TABLE OF CONTENTS 1
UNIT ONE PERSPECTIVE ON PACKAGING 1
Lesson 1 A History of Packaging…………………………………………………………………1What is Packaging?………………………………………………………………………………1Primitive Packaging 2
From Rome to the Renaissance 3
The Industrial Revolution 5
The Evolution of New Packaging Roles 6
Packaging in the Late 20th Century 7
Modern Packaging 8
Laminating Processes 1 12
Waste Management and Environmental Issues ………………………………………………11The Modern Packaging Industry 15
Introduction 17
Lesson 2 Packaging Functions 17
The Contain Function 18
The Protect/Preserve Function 19
Food Preservation 19
The Transport Function 31
The Inform/Sell Function 31
Representative Papermaking Machines 33
Introduction 33
Lesson 3 Paper and Paperboard 33
UNIT TWO PACKAGING MATERIALS AND CONTAINERS 33
Machine Direction and Cross Direction 36
Surface or Dry-End,Treatments and Coatings 37
Paper Characterization 38
Paper Types ……………………………………………………………………………………40Paperboard Grades 42
Paperboard Cartons 43
Lesson 4 Corrugated Fiberboard Boxes 46
Historical Perspective 46
Corrugated Board 47
Properties and Tests 52
Corrugated Boxes 55
Carrier Rules 58
Stacking and Compression 60
Lesson 5 Metal Containers 64
Background 64
Common Metal Container Shapes 65
Three-Piece Steel Cans 67
Two-Piece Cans 69
Impact Extrusion 71
Aerosols 73
Lesson 6 Glass Containers 75
Glass Types and General Properties 75
Bottle Manufacture 77
Bottle Design Features 80
Lesson 7 Plastics in Packaging 83
Introduction to Plastics 83
Extrusion 87
Injection Molding 91
Extrusion Blow Molding 92
Injection Blow Molding 93
Thermoforming 94
Other Forming Methods 96
Recognizing Molding Methods 97
Lesson 8 Flexible Packaging Laminates 98
Laminates 98
Aluminum Foil 99
Vacuum Metallizing 101
Other Inorganic Coating 103
Laminate Structural and Physical Properties 104
Flexible Bags,Pouches and Sachets 106
Sealability 109
Barrier Properties 110
Specifying Laminates 116
Examples of Laminates 116
Color Perception 118
Introduction 118
Lesson 9 Color 118
UNIT THREE PACKAGE PRINTING AND DECORATING 118
Color Terminology 119
Viewing Color 120
Lesson 10 Graphic Design in Packaging 121
Introduction 121
Demographics and Psychographics 121
The Retail Environment 122
Fundamental Messages 123
Equity and Brand Names 126
Graphic Design Basics 127
Typography 127
Lesson 11 Package Printing 128
Introduction 128
Printing Methods 129
Relief Printing 130
Lithography 134
Gravure Printing 136
Comparing Flexography,Lithography and Gravure 137
Other Package Decoration Techniques 138
Printing Inks 141
UNIT FOUR PACKAGING DYNAMICS AND DISTRIBUTION PACKAGING 143
Lesson 12 Shock,Vibration and Compression 143
Shock 143
Quantifying Shock Fragility 146
Cushioning Against Shock 149
Vibration 151
Compression 155
Estimating Required Compression Strength 161
Lesson 13 Mechanical Shock Theory 162
Introduction 162
The Free Falling Package 162
Mechanical Shock Theory 164
Shock Duration 167
Shock Amplification and the Critical Element 168
Lesson 14 Test Method for Product Fragility 170
Shock:Damage Boundary 170
Vibration:Resonance Search ＆ Dwell 174
Lesson 15 Seven Steps for Cushioned Package Development 175
Introduction 175
Step 1 Determine Product Fragility 176
Step 2 Determine Conditions 177
Step 3 Calculate Cushion Requirements 177
Step 4 Recognizing Design Constraints 180
Step 5 Design Prototypes and Test 182
Step 6 Consider Vibration Effects 182
Short History of Distribution Packaging in the USA 184
Lesson 16 Distribution Packaging 184
Step 7 Monitor Performance If it works,question it 184
Functions and Goals of Distribution Packaging 185
The Cost of Packaging 185
The Package Design Process 186
Taking a Total System Approach to Package Design 186
The 10-Step Process of Distribution Packaging Design 189
A Final Check 191
Package Design Project Checklist 191
The Warehouse 192
Unit Loads 193
Lesson 17 Computer Aided Packaging System 196
Introduction to TOPS Pro 196
Using TOPS Pro 199
UNIT FIVE PACKAGING MACHINERY 205
Lesson 18 General Overview 205
Automated Production 205
The New Production Line 206
Speed 208
Changeovers 209
Straight-Line and Rotary Systems 209
Machine Controls 211
Developing Custom Machinery 212
Upgrading Existing Equipment 212
Lesson 19 The Packaging Line 212
The Packaging Line 213
Line Organization 213
Packaging Materials 214
Machine Capabilities 214
Material and Container Characteristics 215
Line Balancing 215
Personnel 216
Lesson 20 Filling Systems 216
Introduction 216
Liquid Filling 218
Dry Product Filling 232
Resources 245
Glossary of Packaging Terms 246