Packaging Design

 Marketing function of Packaging (Displays)

 Information function of Packaging (safety and legislative
requirements)
 Different Packaging bring added value
 CAD systems to support Packaging design (e.g. ArtiosCAD)
 World Design Organization (www.wdo.org)
 Design Awards (e.g. reddot - http://en.red-dot.org/ )
 Others; $ 38bn; 6%

Metal; $ 117bn; 14% Flexible packaging; $

183bn; 22%

Rigid plastic; $ 180bn;

21%

Board; $ 262bn; 31%

Glass; $ 60bn; 7%

Global Packaging Market 2015: $ 839 billion

Source: Smithers Pira
Market Data
 External (Third Party) Market Data -> Market Index
 EUWID – https://www.euwid.de/en/
 S&P Global Platts - https://www.platts.com/
 Bloomberg - https://www.bloomberg.com/markets
Categories of Packaging
 Paper based boxes (corrugated and solid board)
 Plastic foils, bags, sacks, films
 Pallets and wooden packaging
 Bottles, glass packaging
 Thermoformed trays
 Foams
 EPS & EPP
 Beeboard (hexacomb)
 Moulded pulp & Thermoformed Fiber
 Drums, barrels, cans
 Special packaging
 Labels & Printings
 Other packaging
Solid board (Paperboard)
 Solid board (carton) is produced in weights from 200 – 650 g/m2;
it is multi-plyr paper board typically used for folding cartons
 One or more coating layers are applied to improve whiteness, smoothness
and gloss of paperboard usually by:
 pigment, which could be china clay, calcium carbonate or titanium dioxide
 an adhesive or binder as styrene-butadiene emulsions or starches and water
 Grades of paper according DIN 19303 "Paperboard - Terms and grades„
First letter Second letter
Number
(surface treatment) (main furnish)
All except D grades:
•Z = bleached virgin chemical pulp
1.white reverse side
•C = virgin mechanical pulp
2.cream reverse side
•A = cast-coated •N = unbleached virgin chemical pulp
3.brown reverse side
•G = pigment coated •T = recycled/secondary fibre with
D grades only:
•U = uncoated white, cream or brown reverse
1.bulk ≥ 1.45 cm2/g
•D = recycled/secondary fibre with
2.1.3 cm2/g < bulk < 1.45 cm2/g
grey back
3.bulk ≤ 1.3 cm2/g

Example: GC1 would be a "pigment coated", "virgin mechanical pulp" board with a "white
reverse side". Often the used paperboard type would be folding boxboard (FBB), which was
coated on both sides.
Corrugated Board (Cardboard)
 Corrugated cardboard (fiberboard) is material made of one or
more layers of liners with fluted sheet in-between
 Cardboard is typically used for making corrugated boxes
 Based on size of fluting we recognize A – G flutes
 Liners are made of Kraftliner (Kraft Paperboard) with minimum
80% of virgin fibres or Testliner (Recycled Paperboard)
 The European Federation of Corrugated Board Manufacturers
(FEFCO) – www.fefco.org - provide catalogue of designs
 Corrugated board produced from
responsible sources according
Forest Stewardship Councils (FSC)
www.fsc.org
Corrugated Board Cont.
 Basic cardboard performance is measured by:
 ECT – Edge Crush Test (kNm) DIN EN ISO 3037
 BST – Bursting Test or Mullen Test (kPa) DIN 53141 – 1
 BCT – Box Compression Test or Stacking Crush Test (N) DIN 55440-1
 Drop test ASTM D5276 - 98(2009)
 Corrugated board can be used for heavy duty products, pallets
 Printing – Offset / Flexography
 Colour systems – CMYK / Pantone
Plastic foils
 Most common materials for plastic films:
 Polyethylene PE (LDPE, HDPE, Linear LDPE)
 Polypropylene PP (BOPP – Biaxially Oriented PP)
 Polyester PET (BOPET – Biaxially Oriented PET)
 Nylon
 Polyvinyl Chloride PVC
 Production process by casting or blowing (2 – 500 )
 Transparent, coloured, printed, antistatic
 Stretch films, heat-shrinking films
 Processed to bags, sacks, bubble foil etc.
Pallets and Wooden Packaging
 EUR pallet - specified by the European Pallet Association (EPAL),
it is a four-way pallet made of wood that is nailed with 78 special
nails in a prescribed pattern, size of 1200 x 800 mm
 Various materials are used for pallets next to wood such as
plastics, plywood, chipboard, paper
 International Standards For Phytosanitary Measures No. 15 (ISPM
15) – describes need to treat wood materials used to ship products
between countries
 Other types of wooden packaging such as
crates, special pallets, plywood boxes etc.
Bottles & Glass Packaging
 Bottles and jars made from glass in various shapes and sizes used
for preserving and packaging drinks, food and perfumes
 Over 50 billion pcs of bottles is produced in EU per year
 Glass is formed from a specific type called soda-lime glass,
composed of approximately 75% silicon dioxide (SiO2), sodium
oxide (Na2O) from sodium carbonate (Na2CO3), calcium oxide,
also called lime (CaO), and several minor additives
Thermoformed trays
 Thermoforming is a manufacturing process where a plastic sheet is
heated to a pliable forming temperature, formed to a specific
shape in a mold, and trimmed to create a usable product
 Various materials could be thermoformed such as:ABS, ACRYLIC,
HDPE, HIPS, PC, PET, PP, PVC etc.
 Materials are used in rolls up to 1,5mm or sheets above 1,5mm
 Trays in various colours are produces from heatead film by vacuum
technology on an aluminium tool
Foams
 For packaging extremely resistant to vibration, drop and damage
we can use foams typically with closed cell structure:
 PE foam (polyethylene foam)
 PU foam (polyurethan foam)
 XPE foam (extruded polyethylen)
 Foam can be used in rolls, cutted shapes, boards, bags or even as
two component chemical; could be laminated
EPS & EPP
 Expanded Polystyren and Polypropylen are used for shock resistant
packaging which is very light and not absorbing a water
 Could be supplied as cutted boards and further cutted by wire or
moulded in an aluminium tool
 EPP have memory properties and is used for active protection
 EPS & EPP have great insulation properties
 More complex recycling
Beeboard (hexacomb)
 Hexacomb packaging is a paper-based material that offers a unique
combination of superior strength whilst being light-weight
 Features:
 Lightweight and strong, providing superior compression strength
 Good shock resistance and cushioning performance
 Available in a wide range of formats like simple panels, die cut boards, edge and
corner protectors, cradles and wedges
 Easily die cut, assembled, or otherwise fabricated to the shape of the object
 Highly durable and reusable
 100% recyclable and made from a renewable resource
Moulded Pulp & Thermoformed Fibre
 Made from recycled paperboard and/or newsprint
 Used for protective packaging or for food service trays and
beverage carriers. Other typical uses are end caps, trays, plates,
bowls and clamshell containers
 Typically moulded pulp is less expensive than expanded
polystyrene (EPS), vacuumed formed PET and PVC, corrugation,
and foams
 Thermoformed fibre is the highest quality of thin walled products
available today made in heated forming molds which presses and
densifies the molded products (e.g. www.paperfoam.com )
Drums, barrels, cans
 Drums, barrels and cans are made typically of steel, plastic or
aluminium widely used for foods and beverages but also for
products such as oil, chemicals, and other liquids
 Aluminium can (tin can) is produced over 180 billion pcs /year (2015)
and is recycled globally with rate around 70%
 Steel drums are cylindrical containers with a nominal capacity
of 200 litres (55 US or 44 imp gal)
 Some traditional types are replaced by Bag-in-Box (BiB) consists
of a strong bladder (plastic bag), usually made of several layers
of metallised film or other plastics, seated inside a corrugated box
Special Packaging
 Hazardous materials
 Medical packaging
 Li-on batteries
 Magnets
 ESD (electrostatic discharge) packaging
 Anti-Static (typically pink color)
 Dissipative
 Conductive (typically black color)
Labels & Printings
 Label is a piece of paper, polymer, cloth, metal, or other material
affixed to a container or product, on which is written or printed
information or symbols about the product or item. Information
printed directly on a container or article can also be considered
labeling
 Labels with QR codes
 RFID labels
 Industrial label printers (ZEBRA, Toshiba, CAB, VIP-Color)
 Printings e.g. manuals, installation instructions, leaflets
Other Packaging
 Standard Packaging (Catalogue products)
 Steel strapping band, PP/PET strapping band
 Adhesive tapes (pressure-sensitive tape, water activated
tape, heat sensitive tape)
 Void fill (foam, paper, air)
 Adhesives (natural or synthetic)
 Pouches (paper, plastic, with bubble foil)
 Etc.
Food Packaging
 Food safety is a scientific discipline describing handling,
preparation, and storage of food in ways that prevent foodborne
illness. This includes a number of routines that should be followed
to avoid potentially severe health hazards - (HACCP) Hazard
analysis and critical control points
 Special requirements
 Barrier protection
 Shelf life (unfit for use)
 Temperature and humidity
 Micro-organism interaction
 Interaction between food and packaging itself
 Legislation related to food packaging:
 Act 258/2000 Coll. (https://www.zakonyprolidi.cz/cs/2000-258 )
 Act 37/2001 Coll. (https://www.zakonyprolidi.cz/cs/2001-37 )
 Act 186/2003 Coll. (https://www.zakonyprolidi.cz/cs/2003-186 )
Packaging Logistcs
 Packaging Logistics - An approach which aims at developing
packages and packaging systems in order to support the logistical
process and to meet customer/user demands - Dominic et al. (2000)

Packaging Cost Trade-Offs with Other Logistics Activities (Lambert et al., 1998)
Packaging Logistcs Cont.
 Container utilization software – optimization depending
on type of packaging and its possibility to stack
 Proper packaging prevents damage
 Overseas shipments – special requirements resist
humidity (Silicagel, VpCi – Vapor Phase Corrosion
Inhibitor, MCI – Migrating Corrosion Inhibitor)
 Inflatable Cargo Bags - Prevent packages against
unwanted movement in containers during transit
 Air transportation requires special packaging resisting
temperature and pressure losses during transit
Truck Load Safety
 ČSN EN 12195 – Load restraining on road vehicles – Safety: design
of securing methods (blocking, lashing, and combinations) for
securing of loads for surface transport by road vehicles or parts of
them (lorries, trailers, containers and swap bodies), including
their transport on vessels or by rail and/or combinations thereof
 VDI 2700 - Securing of loads on road vehicles (German norm)
 Use antislip pads, sheets, paper to increase friction to
prevent package from movement on truck
Stretch Film (Stretch Wrap)
 Stretch wrap material is linear low-density polyethylene or LLDPE, which
is produced by copolymerization of ethylene with alpha-olefins, giving
rise to enhanced stretch film characteristics, particularly in respect of
elongation at break and puncture resistance
 Many films have about 500% stretch at break but are only stretched to
about 100 – 300% in use. Once stretched, the elastic recovery is used to
keep the load tight
 Films from 10 – 23 microns are used providing security of load on pallet
 Proper combination of stretch and thickness can be optimized
 Testing according EUMOS 40509-2012: Test method for load unit rigidity
Sustainable Packaging
 Sustainable Packaging is the development and use of packaging which results in
improved sustainability. This involves increased use of life cycle inventory (LCI)
and life cycle assessment (LCA) to help guide the use of packaging which
reduces the environmental impact and ecological footprint. It includes a look
at the whole of the supply chain: from basic function, to marketing, and then
through to end of life (LCA) and rebirth.
 Sustainable packaging:
A. Is beneficial, safe & healthy for individuals and communities throughout its life cycle
B. Meets market criteria for performance and cost
C. Is sourced, manufactured, transported, and recycled using renewable energy
D. Optimizes the use of renewable or recycled source materials
E. Is manufactured using clean production technologies and best practices
F. Is made from materials healthy throughout the life cycle
G. Is physically designed to optimize materials and energy
H. Is effectively recovered and utilized in biological and/or industrial closed loop cycles
Sustainable Packaging Cont.
Recycling of Packaging
Global Solid Waste Composition

Source: The World Bank - What a Waste: A Global

Review of Solid Waste Management (2012)
Recycling of Packaging Cont.

Source: European steel, glass and aluminium packaging associations,

CEPI 2012, European Association of Plastics Recycling and Recovery
Organisations
European and Czech Packaging Norms
 Directive 94/62/EC on Packaging and Packaging Waste
 Packaging Act 477/2001 Coll.
 Decree No. 116/2002 Coll. on marking returnable packaging
 Decree No. 641/2004 Coll. on the scope and manner of keeping
records of packaging and reporting the data from these records
 Government order No. 111/2002 Coll. specifying the amount of the
deposit on selected types of returnable packaging
 EKO-KOM (www.ekokom.cz)
 Ministry of the Environment of the Czech Republic:
http://www.mzp.cz/cz/obaly
 Food marking requirements:
 Act 110/1997 Coll. on food and tobacco products
 Decree No. 324/1997 Coll. on marking of food and tobacco products,
on allowed deviation from amount data of products marked with “e“
symbol
Future of Packaging
 Consumers and corporations are more focused on sustainable packaging
 Governments increase pressure for higher level of rycycling
 Biodegradable & Compostable packaging is developed based on various natural
materials, e.g. Starch (from Corn, Potatoes, etc.), Cellulose films, Casein films
 Biodegradability – capacity of a substance to be broken down by micro-organisms
(not set time scale)
 Compostability – a managed biodegradation process, through production of a
useful compost in a maximum period of 180 days. Conformity to agreed norm
required.
 Compostability norms – EU 13432, US ASTM D 6400
Literature
 Coles, R., Kirwan, M.J.: Food and Beverage Packaging Technology, Wiley, 2011. ISBN 978- 1-4051-
8910-1
 Fellows, P.: Food processing technology: principles and practice. Woodhead, Cambridge, 2nd. Ed.,
2000. ISBN 0-8493-0887-9
 Han, J.H.: Innovation in food packaging, Elsevier Academic Press, London, 2005. ISBN 0- 12-
311632-5
 Moskowitz, H.R., Reisner M., Lawlor, J.B., Deliza, R.: Packaging Research in Food Product Design
and Development, Wiley, 2009. ISBN 978-0-8138-1222-9
 Robertson, G.L.: Food packaging: principles and practice. 3rd Ed., Taylor & Francis, 2009. ISBN
978-1-4398-6241-4
 Robertson, G.L.: Food Packaging and Shelf Life; A Practical Guide. Taylor & Francis, 2009. ISBN
978-1-4200-7844-2
 Rooney, M.L.: Active food packaging. Blackie Academic & Professional, London, London, 1995.
ISBN 0-7514-0191-9
 Risch, S.J.: Food packaging: testing methods and applications, American Chemical Society, 2000.
ISBN 0-8412-36-17-8
 Štencl, J.: Balení potravin. Potravinářský zpravodaj 2/2004 – 4/2005, ročník V. a VI., AGRAL Praha
 DOBIÁŠ, J. - SMEJKALOVÁ, A.: Obaly a obalová technika, Praha, ES ČSU, 2004. ISBN 80-7157-161-X
 KAČEŇÁK, I.: Základy balenia potravín, Bratislava, ARM 333, 2001. ISBN 80-967945-6-6

 How it’s made Plastic Bags: https://www.youtube.com/watch?v=8CfL5xl2N1Q

 How it’s made Glass Bottles : https://www.youtube.com/watch?v=LUF_5zrFG9c