INTRODUCTION TO FOOD PACKAGING ○ Plastics

● In today’s society, packaging is pervasive and essential ■ Polyethylene was one of the first plastics used
● It surrounds, enhances and protects the good we buy, from widely for food packaging
processing and manufacturing, through handling and storage, ■ compressing ethylene gas and heating it to a
to the final consumer. high temperature
● Without packaging, materials handling would be a messy, ○ 1960s
inefficient, and costly exercise and modern consumer ■ over 25% of all bread sold was in plastic bags
marketing would be virtually impossible. made from LDPE (Low density polyethylene)
Historical Development of Food Packaging ○ Professor Giulio Natta
● Nomads ■ isotactic polypropylene
○ Era of nomadic lifestyle to staying in sheltered area ■ alignment of molecules improved the
● 7000 B.C characteristics of the films.
○ First evidence of pottery and glass ■ For overwrap snack foods
○ Industrialization of the process by the Egyptians was ○ Coextrusion
not seen until about 1500 B.C. ■ film with two or more layers of different types of
○ It is interesting to note that the primary materials used plastic can be made in one step
to make glass at that time, such as limestone, soda, ■ Multiple-layer films offer better protection for
sand, and silica, are the same materials that are used products as some films are better moisture
today barriers and others offer better barriers to
■ Similar to what are being used today apart from gasses.
other additives ■ Polyester film (good gas barrier) +
● Industrialization polypropylene and ethylene vinyl alcohol
○ Metal cans for snuff (moisture barrier) = Films that give protection
○ 1790s from both moisture and oxygen permeation
■ canning method, heat resistant ● Modern era
■ Nicolas Appert ○ Asia-Pacific will augment with the significant growth
● Paid by Napoleon Bonaparte for his rate in the packaging industry
soldiers ■ Major countries involved: India, China, Japan,
○ 1800s Thailand, South Korea, Australia, and Indonesia
■ Paperboard
● Used for primary food such as biscuits DEFINITION AND FUNCTIONS OF FOOD PACKAGING
and bread Packaging
○ 1890s ● involves the process of enclosing or protecting a product within
■ Crown cork for beverage industry a container to facilitate its distribution, identification, storage,
● Metal cap with cork promotion, and usage
■ First individually packed biscuit ● Primary functions:
● Post World War II ○ Protection and preservation
 ■ Biological Protection: ● Text and graphics serve the purpose of
● Purpose: Create a barrier against product and brand identification as well
microorganisms, insects, and animals, as product promotion.
preventing disease and spoilage. ■ Essential Data Included in Printing:
● Functions include preventing access, ● Includes crucial data such as a list of
odor transmission, and maintaining ingredients, nutritional information,
internal environment for food packaging. production date, sell-by date, price,
■ Chemical Protection: barcode, and traceability information.
● Purpose: Minimize compositional ■ Future Innovations:
changes due to environmental ● Temperature-Time Indicators:
influences (e.g., oxygen, moisture, light). ○ Potential future inclusion in
● Various packaging materials offer a packages of chilled foods.
chemical barrier. ○ Provides information on probable
■ Physical Protection: mishandling during storage and
● Purpose: Shield food from mechanical transportation.
damage during distribution. ○ Emergence of 'Intelligent
● Materials: Typically from paperboard Packages':
and corrugated materials. ○ Packages featuring
● Resists impacts, abrasions, and temperature-time indicators are
crushing damage. sometimes referred to as
● Commonly used as shipping containers 'intelligent packages.'
and for delicate foods (e.g., eggs, fresh ○ The color changes in the
fruits). indicator offer insights into
● Ensures consumer safety (e.g., potential issues during handling
child-resistant closures). and storage.
● Substitution of plastic packaging ○ Convenience
reduces danger from broken glass ■ Significant 'Selling' Attribute:
containers in various products (e.g., ● Convenience has been and remains a
shampoo, soda bottles). key selling point for foods
○ Containment ■ Adaptive Packaging Sizes:
■ Essential for efficient transportation, storage, ● Tailoring package sizes to cater to
and distribution of the product. specific consumer groups (family size,
■ Sealing and closure, structural integrity, and individual, special sizes for food service
leak prevention delivery).
○ Information and communication ■ Innovative Package Features:
■ Purpose of Printing:
 ● Pressurized packages (e.g., whipped
cream), aerosols (for coating, flavoring,
oiling, etc.).
● Easy-open and/or re-sealable packages.
● Packages designed to serve as heating
utensils or as plates, cups, bowls, etc
Levels of Packaging
● Primary Package
○ the packaging that comes into direct contact with the
product.
● Secondary Package
○ Used to group and protect primary packages during
storage and distribution
● Tertiary Package
○ Outermost packaging used for transportation and
handling in bulk
Types of Packaging Materials
● Glass
○ Drawbacks of Glass Packaging:
■ High Manufacturing Energy Requirement:
● Glass production demands significant
energy, resulting in a large carbon
footprint.
■ Elevated Production Cost:
● Glass production is costlier compared to
other materials.
■ Challenges in Shipping:
● Glass containers are prone to breakage
during transit, posing shipping
difficulties.
● Metal
○ Steel:
■ Commonly used for shipping large quantities
within industrial manufacturing.
■ Examples include steel drums and large
containers, often reusable.
■ Highly durable, designed to withstand harsh
handling, weather conditions, and heavy loads.
■ One of the most recycled materials globally,
with 70% of steel used in shipping being reused
○ Aluminum:
■ Versatile material used for cans, foil, and
aerosol products.
■ Highly resistant to corrosion and provides
excellent protection against light, UV rays, oils,
and oxygen.
■ Frequently used for packaging food and
medications due to its hygienic and nontoxic
properties.
■ Light and durable, can be used with laminates
to offer thin barrier protection, reducing material
usage and saving resources.
■ Approximately 65% of all aluminum is recycled
globally
● Paper and cardboard
○ Common Packaging Materials:
■ When thinking of packaging, boxes and bags
come to mind. Paper, paperboard, and
cardboard are widely used in stores and
shipping.
■ Benefits of Corrugated Cardboard:
● Corrugated cardboard provides
excellent structural stability for shipping,
storing, and marketing products.
● Its paper-based surface is easily
printable, allowing for seamless
branding integration into packaging.
■ Recyclability and Sustainability:
● Paper and cardboard are easily
recyclable, completely renewable, and
often reusable for
environmentally-conscious companies
and consumers.
 ■ Limitations of Paper-Based Packaging:
● While inexpensive, lightweight, and
flexible, paper-based materials are not
as sturdy as some alternatives.
● Despite this, they are easy to stack,
store, and collapse for recycling
● Plastic / Thermoplastics
○ Revolutionized packaging industry
○ Synthesized from oil, coal, and natural gas
○ Films have barrier properties against many gases,
lightweight, have good tensile strength, tear strength,
impact resistance and moisture resistance
○ films have thickness of <100 μm
○ Polyethylene (PE)
■ polymerized
■ most important widely used packaging material
■ good moisture and water barrier properties
■ good heat sealing characteristics and will retain
its flexibility at very low temperature (MP
120°C)
■ small bags, big bags for bulk packaging,
pouches and wrappings
■ Classifications:
● Low-density polyethylene (LDPE)
○ Has the ability of the polymer to
be moved around
○ Branched structure
● High-density polyethylene (HDPE)
○ Linear structure
○ Polypropylene (PP)
■ stiffer than PE and has better tensile strength
and higher transparency (MP 160°C)
■ low moisture permeability values
■ small and big bags and pouches, wrappings
and sacks
○ Polystyrene (PS)
■ from vinyl compound where a hydrogen atom is
replaced with a benzene (nonpolar) ring
● Too big that it disrupts structure; steric
hindrance
■ low barrier to moisture vapor and common
gasses
■ high transparency; rigid; has a deadfold
property
■ used as carton windows
○ Polyethylene terephthalate (PET)
■ polyesters, from the reaction of a carboxylic
acid (terephthalic acid) and an alcohol (ethylene
glycol)
■ clear, tough, and good barrier to gas and
moisture
■ when heated above 72°C changes from a rigid
glass-like
■ state into a rubbery elastic form used in
beverage, food, and other liquid containers
■ If cooled too quickly, material becomes
amorphous
● Depends on the processing
○ Ethylene vinyl alcohol (EVOH)
■ copolymer of ethylene and vinyl alcohol
■ high-barrier material with respect to oil, grease,
organic solvents and oxygen
■ moisture-sensitive
■ used in combination with other plastic films
○ Polyvinylidene chloride (PVdC)
■ from ethylene in which 2 hydrogen atoms are
replaced by chlorine atoms
■ excellent barrier to water vapor, gases, fatty
and oil products
■ used to protect flavor and aroma sensitive
foods
■ component in the packaging of cured meats,
cheese, and snack food.
 ○ Polyethylene naphthalene dicarboxylate (PEN) ■ Compatibility between nanomaterials and
■ polyester, made from ethylene glycol polymer matrices is a key challenge in
■ UV resistant and has higher temperature bionanocomposites.
resistance compared with PET ■ Ensuring the proper distribution of nanoparticles
■ very good oxygen barrier (bottling beverage) into the polymer matrix is crucial.
● Composite materials ○ Preparation of nanocomposites and improvement of
○ Bionanocomposites in Food Packaging: the barrier properties
■ Opportunity for novel, high-performance,
lightweight, and eco-friendly composite
materials.
■ Aim to replace traditional non-biodegradable
plastic packaging materials.
○ Role of Biopolymers:
■ Biopolymers such as chitosan, carboxymethyl
cellulose, starch, and cellophane address
environmental hazards due to biodegradability
and non-toxicity.
■ However, biopolymers may have poor
mechanical properties and low water
■
resistance.
Packaging Technologies
○ Integration of Nanomaterials:
● Vacuum Packaging
■ Nanomaterials (e.g., layered silicate nanoclays -
○ Control the amount of air in the headspace
montmorillonite, zinc oxide, titanium dioxide,
○ 2 Forms:
silver nanoparticles) enhance thermal,
■ Involving rigid or semi rigid package
mechanical, and gas barrier properties without
■ Involving flexible package
compromising biodegradability.
● Modified Atmosphere Packaging (MAP)
■ Improve barrier properties against oxygen,
○ Replaces air (usually O2) with N2 & CO2
carbon dioxide, and flavor compounds diffusion
○ Packaging that controls gas transmission
through packaging films
○ Controlling biochemical metabolism
○ Smart and Intelligent Properties:
○ Advantages
■ Nanomaterials offer smart and intelligent
■ Increased shelf-life
features in food packaging.
■ Reduction in retail waste
■ Examples include oxygen scavenging,
■ Improved presentation
antimicrobial activity, and indicating exposure to
■ Hygienic stackable pack, sealed and free from
harmful factors like oxygen levels or insufficient
product drip and odor
temperatures.
■ Little or no need for chemical preservatives
○ Challenges and Considerations:
 ■ Reduced transport costs due to less frequent
deliveries
■ Centralized packaging and portion control
■ Reduction in production and storage costs due
to better utilization of labor, space and
equipment
○ Disadvantages
■ Additional production cost (gases, packing
material)
■ Increased pack volume which will adversely
affect transport costs and retail display space
■ Benefits of MAP are lost once the pack is
opened or leaks
● Active and Intelligent Packaging
○ Active Packaging (AP)
■ incorporation of certain additives into packaging
film or within packaging containers
■ Biological sensors (biosensors)
■ Multi-layered moisture absorbent pad
● Applying moisture absorbing materials in
manufacturing of polymeric packaging
tray is a new approach for humidity
control
■ Antimicrobial packaging
○ Intelligent Packaging (IP)
■ sense and provide information about the
function and properties of packaged food
■ C2H4 gas indicator
● Releasing of C2H4 from the climacteric
fruits is an important phenomenon in
postharvest handle, ripeness and
senescence of these fruits which are
severely related to emission of the
ethylene gas.
■ proposed device application as a food
qualifying system
Film Packaging Testing
● Barrier Properties
○ Barrier properties are the resistance that a
package has to moisture, air, light,
microorganisms, puncturing
○ Gives an indication of the amount of protection
that is given to a food by a particular packaging
material
○ Flexible packaging materials have large
variations in their barrier properties
○ Factors that describe the barrier properties of
films
■ Water Vapor Transmission Rate (WVTR)
■ Oxygen Transmission Rate
● measure of how much water
vapor or oxygen can pass
through a known area of
packaging material in a given
time (amount passing through
one square meter of material in
24 hours)
● unit = g or ml/m2/24hr
■ States how much water or oxygen can
pass through the plastic film
■ There should be minimal passage
○ The higher the value of WVTR or OTR the more
permeable the material is to moisture or air
○ The lower the value the better the barrier to
moisture or air
■ Higher value means more permeable to
air
○ Permeability varies with the temperature and
humidity of the surrounding air
○ WVTR and OTR are measured under known air
conditions ( 25°C and 65% RH)
■ Mimics environment condition
 ●Quality Control for Film
○ Major faults
■ incorrect yield ( area per unit weight of
film), a measure of thickness of a film
● Divisions from a specified yield
that indicate variation
thickness affecting the film’s
performance
■ incorrect printing
● Can lead to misinformation and
affect visual appeal
■ odor
● Could indicate contamination
issues
■ blocking
● cause the film to be misaligned
● Can lead to operation issues
which results in damage of
package
○ Minor faults
■ Marks
● presence of blemishes on the
film
■ Dimensions
● Different size and shapes
■ Curl
● Tendency of film to bend
■ slip
● Ease of movement between
layers of film
GLASS CONTAINERS
● Glass has been defined by the ASTM (American Society for
Testing and Materials) (2010) as
○ “an amorphous, inorganic product of fusion that has
been cooled to a rigid condition without crystallizing.”
● often regarded as a synthetic material,
● formed naturally from common elements
○ (in the earth’s crust long before the world was
inhabited)
● Natural materials such as;
○ obsidian (from magma or molten igneous rock) and
○ tektites (from meteors) have compositions and
in ○ properties like those of synthetic glass;
● Pumice is a naturally occurring foam glass.
● Physical properties
○ Because of its amorphous structure, glass is brittle and
usually breaks because of an applied tensile stress.
○ It is widely accepted that fracture of glass originates at
small imperfections or flaws, the large majority of which
are found at the surface.
○ A bruise or contact with a hard object can generate
very small cracks or checks on the glass surface,
which might remain imperceptible to the naked eye.
● THERMAL PROPERTIES
○ The thermal strength of a glass container is a measure
of its ability to withstand sudden temperature change.
■ Subjected to pasteurization and sterilization
○ In the food industry, the behavior of glass with respect
to temperature is of major significance, because
relative to other forms of food packaging, glass has the
least resistance to temperature changes.
○ The resistance to thermal failure depends on the type
of glass employed, the shape of the container and the
wall thickness.
○ Thermal shock resistance cannot be calculated directly
because the strength of glass containers is greater
under momentary stress than under prolonged load.
○ empirical testing procedures are used:
■ ASTM C149 - determination of the relative
resistance of glass to thermal shock,
○ Intended to apply to all types of glass containers that
are required to withstand sudden temperature changes
(thermal shock) in service such as in washing,
pasteurization or “hot fill” processes, or in being
 transferred from a warmer to a colder medium or vice
versa.
○ Resistance to breaking is determined
■ by transferring glass containers which have
been totally immersed in a hot water bath
(typically at 63°C) for 5 min
■ to a cold-water bath (typically at 21°C) and
observing the number of breakages.
● OPTICAL PROPERTIES
○ Because glass has no crystalline structure, when it is
homogeneous and free from any stresses, it is optically
isotropic
○
■ Remain uniform across all directions from which
○ liquid products generally have
it is observed
■ small diameter finishes for easier pouring;
○ The optical properties of glass relate to the degree of
■ solid products require larger finishes for filling
penetration of light and the subsequent effect of that
and removing the contents. requirements,
transmission, transmission being a function of
consideration must also be given to the nature
wavelength.
and manner of labeling the container,
○ The spectral transmission of glass
○ As well as filling and emptying and its compatibility with
■ is determined by reflection at the glass surface
packaging and shipping systems.
and the optical absorption within the glass.
○ The container finish is the part of the container that
■ silicate glasses, transmission is limited by the
holds the cap or closure (i.e., the glass surrounding the
absorption of silica at approximately 150 nm in
opening in the container).
the UV and at 6000 nm in the IR region.
○ It must be compatible with the cap or closure and can
■ Iron impurities further reduce transmission in
be broadly classified by size (i.e., diameter), sealing
the UV and near-IR regions (Boyd et al., 1994).
method (e.g., twist cap, cork, etc.) and special features
● Glass container design
(e.g., snap cap, pour-out, etc.).
○ Has a critical role in preserving quality, freshness, and
integrity of the contents
Metal Containers
○ Most important: glass finish
● Cans were traditionally made from tin plate sheet, but now
■ Affect closure systems, seals, and shapes
more commonly aluminum is used (for drinks). The inside of
which can impact air tightness, protection from
the can is often sheet coated with lacquers to prevent the cans
light and prevention from contamination
rusting and reacting with the contents, especially acidic foods.
■ Others are just for product visibility, brand
○ Pure form of aluminum, and as metal alloys such as tin
identity, and transportation and storage
and steel plates
efficiency
 ○ Aluminum is lightweight, recyclable, and
corrosive-resistant
● The total world market for metal containers is estimated at 410
billion units per annum. Of this, drink cans account for 320
billion and processed food cans account for 75 billion. The
remainder are aerosol and general line cans.
● Drink cans may be divided into those for non-carbonated
drinks (liquid coffee, tea, sports drinks etc.) and carbonated
beverages (soft drinks and beer), many of which pass through
a pasteurization process.
● Five fundamental characteristics of metals make them
particularly feasible for packaging.
○ Compactness of the molecular structure and the
consequent high density
■ impossibility of diffusive phenomena (light,
vapour or gas) through very thin materials,
leading to ‘absolute barriers’
○ Tough
■ makes metal packages resistant against
possible stress and abuse
○ Malleability
■ the possibility of molding metals to reach almost
any shape
○ High thermal conductivity
■ makes feasible thermal treatments
(pasteurization, sterilization) on the closed
metal package to achieve the longest food shelf
lives
○ Easiness of a selective collection of the metallic waste
■ (due to magnetic behavior and high-density
values) and the opportunity of thermal recycling
without any loss of the original performances
● Efficient and sustainable
● Four metals are commonly used for the packaging of foods
○ steel, aluminum, tin and chromium.
● Sometimes, minor metals occur in metal packaging
construction (nickel, copper, titanium).
Types of Metal Cans
● Three-piece welded cans
○ only constructed from steel, as aluminium is not
suitable for welding by this particular process.
○ The cut sheets are then coated, and printed if
necessary, to protect and decorate the surfaces.
○ coatings and inks
■ Safeguard and enhance can surfaces
■ dried by passing the sheets through a thermally
heated oven where the temperature is in the
range 150–205°C.
○ Alternatively, for some non-food contact uses,
ultraviolet (UV)-sensitive materials may be applied.
■ These are cured instantaneously by passing the
wet coating/ink under a UV lamp.
○ Areas welded are left without coating to ensure
integrity
○ Three main parts:
■ The can body
● This cylinder corresponds to a coated
sheet.
○ After coating, this laminate (wall)
is rolled and the seam is welded.
● responsible for the total mechanical
resistance.
● resistance is improved with the creation
of several lines that are perpendicular to
the main axis of obtained cylinders.
○ Reduce tensions in stacked
pallets
● lines are not obligatory but can lighten
all expected tensions caused by the total
weight of superimposed containers into
final pallets.
■ Can ends: (top and bottom)
● Distinctive elements are several
concentric lines that have been obtained
 by pressure so that one end may be
considered as the hypothetical union of
‘expansion panels’.
● This stratagem makes possible the
extension by volumetric increase of the
whole can and consequent dilatation of
ends during pasteurization and
sterilization procedures. Expansion
panels are not compulsory.
● Can ends for mechanical double
seaming are constructed from
aluminum, tinplate or TFS.
● Aluminum and TFS are always coated
on both sides with organic lacquer or
film laminate whilst the metal is still in
coil or flat sheet form.
● Plain food can ends and shells for
food/drink easy-open ends
● Conversion of end shells into easy-open
ends
● weld uses less metal than an interlocked
○ Internal and outer coatings: All components (body and
ends) have to be coated with some particular
exceptions (general line cans, for vegetable oils), but
the coating processes are different and temporarily
extended until the forming and seaming steps.
○ Polyvinyl chloride (PVC) gaskets into ends: Indeed, top
and bottom ends cannot assure the hermetic seal of
the final can without this rubber product.
○ The correct seaming of the can body and ends:
■ This operation
● called double seaming
● is extremely important and is dependent
at least on the dimensions of flanges
and end curls.
■ Double-seaming is managed by can makers
(top ends) and FO (filler operator) (bottom ends
only).
○ The side seam:
■ This welding is electrically carried out on two
opposite sides of the coated laminate (wall).
■ It has to be highlighted that these sides are
partially uncovered so that two opposite and
equal areas (solder margins) are obtained.
■ In fact, these operations cannot be carried out
on coated surfaces.
■ The obtained side seam is coated with
thermosetting products (epoxy phenolic
coatings, white enamels) with to protect against
acid agents and other degrading effects.
■ As a result, the global thickness is not constant
in this area
○ Welded Side Seams
■ welding offers savings in cost, and
environmental impact
■ material, since the overlap needed to produce a
soldered seam.
■ The wire-welded operation used today for the
high-speed welding of tinplate and ECCS
containers utilizes a sine wave alternating
 current (and in the case of tinplate, a
continuous copper wire electrode)
● Allows efficient mass production
● Controlled welding systems results in
precise seams with consistent quality
across large volume of containers
■ to produce a weld with an extremely low
(0.4–0.8 mm) metal overlap (Turner, 2001).
○ Soldered Side Seams
■ Apart from some developing countries, very few
food cans are produced with soldered side
seams, the concern of public health authorities
being that lead from the tin/lead (2:98) solder
would migrate into the food.
■ Since the 1970s, most countries insisted that
only pure tin solder be used on cans intended
for baby foods, which added significantly to the
cost of such cans.
■ The use of tin/lead solder ceased when the
U.S. FDA issued a final rule in July 1995
prohibiting its use in food containers.
○ Double Seaming
■ After the side seam has been welded, the
bodies are transferred to a flanger for the final
metal forming operation:
● necking and flanging for beverage cans
● beading and flanging for food cans.
■ The can rim is flanged outward to enable ends
to be seamed on.
● Securely seam the ends
■ The top of beverage cans is necked to reduce
the overall diameter across the seamed end to
below that of the can body wall, yielding
savings in the cost of metal using smaller
diameter ends.
● Could result in cost saving
■ This allows more effective packing and stacking
methods to be adopted, and prevents damage
to the seams from rubbing against each other.
■ Simultaneous creation of the neck and flange
using a spin process is used.
■ Double-, triple- and quadruple neckings are
now quite common, the latter reducing the end
diameter from 68 to 54 mm for the common
beverage can.
■
○ Three-piece metal cans without body beads are
destined to the following uses:
■ Canned vegetables
● (peas, mushrooms, similar food
preparations, and so on) with different
weights and dimensions.
■ Canned sauces:
● Tomato juice, spicy recipes (paprika,
harissa and other Maghreb recipes, and
so on).
■ Salted snacks
● (peanuts, almonds, and so on).
■ Ready-to-eat products.
■ Meat-based foods
 ● (chopped pork, cooked ham, meat in
jelly, and so on).
■ Agicultural products.
■ Oriental recipes
● (surimi and other fish-based food
products such as soups of carps • and
soyabean, and so on).
■ Canned fish
● (tuna fish, salmon, crabmeat, and so
on).
■ Luxury brands
● (coffee and cocoa powders, and so on).
● Two-piece single drawn and multiple drawn (DRD) cans
○ Single:
■ Pre-coated, laminated and printed tinplate or
(tinfree steel) TFS is fed in sheet or coil form in
a reciprocating press that may have single or
multiple tools.
● This would result in single draw shapes
● with specific diameter and height
○ Multiple:
■ it may be re-drawn into a can of smaller
diameter and greater height to make a
draw–redraw can (DRD).
■ Allows further refinement of the can’s dimension
■ Provides specific structural characteristics
● Two-piece drawn and wall ironed (DWI) cans
○ The DWI cans are constructed from uncoated tinplate
or aluminum.
○ Sidewalls are ironed or stretched to achieve desired
dimension which results in thin sidewalls
○ DWI cans for processed food are only made from
tinplate as thin wall aluminum cans do not have
sufficient strength to withstand the heat process cycles.
Metal Can Container Design
● In can design, metal thickness is determined by the need for
physical performance in handling, processing and storage of
the filled container.
○ Optimal thickness should have balance between
integrity and avoiding unnecessary weight that could
compromise efficiency
● Surface area is determined by the volume contents and the
chosen shape of the container.
● For ease of manufacture, handling, filling a closing, most food
and drink cans have a circular cross section.
● However, for different physical performance, cost and product
uses, cans may vary from shallow (height less than the
diameter) to tall (height greater than the diameter).
Coatings, film laminates and inks
● Organic materials are used to provide barrier or decorative
coatings to metal containers and closures.
● These may be in the form of liquid applied coatings and inks or
film laminates.
● For functional barrier and decorative element
● three-piece cans, two-piece drawn containers and can ends,
○ The metal is coated and printed while it is flat, in coil or
sheet form, prior to the can or end forming operations.
○ In coil form
○ Ensure adhere well to the metal surface
● For two-piece drawn and wall-ironed containers
○ all coating and decoration is carried out after the can
body has been formed.
Protective Coating
● Container coatings provide a number of important basic
functions (Turner, 1998):
○ They protect the metal from the contents.
○ They avoid contamination of the product by metal ions
from the container.
 ○ They provide a basis for decoration and product
identification.
○ They form a barrier to external corrosion or abrasion.
○ 4–12 μm thick
○ dry film that is too thin may not cover the surface
completely,
○ while an overly thick film leads to brittleness and
impaired protection, as well as being uneconomical
○ and uronic acids, with the composition
Decorative Coating
● primary purpose in decorating the external surface of a metal
container is to improve its appearance and assist its
marketability,
● It also significantly improves the container’s external corrosion
resistance.
Paper and Paperboard
Paper
● Pulp is the fibrous raw material to produce paper, paperboard,
corrugated board and similar manufactured products.
● It is obtained from plant fiber and is therefore a renewable
resource.
● Paper derives its name from the reedy plant papyrus, which
the ancient Egyptians used to produce the world’s first writing
material by beating and pressing together thin layers of the
plant stem.
● Sources:
○ About 97% of the world’s paper and board is made
from wood
○ pulp and about 85% of the wood pulp used is from
spruces, firs and pines—coniferous trees that
predominate in the forests of the north temperate zone.
● Main Constituents of Wood Cell Wall
○ Cellulose.
■ This is a long-chain, linear polymer built up from
many glucose molecules (weight-average DP
3500 for native wood cellulose in situ) and is
the most abundant, naturally occurring organic
compound.
■ Backbone of paper
○ Hemicelluloses.
■ These are lower MW (weight-average DP 15)
mixed sugar polysaccharides consisting of one
or more of the following molecules:
● xylose, mannose, arabinose, galactose
differing from species to species.
○ The principal hemicelluloses are xylan in hardwoods
and glucomannon in softwoods.
○ Lignin
■ This is the natural binding constituent of the
cells of wood and plant stalks.
■ It is a highly branched, three-dimensional (3D),
alkyl aromatic, thermoplastic polymer of
uncertain size, built up largely from substituted
phenylpropane or propylbenzene units.
 ■ Hydroxyl or methoxyl groups are attached to
the benzene carbon atoms.
■ It has no fiber-forming properties and is
attacked by chlorine and sodium hydroxide with
formation of soluble, dark brown derivatives. It
softens at about 160°C.
Types of Paper
● Kraft Paper
○ Kraft paper is typically coarse with exceptional
strength, often made on a Fourdrinier machine and
then either machine-glazed on a Yankee dryer or
machine-finished on a colander.
○ It is sometimes made with no calendering so that when
it is converted into bags, the rough surface will prevent
them from sliding over one another when stacked on
pallets.
○ 70-80 g/sq. m.
○ strong paper that can be bleached white and printed or
unbleached (brown)
○ used in multiple layers or plies(3-4 plies)
○ laminated to polyethylene or wax treated for moisture
protection
○ used in 25-50 kg sacks for flour, sugar, dried fruits and
vegetables
○ Types of Kraft Paper:
■ Recycled Brown Kraft Paper
● brown kraft paper
● size: in sheets and in rolls
● Grams/paper quality:
○ 60gsm, 80gsm,100gsm
■ Bleached Kraft Paper
● The main use of this paper is for
manufacturing the sticker (self adhesive)
paper.
● available from 40 GSM to 140 GSM
■ Clay Coated Kraft Paper
● utilizes a clay coating to smooth out the
rough surface of a lower grade of paper
in order to improve coat-ability and
printability.
● colors such as white, yellow and blue
● ranging from 40 GSM to 200 GSM.
● Greaseproof Paper
○ Greaseproof paper is a translucent, machine-finished
paper which has been hydrated to give oil and grease
resistance.
○ Prolonged beating or mechanical refining is used to
fibrillate and break the cellulose fibers which absorb so
much water that they become superficially gelatinized
and sticky.
○ 40-60 g/sq. m.
○ made by beating fibers more thoroughly during the
manufacture of sulfite pulp
○ smaller fibers make a denser surface which are oil
resistant
○ used in fresh fish or meat, liner for packs of biscuits,
fats and other greasy foods
○ bleached / unbleached greaseproof paper
○ color:
■ White
■ Gray
■ blue
○ size:
■ in sheets 50x75cms,
■ in reels width 370mm-800mm
○ Paper quality, grams: 28-50gsm
● Glassine Paper
○ Glassine paper derives its name from its glassy,
smooth surface, high density and transparency.
○ It is produced by further treating greaseproof paper in a
supercalender, where it is carefully dampened with
water and run through a battery of steam-heated
rollers.
 ○ 20-40 g/sq. m. ● Wax-laminated - laminating wax onto
○ translucent sulfite paper the surface
○ high gloss water resistant when dry ■ Cooking and frying
○ liners for biscuits, cooking fats, and baked goods foods ■ Baking
○ translucent ■ Freezing food
○ Glassine paper is very thin and smooth and air and ■ piping
water resistant. It is translucent unless dyes are added ■ to cut on
to color it or make it opaque ○ Baking Paper
○ Can be transparent, resilient glazed paper ■ High tolerance to high temperature ensuring
● Vegetable Parchment reliable performance in baking applications
○ Vegetable parchment takes its name from its physical ■ siliconized baking paper baking paper, which is
similarity to animal parchment (vellum) which is made coated by silicone on double side or single side,
from animal skins. is used to bake bread etc. in the oven.
○ 40-75 g/sq. m. ● Silicon provides non-stick property
○ Kraft paper treated with acid for smoother surface and ■ Its features: good temperature, non-stick,
more resistance to oil and water multi-baking.
○ more greaseproof and greater wet strength than kraft ■ color: white and brown
○ no barrier to air or moisture and not heat sealable ■ size: in sheets or in small rolls
○ used for packaging butter or lard fresh/smoked fish ■ Grams:35-51gsm
○ Parchment bags are the best available way to ○ Tissue paper
microwave popcorn ; for butter ■ 25 g/sq. m.
● Other Types of Paper ■ thin weak sulfite paper
○ Waxed paper ■ wrapping fresh fruit
■ Waxed papers provide a barrier against ○ Meat soaker pad
penetration of liquids and vapors. Many base ■ meat soaker pad is composed of 100% natural
papers are suitable for waxing, including wood pulp and rayon fiber, with excellent
greaseproof and glassine papers. absorption capacity, lint free.
■ The major types are wet-waxed, dry-waxed and ■ The long fiber won’t break off, sticking onto
wax-laminated. Wax-sized papers, in which the food.
wax is added at the beater during the ■ The soaked liquid is usually 15-20 times the
papermaking process, have the least amount of weight of the soaker pad itself.
wax and therefore give the least amount of ■ size: in sheets and in small rolls
protection. ■ grams: 52gsm
● Wet waxed - application of wax is after ○ Acid free tissue paper
process ■ acid-free tissue paper should be used for
● Dry-waxed - applied after process after it storing heirloom garments and fibers, just the
is dried
 same way acid-free photo albums protect your
keepsake pictures from color change and decay
■ Manufactured with neutral pH thus preventing
acidic content items may carry
Quality Control for Papers
● Weight
○ weight of one square meter of paper measured in
grams
● Yield
○ area of paper and the number of packs that can be
made from a unit weight of paper or film (m2/kg)
● Surface formation
○ should be smooth and even without loose fibers or
other faults
● Folding endurance
○ important to papers used in twist wrapping
● Major defects
○ tears or stains in paper
○ incorrect surface preparation
○ excessively high or low yield
● Minor defects
○ creases
○ minor surface imperfections
○ minor color variations
Storage of Paper
● Sensitive to changes in temperature and humidity
● Stored without opening the outer wrapping
● Rolls should be stored upright
● Flat sheets should be stored on a firm, flat surface
● Should be kept off the ground
shapes; they are delivered in a collapsed state for erection at
the packaging point (Obolewicz, 2009).
● Beverage Cartons
Paperboard Grades
● Linerboard
○ board having at least two plies, the top layer being of
relatively better quality; usually made on a Fourdrinier
machine with 100% virgin pulp furnish
● Foodboard
○ board used for food packaging having a single-ply or
multi-ply construction, usually made from 100%
bleached virgin pulp furnish
● Folding boxboard
○ multi-ply board used to make folding boxes; middle
plies are made from mechanical pulp sandwiched
between two layers of virgin chemical pulp
● Chipboard
○ multi-ply board made from 100% recovered
(secondary) fiber
● Baseboard
○ board that will ultimately be coated or covered
● Molded Pulp Containers
○ The term “molded pulp” is used to describe 3D
packaging and food service articles that are
manufactured from an aqueous slurry of cellulosic
fibers and formed into discrete products on screened
molds (Waldman, 2009).
○ Typically, the raw materials consist of virgin mechanical
and chemical wood pulp, and waste paper pulps with
or without the addition of the former materials.

Paperboard Products
● Folding cartons are containers made from sheets of
paperboard (typically with thicknesses between 300 and 1100
μm) which have been cut and scored for bending into desired