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TABLE OF CONTENTS 1

UNIT ONE PERSPECTIVE ON PACKAGING 1

Lesson 1 A History of Packaging…………………………………………………………………1What is Packaging?………………………………………………………………………………1Primitive 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 ………………………………………………11The 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 ……………………………………………………………………………………40Paperboard 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