Shock Test
Pressure
Impact Testing
Density Test
Gauging
Chemical Methods of Testing

ALUMINIUM FOIL

What is Aluminium Foil
Manufacture of Aluminium Foil
Plain Foil Main Quality Parameters
Properties of Aluminium Foil
Comparison of Barrier Properties of Some Common Flexible Materials
Comparison of Transmission rates for various  Flexible Packaging Materials
Advantages in Use of Aluminium Foil in Strip Packaging of Pharmaceuticals
Applications and Uses  in Packaging
Laminates
Foil/Film Laminates and Extrusions
Laminating Processes
Adhesives Used in Foil/Film Lamination
Coating on Aluminium Foil
Aluminium AN Energy Store
Some Aluminium Foil Products and Their Uses
New Applications
Conclusion
Collapsible Tubes
Advantages of Aluminium Collapsible Tubes
Major Uses of Collapsible Tubes
Industrial Products
Cosmetics and Toiletries
Food Products
Household items
Pharmaceuticals
Availability of Collapsible Tubes
Filling Equipment
Quality Control Measures Collapsible Tubes
How to Order Collapsible Tubes
Major Uses of Rigid Cans and Containers
Most Common Sizes Rigid Cans and Containers


MANUFACTURE OF BLACK PLATE AND TIN PLATE

Introduction
Production of Black Plate
Steel Production
Other Methods of steel Production
Continuous Casting Method
Rolling Strip
Black Plate Specifications
Production of Tin Plate
Surface Preparation
Hot Dip Tinning
Electrolytic Tinning
Post Treatment
Advantages of Electrolytic Tinning


G.I. DRUMS OIL DRUMS CLOSURES

Introduction
Capacity
Type of Drums
Fixed Head Drums
Removable Head Drums (open Top)
Internally Lined Drums
Composite Drums
Glvanised Drums
Standardisation of Metal Container
Selection of Drums
New or Reconditioned Drums
Handling and Transport
Physical and Chemical Properties
Manufacture or body or shell
Manufacture of Ends
Assembly of Barrel
Reconditioning Industry
Quality Control
Closures
Introduction
Screwed Closures
Neck and seal Closure
Lever Lid Closure
Note on Screwed Closure
Flange
Bung
Washer
Sealing Ring
Cap Seal
Essential Functions of Closures
Optional
Recent Development in Drums
Light weight Drums
Conical Drums
Lithographed Drums
Composite Drums
Fibre Drums

ADHESIVE TAPES

Introduction
Properties and Application Areas
Important Terms in Pressure Sensitive Tapes
Adhesives Used with Tapes
Silicone Based Adhesives
Drying After Coating

WOODEN CONTAINERS

Classification of Timber
Moisture in Timber
Effect of Moisture on the Properties of Wood
Seasoning of Wood
Physical and Mechanical Properties of Timber
Physical
Mechanical Properties
Defects in Timber
Natural Defects
Knots
Cross Grain
Seasoning Defects
Preservation of Timber
Methods of Preservation of Timber
Form and Size of Each Component
Thickness of Components
Size and Spacing of Nails
Cement Coated Nails
Barbed Nails
Number of Planks in a shook
Type of Joints
Style of container
Reinforcements
Workmanship
consideration for a Design of the Box   
Easy Load
Average Load
Difficult Load
Grouping of Indian Timbers
Plywood Boxes Battened Construction
Timber Species Suitable for the Manufacture of Packing Cases

SYSTEMS PACKAGING

What is system packaging
System Packaging as cost  saving Method
Types of System Packaging
Indian Scene
Selection of Appropriate System
Salient Features of Different Types of Systems
Lined Carton System
Coated and laminated carton system
Stand up Pouches
Form Fill Seal (FFS) System
Vacuum Thermoforming System

ASEPTIC PACKAGING

What is Aseptic Processing & Packaging
Aseptic
Aseptic System
Aseptic Processing System
Aseptic Filling & Packaging System
Aseptic Zone
Aseptic Processing System
Aseptic Processing and Packaging
Characterstics of Specific Elements
Flow Control
Heat Transfer (Heating/Cooling)
Direct Heating /Cooling
Indirect Heating /Cooling
Holding Tubes
Deaerator
Aseptic Surge Tank
Automatic Flow Diversion
Aseptic Filling and Packaging Systems
General Requirements
Sterilisation Agents
Heat
Chemicals
Radiation
Classification of Aseptic Packaging Systems

VACUUM PACKAGING

Gas Packaging
Methods
V.P.
Gas Packaging
Mechanical Air Replacement
Gas Flushing
Compensated Vacuum
Passive Atmosphere Modifications
Active Packaging
Methods
V.P.
Gas Packaging
Mechanical Air Replacement
Gas Flushing
Compensated Vacuum
Passive Atmosphere Modifications
Active Packaging
Oxygen  Absorbents
Carbon Dioxide
Absorbents/Emitters
Ethylene Absorbents
Ethanol Vapour Generators
V.P. Machinery
Nozzle Vacuumizing
Chamber Vacuumizing

STRIP PACKAGING

A Well Designed Machine
The Roller Mounting Shafts
The Shaft Suspension Systems
The Reference  Shaft Suspension system and its important features
The Adjustable Shaft Suspension system and its important features
Moulding of the suspension system to the body of  the Machine
Opening skill
Selection and qualities of the film material
Choice of Film Materials
Strip Pack Designing
Speed of a Machine
Dwell Time

AEROSOL PACKAGING TECHNOLOGY

Introduction
Working Principle of Aerosol
Pack Contents (Product and Propellant)
Aerosol Cans
Aerosol Valve
Methods of Filling Aerosol Containers
Market in India
Growth Potential
Legislation
Flammability
Developments
New Products
Alternative Propellants
Cans
Valves

FORM FILL SEAL MACHINE (SYSTEMS)

Vertical Form fill seal Machines
Filters
Horizontal Bag Machines
Pouch Types
Filling Operation
Pouch Material
Choice of Materials
Pouch & Bag Structures
Conclusion

LABELS AND LABELLING

Definition
Purpose of Labels
Types of Labels
Plain Paper Labels
Pre -Gummed Paper Labels
Thermoplastic Paper Labels
Pressure Sensitive Labels
Swing Labels Tie on Tags
Paper
Adhesives
Labelling Machinery
Regulations
End use and importance of Labels
Labels for freight containers
Information
Position
Language
Marking and Labelling
Indentification Marks
Dangerous Cargo
Method and Type of Marking
Recommended Size
Colour
Positioning
General
References


THERMOFORMING IN PACKAGING

Skin and Blister
Packaging
Skin Packaging
Blister Packaging
Packaging Essentials
Constituent  MaterialsProperties
Typical Thermoformed Packaging
Shrink Wrapping

PACKAGING OF HORTICULTURAL CROPS

Main Causes of Deterioration
Role of Ethylene
Degreening of Citrus
Ethylene Effects on Quality
Effect of Ethylene on Watermeton Quality
C2H2 Pollution Sources
Avoiding Exposure to Ethylene
Precooling

PACKAGING OF MEAT, FISH & POULTRY

PACKAGING OF DAIRY PRODUCTS

Requirements of Package
Design of a Pack
Primary Packaging Materials
Secondary Packaging Materials
Packaging Material and The Diary Industry
Milk Powder
Liquid Milk
Butter
Cheese/Cheese Spread
Bread Spread
Ghee
Chocolates Aluminium Foil
Indegenous Milk Products
Ice Cream
Present Scenario

PACKAGING OF BISCUITS, BREAD AND CONFECTIONERY

Primary Barrier
Cushioning/Shape
Protective Wrapper
Decorative Wrapper
Bread
Confectionery

FOOD PRODUCTS PROCESSED AND DEHYDRATED

Objectives of Food Processing
Preservation and Stabilization of Perishable Foods
Manufacture of Pure Products and their  Derivatives
Creation of New Foods
Methods of Food Processing
Thermal Processing
Cold Storage and Freezing
Dehydration
Sun Drying
Artificial Drying
Chemical Preservation
Biological Food Processing (Fermentation)
Effect of Processing on the Nutritive Value of Foods
Food Packaging
Metal Containters
Glass  Containers
Plastic Materials
Paper

PACKAGING OF FRUIT JUICES

Objectives
Phalsa Juice
Plum Pulp
Recommendations

PACKAGING OF READY TO EAT FOODS

Ready to Serve (RTS) and Ready to Eat (RTE) Food
Intermediate Food Items
Instant Mixes and Premixes
Moisture
Low Moisture Foods
Medium Moisture Foods
High Moisture Foods
Oxygen/Air Permeability
Nitrogen Permeability
Grease and fat Barrier Properties
Light Sensitivity
Processing Parameters and Special Packaging requirement of RTE Foods
Conceal the Crumbs
Storage Stability of Potato Wafers Vis-a-Vis Packaging
Most Commonly Used Packaging Materials for such Snacks are
Canned Foods
Retort Pouch Packed RTE Foods
Advantage of Retort Pouch
Aseptically Packed RTE Foods


PACKAGING OF PHARMACEUTICAL PRODUCTS ORALS

Rigid and Semi Rigid Containers
Class  Containers
Aluminium Tube/Tinplate Containers
Plastic Containers
Permeability of the Plastic Materials
Extraction of Plastic  Components by the Packed Materials
Sorption of Active Agents by the Plastic Material
Translucency of Plastic Materials
Damage to Plastic Container During Storage
Flexible  Packaging Materials
Paper
Cellulosic Films
Aluminium Foil
Selection of the Material for ideal strip pack
Advantage of strip packing
Blister Pack
Auxillary Packaging
Materials
Space Fillers
Closures
Cartons
Bulk Packing
Marketing
Printing of Batch Number and Other Particulars on Strips

PACKAGING OF PHARMACEUTICAL PRODUCTS INJECTABLES

Single Dose Injections
Multiple Dose Injections
Transfusions
Materials Used
Glass
Rubber
Plastics
Aluminium
Paper and Board
Conclusion

PACKAGING OF COSMETIC PRODUCTS

Air
Light
Heat
Cold
Cosmetic Packaging Materials

PACKAGING OF SOAPS & DETERGENTS

What is Soap
What is Detergents ?
Why Detergents ?
What is Dirt ?
How Soaps and Detergent work ?
Desired Attributes of a Soap
Desired Attributes of a Detergent
Specific Attributres that packaging Must Satisfy
Forms of Soap Packaging
Forms of Detergents
Bar Packaging
Forms of Detergent
Powder Packaging
Forms of Detergent Liquid Packaging
Envelop Wrapping
Merits
Demerits
Flow wrapping
Merits
Demerits
Carton
Merits
Demerits
Cling/Pleat Wrapping
Merits
Demerits
Flexible Pouches (Laminated)
Merits
Demerits
Bottles
Merits
Demerits
Packaging Material for Soaps
Packaging Materials for Detergent Bars
Packaging for Detergent Powders/Liquids
Primary Packaging Outers
Packaging Machines Used
Future Trends Anticipated Packaging Option

PACKAGING  OF HAZARDOUS CHEMICALS

Hazardous Chemicals
Requisites for Packaging Materials
Common Packages for Hazardous Chemicals
Packaging Hazardous Chemicals

PACKAGING OF FERTILIZERS

Packaging Materials
Jute Bags
Multiwall Paper Sack
Combination Materials from Paper, Polyethylene Jute and Bitumen
Cotton Fabric Laminated with Polyethylene
PVC Sack
Low Density Polyethylene Sack
Low Density Polyethylene Woven Sack
High Density Polyethylen Woven Sack
Polypropylene Woven Sack
Lamination vs. Loose Liner
Recent Developments

PACKAGING AND PESTICIDES INDUSTRY

Formulation Types
Major Features
Packaging
Major Factors Governing the Selection of Packaging Materials and Packages
Chemical Compatibility
Requirements of  Transport and Storage
Requirements of Market and End Use
Ecnomics
Legal Obligations
MOC of Packaging Materials

PACKAGING OF HANDICRAFTS FOR EXPORT

Comparative Properties of Puffed Rice and Expanded Polystyrene Beads

PACKAGING OF TEXTILES

Introduction
Difference items of Textiles Requiring Packaging
Need for Packaging of Textiles
Different items of Packaging Used in Textiles
Different Styles of Packaging
Modes of Packaging in Different Types
Packaging of Textiles

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