Packaging - a very vital &

dominant role in modern

world
■ Urbanization, double-income nuclear families, improved
living standard & higher disposable income
■ Concern for health, requiring prevention of adulteration
and providing hygienic products
■ Movement of goods within and across countries from
place of production to place of utilization
■ Elimination of waste through preservation of perishable
goods
■ in short, packaging provides for Protection, Preservation
and Promotion
Definitions of Packaging
■ Packaging may be defined as the
means of ensuring the safe delivery of
a product to the ultimate consumer in
sound condition,at the minimum overall
cost. Packaging materials must be
Environmental friendly.
■ Packaging must protect what it sales,
and sell what it protects.
 Criteria for Packaging
■ Packaging should arrive destination in an attractive
condition
■ Product will just call for unpacking and installation
to be commissioned for usage
■ There will be no need for replacement of damage
parts
■ There will be no mishap or malfunctioning of the
equipment
■ There will be no spillage of the contents leading to
a loss or contamination of the Environment
 Criteria for Packaging
■ Appearance
■ Identification
■ Instruction for use
■ Information about contents in
order to satisfy legal requirements
■ Carry the Brand name
■ Sales aid
 Protection
■ Chemical
■ Product/Packaging material COMPATIBILIRTY
■ Ingress of liquid & vapour
■ Loss of liquid or vapour
■ micro-organisms (BIOLOGICAL)

■ Physical
■ Compression
■ Impact
■ Puncturing / vibration
■ Effect of Temperature & Light
■ Pilferage (BIOLOGICAL)
 Function
■ Machine Performance
■ End - use Performance
■ Display
■ Ease of Opening / Closing
■ Dispensing
■ Disposability
■ Recycling
Corrugated Fibre Board
Boxes
■ History : 1st rule for constructing CFB containers established in US
Railroad’s freight classification committee in 1906 updated many
times, continue today as the Uniform Freight Classification (UFC).
■ UFC require certain construction requirements depending on the
weight & dimensions of the intended box.
■ Until recently, rules guided corrugated container design by Mullen
burst test.
■ Box compression strength became a overriding consideration.
■ Burst test related to board’s rupture / tensile properties.
■ Edge crush test ( ECT) is more suitable for grading CFB
■ Dual grading system ( Burst test & ECT) in effect since 1991.
Corrugated Fibre board
■ Most common form is made up of two facingis/liners bonded to
a fluted or corrugating medium – called singlewall / 3-ply
board. Doublewall / 5-ply board i.e. 2 fluted medium & 3 liner.
Tripple wall / 7-ply i.e. 3 fluted medium & 4 liner.
■ Only one facing/liner bonded to a flute called single face is
flexible in one axis and is used for wrappings.
■ Fluted medium is the basis of corrugated board’s significant
stiffness. Crushing or flattening the flutes even slightly reduces
the board’s stiffness.
■ The manufacture & handling of corrugated material should be
done in a manner that maintains flute integrity if maximum
stiffness & stacking strength is to be preserved.
 C F B Grades
■ Grammage: The mass in grams per square metre (g/m2)
■ Basis weight: The mass in pounds per square feet (lb/f2)
■ Presently high performance boards is being made to meet ECT rather
than Mullen burst test & basis weight requirements
■ There are no standard basis weight kind found in the older Mullen
system to meet stiffness values measured by ECT
■ A linerboard with a white surface provide better graphics by using
bleached fibre in the second headbox giving a somewhat ‘Mottled
white’. Solid bleached white kraft is used for top quality graphics
■ Recycled board is slightly thicker to compensate weaker recycled fibre,
has a smoother finish, lower Cof, excellent printing surface
 Flute Standards
■ Type Flutes/30cm Thickness Take-up Factor
mm

without facing
■
■ A 32-38 4.2-4.6 1.54

■ B 50-56 2.2-2.8 1.32

■ C 36-43 3.5-3.7 1.42

■ E 90-96 1.2-1.6 1.27

 Board Manufacture
■ Single-facer station: medium is preconditioned to of being
formed into fluted configuration. The medium is fluted by
being passed between large rolls with a geared surface.
Linerboard is also pretreated to bring it to same
temperature & moisture condition as the medium.
■ Older m/c have brass ‘fingers’ to hold the fluted
media.Newer ‘fingerless’ use vacuum system. Fingerless
board have better EC
■ Adhesive is applied to the flute tips pressed against
preconditioned liner where heat & pressure gel the starch
adhesive. This liner has visible lines hence constructed as
‘inner liner’
■ Single faced material is flexible in one axis
 Board Manufacture
■ Double-facer station: single faced material sent through a bridge
to isolate the two ends of corrugating medium.
■ At double-facer station adhesive is applied to the flute tips on the
other side of the media, and outer liner is matched to the single
faced board.
■ The assembled corrugated board is no longer flexible in any axis.
The final heat setting & cooling is done between two long flat belts.
■ The edges are trimmed & the finished board is slit to widths & cut to
lengths corresponding to the requirements. Finished sheets are
stacked for further operations.
■ Different score geometry might be needed depending on the use:
Three point score is used when flaps will be folded in one direction,
Five point score is preferred when filling operation need flaps first
be bent outwards.
Selecting the Correct Flute
■ E & F flutes are generally not associated with shipping
containers; rather to replace thicker grades of solid
paperboards
■ A flutes should give the highest top-to-bottom
compression strength, useful for cushion pads added
thickness is an advantages
■ B flute’s high Flat crush strength is advantageous for
heavy goods such as bottles or cans. It can also be used
where a high stack strength is not needed or where
distribution strength is very short.
■ C flute has about 10 % better stacking strength than the
same board weights in B-flute
 Box manufacture
■ CFB may be fabricated to a variety of shapes,
generally fall into one of three manufacturing
categories.
■ Regular slotted containers ( RSC ), Die-cut, Bliss box.
■ Manufacturer’s joint: is that corner where materials
overlap, joined the material with glue, tape or
staples. Gluing offers better compression strength of
the box, being processed at high speed. Taping &
stapling or stitching are usually semiautomatic and
are slower operation.
Properties and Tests for
Paper
■ Conditioning: The % of water retained by paper is a function of
Temperature & RH. Paper moisture content affects all
mechanical properties like Mullen Bursting Strength, Stiffness
etc. There is degradation with increase moisture content. Paper
test must always be done at the same temperature & RH .
Indian Condition is 27 + 10 C & 65 + 2 % RH, ASTM
Condition is 23 + 10 C & 50 + 2 % RH.
■ Hygro-expansiveness: when paper absorbs moisture, it
expands ; when dries, it shrinks. Between 0 & 90% RH
dimensions may change by 0.8 % in the MD and 1.6 % in the
CD. Un
event moisture contents in the two liners as board comes of the
corrugator may lead to board warpage when the liners come to
equilibrium.
Properties and Tests for
Paper
■ Caliper / Thickness : in points ( one – thousandth of and
inch is 1 point / in microns
■ Basis weight / Substance : lbs per. sq. ft / gm /m2
■ Stiffness : in taber unit / newtons
■ Ring Crush test : newtons / length
■ Mullen burst test : lbs per sq. inch / kpa / kg/cm2
■ Moisture content : %
■ Water absorbency ( Cobb) : gm per m2 per minute
■ Type of pulp : mechanical / chemical / mixed
■
Corrugated Fibre Board (CFB)
Test
■ Edge Crush Test ( ECT) : newton per length
■ Flat Crush Test :
■ Thickness of CFB : Points / microns
■ Mullen burst test : lbs per sq. inch (psi)/ kPa
(psi X 6.895 = kPa)/kg per cm2
■ Puncture resistance : ozs inches per tear inch
■ Pin adhesion:Strength of the bond between fluting media & liner
■ Ply separation : Resistance to ply separation when exposed to
water
■ Moisture content : in percentage
■ Water absorbency(Cobb):gms per sq meter per 30 minutes
■ Total Grammage : gms per sq. meter
■ Combined weight of facings :This is not required for ECT system
Carrier rules & regulations

■ Type Max. Mass Max. comb. Dimn. Min. B St. Kg

(L + W + H) Kg/sq.m
■ 3 ply 5 635 6
■ 8 750 8
■ 10 1025 9
■ 5 ply 15 1275 10
■ 20 1525 12
■ 25 1575 13
■ 7 ply 30 1650 14
■ 40 1775 17
■ 55 1900 24
■ 75 2150 29
 CFB Boxes - Tests
■ Compression strength : newtons / lbs /
kgs
■ Box compression strength =
5.87 X ECT X /BPXT
ECT = Edge crush test
BP = inside box perimeter, m (in.)
T = combined board thickness, m
(in.)
 WHY TEST ?
■ 1. To predict Performance in practice

■ 2. To Control Quality

■ 3. To obtain information to Modify,

Improve or Reduce the cost
of the Package
 To predict Performance in
Practice FOUR co-relations are
Needed
■ Between the “TESTS” carried out in the laboratory & the
behaviour of the ‘PACKAGE’ in Practice.
■ * Field Performance of the Package & Laboratory
Transport Simulation Tests.
■ * Laboratory Transport Simulation Test on Filled
Package & Test on The Empty Container & on any
Fittings or Components.
■ * Between the Strength & Other properties of the
various Materials used in making the container & the
tests on the Empty Container.
■ * Properties of the Packaging Materials & its
Manufacturing Variables.
To Control Quality
■ * Must be Relatively Simple

■ * Must also be capable of

being carried out Rapidly

■ * Preferably they should give a

Numerical results
 Eco safe Packaging
ENVIRONMENTAL ISSUES
Packaging - a cause of Environmental
Problem
Municipal Solid West (MSW) 20.8
% Gaseous Emissions*
2.0 % Water Consumption
1.5 % Energy Consumption
3.7 % *Phosgene, Carbon monoxide,
Sulphur dioxide, Nitrogen dioxide, Chlorine
& Dioxin etc.
Source OCED
REGULATIONS / LEGISLATIONS
■ New regulations / legislations have been introduced by
countries like Germany, Netherlands, Denmark, France &
many others.

■ New legislations give more emphasis on INTRODUCING ECO-

FRIENDLY / ECO-LABELLED Packages.

■ Eco-friendly materials are generally defined as materials

which do not pollute the Atmosphere. This is still a
DEBATABLE ISSUE.

■ The legislation yet does not list materials which CAN / CAN
NOT be used.
GERMAN ORDINANCE ON PACKAGING
WEST

■ It is the liability of the exporter to bring back all

Packaging materials from Germany - not Practical.

■ German buyer to take responsibility to dispose

Packaging materials in a suitable manner.

■ Exporters can directly take Green Dot License, so

that the organisations is responsible for collecting /
segregating / sending for Recycling of Packaging
materials.

■ Fee is levied, depending on the type of Packaging

material.
Eco-friendliness characteristics

■ * Packaging material which will

make no harm or less harm to
the Environment.

■ * Environment - Compatible.

■ * Bio-degradability may be
considered but not essential.
HOW TO MAKE PACKAGE MORE ECO-FRIENDLY ?

■ 1. AVOIDANCE
■ 2. REDUCTION
■ 3. REUSABILITY
■ 4. RECYCLABILITY
– a. Selection
– b. Segregation
– c. Processing
■ ASTM D 5033-90 “STANDARD GUIDE FOR THE DEVELOPMENT OF
STANDARDS RELATING TO THE PROPER USE OF RECYCLED
PLASTICS
■ IS : 2828 “GLOSSARY OF TERMS USED IN PLASTIC INDUSTRY”
■ DOC:PCD 12(1170) GUIDELINES FOR RECYLING OF PLASTIC
■ 5. INCINERATION with possibility of ENERGY RECOVERY
■ 6. LAND FILL
Environmental Management System (EMS) ISO

14000

■ Separate ISO designations assigned to each disciplines: 14001

to 14025 for various stages of consideration or adoption.
■ Elements within 14001
■ 1. Environmental Commitment Policy
■ 2. Planning
■ 3. Implementation
– a) Resources
– b) Training
– c) Communication
– d) Record keeping
■ 4. Measurement & Evaluation
■ 5. Review & Improvement

■
Thank you for your time
and attention !

■ For further details please contact:

■ S.K.Sarkar, Deputy Director I/c
■ Indian Institute of Packaging
■ Block CP, Sec. V, Salt lake, Kolkata 700 091
■ E-mail: iipcal@cal.vsnl.net.in
■ Tel 033 2367 9561/0763/6016
■ Fax: +91-33-2367 9561
■ E-mail: iipcal@cal.vsnl.net.in
■ Website : www. iip-in.com
 Packaging of
HAZARDOUS/DANGEROUS
Materials
■ All materials fall into two categories:
Hazardous/Dangerous or General / Non-hazardous.
■ Dangerous goods are articles which are capable of posing
a significant risk to health, safety or to property when
transported.
■ Transportation of Dangerous goods need to comply the
recommendation of United Nation Committee of Experts
for the same.
■ The International Maritime Dangerous Goods Code (IMDG
Code) for the safety of life at Sea.
■ UN tested and certified packages are mandatory for all
international transport of dangerous goods. UN has
standardized the test methods and levels of performance
for all transport package.
 Classification of
Dangerous Goods
■ Class 1 Explosives
■ Class 2 Gases
■ Class 3 Flammable Liquids
■ Class 4 Flammable Solids
■ Class 5 Oxidizing Substances / Organic
Peroxides
■ Class 6 Toxic and Infectious Substances
■ Class 7 Radioactive Materials
■ Class 8 Corrosives
■ Class 9 Miscellaneous
 Packaging Type Code
■1 - Drum
■2 - Wooden barrel
■3 - Jerrican
■4 - Box
■5 - Bag
■6 - Composite packaging
Packaging Material Code
■ A – Steel
■ B – Alluminium
■ C – Natural wood
■ D – Plywood
■ F – Reconstituted wood
■ G – Fibreboard
■ H – Plastic material
■ L – Textile
 Packing Group
■ Packing Group I(X) – High danger
■ Packing Group II(Y) – Medium
danger
■ Packing Group III(Z) – Low danger
 Complete Code

4G/Y114/S/0105
U
IND(CA)/005115
N

1A1/X1.4/150/0205
U IND(CA)/003116
N
Corrugated Fibre Board &
Paper
■ Conditioning for testing 7031
■ CFB Boxes 2771(Part-I)
■ Test of CFB Boxes 7063
■ Kraft Paper 1397
■ Kraft Liner 9588
■ Sampling & Test of Paper 1060/4006
■ Wrapping Paper 6615
■ Tissue 8460
■ Waxed Paper 3962
■ Glossary 4261
■ Bitumen laminated paper 1398
■ Rectangular, rigid, dimensions 8470
■ Gummed Paper tape 4185
Corrugated Fibre Board &
Paper
■ CFB for can sea food 7149
■ CFB for Cigarettes 1006
■ CFB for soap 10176
■ CFB for para dropping 7151
■ CFB for butter 12212
■ Code practice for pkg. 6211
■ Fibre analysis 5385
■ Substance 1763
■ Field performance 9773
■ Terminology transport pkg. 9111
■ Transport Pkg test 7028
■ Conditioning for Transport pkg. 7031
■ Identification of Transport pkg. Parts 7030
■
Developments in Plastics
■ PE - LD, HD, HM-HD, LLD & Blends
■ PP - TQPP, CPP, OPP, Metallised & Clear
■ PS - HIPS, EPS
■ PVC, PVDC, PVAc
■ Polyester - Metallised & Clear
■ Nylon, EVOH
■ EAA
Developments in the field
of Packaging
■ Metal can - continuous annealing, double cold
reduction, beading, DRD, DWI,electrolytically
coated, differentially coated,TFS, welded
can,easy open ends
■ Glass - light weight & PE coated
■ Canning to aseptic system to irradiation
■ Metal & Glass to Plastic
■ HACCP, ISO 9000, ISO 14000
Transport
Packages

Evaluation
 Developments

Mono layer, Multi layer, Co-

extrusion, Coating &
Lamination.
Developments in the field
of Engineering Products
■ Skin / Blister Packaging
■ Shrink Packaging
■ Stretch wrapping
■ VPI / VCI
■ Use of Desiccant
■ EPS / Plastic foam
■ Corrugated Fibre Board
Relevant Indian Standards
■ Wooden Packaging
■ Specification of Timber 6662
■ Packing Case 1503
■ Crates 3071
■ Terminology 6703 Code 10106
■ Containers guidelines 10687
■ Performance Test 8358
■ Preservation 4973,218,6341,6791,10013,4833
■ Specification of Ply-wood 303, Test 1734