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TABLE OF CONTENTS1

UNIT ONE PERSPECTIVE ON PACKAGING1

Lesson 1 A History of Packaging…………………………………………………………………1What is Packaging?………………………………………………………………………………1Primitive Packaging2

From Rome to the Renaissance3

The Industrial Revolution5

The Evolution of New Packaging Roles6

Packaging in the Late 20th Century7

Modern Packaging8

Laminating Processes 112

Waste Management and Environmental Issues ………………………………………………11The Modern Packaging Industry15

Introduction17

Lesson 2 Packaging Functions17

The Contain Function18

The Protect/Preserve Function19

Food Preservation19

The Transport Function31

The Inform/Sell Function31

Representative Papermaking Machines33

Introduction33

Lesson 3 Paper and Paperboard33

UNIT TWO PACKAGING MATERIALS AND CONTAINERS33

Machine Direction and Cross Direction36

Surface or Dry-End,Treatments and Coatings37

Paper Characterization38

Paper Types ……………………………………………………………………………………40Paperboard Grades42

Paperboard Cartons43

Lesson 4 Corrugated Fiberboard Boxes46

Historical Perspective46

Corrugated Board47

Properties and Tests52

Corrugated Boxes55

Carrier Rules58

Stacking and Compression60

Lesson 5 Metal Containers64

Background64

Common Metal Container Shapes65

Three-Piece Steel Cans67

Two-Piece Cans69

Impact Extrusion71

Aerosols73

Lesson 6 Glass Containers75

Glass Types and General Properties75

Bottle Manufacture77

Bottle Design Features80

Lesson 7 Plastics in Packaging83

Introduction to Plastics83

Extrusion87

Injection Molding91

Extrusion Blow Molding92

Injection Blow Molding93

Thermoforming94

Other Forming Methods96

Recognizing Molding Methods97

Lesson 8 Flexible Packaging Laminates98

Laminates98

Aluminum Foil99

Vacuum Metallizing101

Other Inorganic Coating103

Laminate Structural and Physical Properties104

Flexible Bags,Pouches and Sachets106

Sealability109

Barrier Properties110

Specifying Laminates116

Examples of Laminates116

Color Perception118

Introduction118

Lesson 9 Color118

UNIT THREE PACKAGE PRINTING AND DECORATING118

Color Terminology119

Viewing Color120

Lesson 10 Graphic Design in Packaging121

Introduction121

Demographics and Psychographics121

The Retail Environment122

Fundamental Messages123

Equity and Brand Names126

Graphic Design Basics127

Typography127

Lesson 11 Package Printing128

Introduction128

Printing Methods129

Relief Printing130

Lithography134

Gravure Printing136

Comparing Flexography,Lithography and Gravure137

Other Package Decoration Techniques138

Printing Inks141

UNIT FOUR PACKAGING DYNAMICS AND DISTRIBUTION PACKAGING143

Lesson 12 Shock,Vibration and Compression143

Shock143

Quantifying Shock Fragility146

Cushioning Against Shock149

Vibration151

Compression155

Estimating Required Compression Strength161

Lesson 13 Mechanical Shock Theory162

Introduction162

The Free Falling Package162

Mechanical Shock Theory164

Shock Duration167

Shock Amplification and the Critical Element168

Lesson 14 Test Method for Product Fragility170

Shock:Damage Boundary170

Vibration:Resonance Search ＆ Dwell174

Lesson 15 Seven Steps for Cushioned Package Development175

Introduction175

Step 1 Determine Product Fragility176

Step 2 Determine Conditions177

Step 3 Calculate Cushion Requirements177

Step 4 Recognizing Design Constraints180

Step 5 Design Prototypes and Test182

Step 6 Consider Vibration Effects182

Short History of Distribution Packaging in the USA184

Lesson 16 Distribution Packaging184

Step 7 Monitor Performance If it works,question it184

Functions and Goals of Distribution Packaging185

The Cost of Packaging185

The Package Design Process186

Taking a Total System Approach to Package Design186

The 10-Step Process of Distribution Packaging Design189

A Final Check191

Package Design Project Checklist191

The Warehouse192

Unit Loads193

Lesson 17 Computer Aided Packaging System196

Introduction to TOPS Pro196

Using TOPS Pro199

UNIT FIVE PACKAGING MACHINERY205

Lesson 18 General Overview205

Automated Production205

The New Production Line206

Speed208

Changeovers209

Straight-Line and Rotary Systems209

Machine Controls211

Developing Custom Machinery212

Upgrading Existing Equipment212

Lesson 19 The Packaging Line212

The Packaging Line213

Line Organization213

Packaging Materials214

Machine Capabilities214

Material and Container Characteristics215

Line Balancing215

Personnel216

Lesson 20 Filling Systems216

Introduction216

Liquid Filling218

Dry Product Filling232

Resources245

Glossary of Packaging Terms246