El 15: Fundamentals of

Packaging

Packaging is best described as a coordinated system of preparing goods for transport,

distribution, storage, retailing, and use. It is a complex, dynamic, scientific, artistic, and
controversial business function, which in its most fundamental form contains, protects/
preserves, transports, and informs/sells. Packaging is a service function that cannot exist
by itself; it needs a product. If there is no product, there is no need for a package.
Packaging also is the technology of enclosing or protecting products for distribution,
storage, sale, and use. It refers to the process of design, evaluation, and production
packages. All products made of any materials of any nature to be used for the
containment, protection, handling, delivery and preservation of goods from the producer
to the user or consumer.
The importance of packaging can be summarized as follows.

If adequately packaged, the shelf-life of local surpluses of food may be extended,

and this allows the food to be distributed to other areas. In doing so, consumers
are given more choice in terms of food available, food resources can be more
equitably distributed, and rural producers may be able to generate income from
surplus produce.
Correct packaging prevents any wastage (such as leakage or deterioration) which
may occur during transportation and distribution.
Good packaging and presentation encourages consumers to buy products.

Packaging should provide the correct environmental conditions for food starting from the
time food is packed through to its consumption. A good package should therefore
perform the following functional purposes:
it should provide a barrier against dirt and other contaminants thus keeping the
product clean
it should prevent losses. For example, packages should be securely closed to
prevent leakage
it should protect food against physical and chemical damage. For example the
harmful effects of air, light, insects, and rodents. Each product will have its own
needs
the package design should provide protection and convenience in handling and
transport during distribution and marketing

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El 15: Fundamentals of
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it should help the customers to identify the food and instruct them how to use it
correctly
it should persuade the consumer to purchase the food.

HISTORY OF PACKAGING
Packaging as we know today is the result of a long development process. The very first
people to roam the earth, back in depths of prehistory, sought to conserve the surplus
food collected during hunting, fishing and food-gathering for the longest possible time, to
be prepares for any future food shortages. In the middles age, wooden barrels became
the most frequently used way of preserving goods. They were used for storing all kinds
of solids and liquids, protecting them from light, heat and dampness.
EARLIEST PACKAGING

TINNING
The use of tinplate for packaging dates back to the 18th century
The manufacture of tinplate was long a monopoly of Bohemia
1667 Andrew Yarranton, an English Engineer, & Ambros Crowley brought
the method to England where it was improved by ironmasters including Philip
Foley
1697 John Hanbury had a rolling mill at Pontypool for making Pontypoole
Plates. The method of rolling iron plates by means of cylinders pioneered
there, enabled more uniform black plates to be produced than was possible
with the old plan of hammering.
1725 Tinplate boxes first began to be sold from ports in the Bristol Channel.
The tinplate was shipped from Newport, Monmouthshire.
1805 80,000 boxes were made and 50,000 exported.
Tobacconists in London began packaging snuff in metal-plated canisters.
CANNING
1810 discovery of the importance of air tight containers for food
preservation by French inventor Nicholas Appert, the tin canning process was
patented by British merchant Peter Durand.
1812 Durand sold his patent to two other Englishmen, Bryan Donkin and
John Hall, who refined the process and product, and set up the worlds first
commercial canning factory on Southwark Park Road, London.
1813 they were producing the first canned goods for the Royal Navy
1855 invention of the can opener
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Robert Yeates, a cutlery and surgical instrument maker of Trafalgar Place

West, Hackney Road, Middlesex, UK, devised a claw ended can opener with a
hand-operated too that haggled its way around the top of metal cans.
1858 - another lever-type opener of a more complex shape was patented in
the United States by Ezra Warner of Waterbury, Connecticut.
PAPER-BASED PACKAGING
16th century Set-up boxes were first used
1839 modern folding cartons
1817 first corrugated box was produced commercially in England
Corrugated (also called pleated) paper received a British patent and was
used as a liner for tall hats.
1890 the Scottish-born Robert Gair invented the pre-cut paperboard box flat pieces manufactured in bulk that folded into boxes Gair's invention came
about as a result of an accident: as a Brooklyn printer and paper-bag maker
during the 1870s, he was once printing an order of seed bags, and the metal
ruler, normally used to crease bags, shifted in position and cut them. Gair
discovered that by cutting and creasing in one operation he could make prefabricated paperboard boxes
1844 - Commercial paper bags were first manufactured in Bristol, England
1852 - American Francis Wolle patented a machine for automated bagmaking
th
20 CENTURY PACKAGING
Packaging advancements in the early 20th century included Bakelite closures
on bottles, transparent cellophane overwraps and panels on cartons,
increased processing efficiency and improved food safety.
As additional materials such as aluminum and several types of plastic were
developed, they were incorporated into packages to improve performance
and functionality
1952 Michigan State University became the first university in the world to
offer a degree in Packaging Engineering.
1920 - Invention of transparent cellophane marked the beginning of the era
of plastic. Polyethylene was the first plastic used for packaging and was
discovered in 1933 by mistake. Aluminium foil made it possible to effectively
seal medications and other sensitive products.
1940 - packaging was developed for frozen foods
1952 - aerosol came into the market. Cans, available from the 1960s,
heralded the expansion of the soft drinks market.
1961 - Aseptic cartons were invented and used for preserving long-life milk

INDUSTRIAL REVOLUTION
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El 15: Fundamentals of
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Began in England in the late 17th century

The shift from individual crafts at home or in small groups to mass production in
factories brought large-scale migration of workers and their families to towns and
cities.
Foods and basic commodities previously produced and readily available at home,
now had to be transported to shop in the cities to be brought by the workers using
their hard-earned wages.
This increased the demand for barrels, boxes and bags to bring in supplies on a
larger scale and it also brought a need to supply goods in small quantities now
demanded by the workers.
Goods were often measured out into the purchasers own container, but gradually
this was changed to the shopkeeper pre-packing items such as medicines,
cosmetics and tea, and having them available for sale in measured quantities, thus
offering the buyer some assurance as to the quality and quantity of the goods.
Eventually this pre-packing moved back a further stage from the buyer, to the
situation where most goods are packed at the point of production rather than sale.
19th century - started the rise of the brand name used as a mark of quality by
producers who wanted to make sure the buyer knew which product they were
buying and were not misled by inferior goods.
Some of the oldest brand names:
Schweppes (1972)
Perrier (1863)
Quaker (1901)

MODERN PACKAGING

The move from packing goods at the point of sale to packing at the point of
production brought about a shift from bulk to consumer packs, which had to
survive the journey not just from the shop to home, but, more importantly, from
factory to shop.
It also gave producers the opportunity to develop their own style of packs to
promote their own products, and this has brought us the modern-day pack.
Now, having a range of goods to choose from, packaging helps the consumers
differentiate between the options available from various companies.
Now, consumers expect products to be free from damage, and in the case of
foodstuffs, wholesome and safe through packaging.
Brand owners now expend their resources in developing packs which attract the
attention of the would-be purchaser and at the same time provide the product with
the protection needed.

LIFESTYLE CHANGES AND THEIR IMPACT ON PACKAGING

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Reduction in the size of the family unit, due to decreased birth rates, increased
number of one-parent families and increased longevity. This means a requirement
for smaller packs, thus more packaging per kilogram of goods.
Growth in the number of households in which all adults are in either full-or-parttime work, outside of the home. This means less formal meals where everyone sits
down together; meals are required at different times, and with minimum
preparation.
This brings a higher than ever consumer demand for convenience in terms of
portion size and food which can be made ready-to-eat at short notice. Ready meals
and packaging formats in which they are presented to make a key contribution to
meeting this demand.
Growth in ownership of domestics appliances such as the fridge and freezer has
allowed consumers to buy larger quantities of fresh goods, which are expected to
remain in good condition for prolonged periods of time. The development of a low
cost domestic microwave oven brought with it a requirement for microwavesuitable packaging.

BUSINESS DEVELOPMENTS: Effects of Globalization and Modern Retailing

The growth of modern supermarket brings a highly competitive retail environment,
with different versions of brands of the same product all displayed together. The timepressed shopper relies on the subliminal cues of the packaging to make a selection,
usually based on almost instant recognition of familiar features such as colour, graphics
or shape.
The globalization of manufacturing, with products being shipped over long
distances and through different climatic conditions places strong emphasis on packaging
to provide protection against likely hazards.
Modern supermarkets demand fast stock replenishment with a minimum manual
effort. This has brought the requirement of secondary packs which can double up as
shelf ready display packs, with no handling of the individual primary packs.
Marks & Spencer first company to introduce this concept in 1970s. The
straight-on-tray, as it was then called, was initially used for food, and then
extended to other goods such as toiletries.
Modern supermarkets also demand rapid service at the checkout, and here the
ubiquitous bar code provides a quick and reliable means of identifying the product and
its price. Importantly, this data is also used for stock control purposes, often linked to
automatic ordering to replenish supplies.
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El 15: Fundamentals of
Packaging

PACKAGING MATERIALS: Usage & Development

Around 70% of packaging is used for food and drink, but other sectors such as
healthcare, beauty products, chemicals, clothing, electrical and electronic equipment all
need packaging to ensure they stay in an acceptable condition from manufacturer to
consumer.
Todays global packaging industry is valued at over $400 billion, roughly broken down
into:

36% - paper and board (corrugated boards)

34% - plastics
17% - metals (steel and aluminum)
10% - glass
Others wood and textiles
Glass probably the oldest in its use as a packaging medium dating back to its
use for hollow vessels in about 1500 BC. Made by layering molten glass around
a sand core and then removing the sand once the glass had cooled and
solidified.
Glass Blowing started to develop around the first century BC and brought
with it the ability to make glass containers of different shapes and sizes, as a
formability of molten glass was exploited.
Examples: beers, wines and spirits, perfumes and some pharmaceuticals
Metal packaging reported to date back to Napoleonic times and the
development of metal containers for food has gone hand-in-hand with the
introduction and development of food sterilization systems such as those used
in canning.
Steel continues to be used for heat-sterilized cans for food and drink and for
large containers such as drums and immediate bulk containers (IBCs).
Aluminum first used for cans in the 1950s and today is widely used for drink
cans, especially for carbonated soft drinks.
Papermaking date back to China in the second century AD and originally
used woven strips of wet papyrus, laid down by hand and then dried.
Papermaking machinery developments in the 19th century brought the ability
to build up layers of cellulose fibers (initially obtained from rags and from trees)
into a continuous web, thus allowing a wide range of materials of different
thicknesses and performance to be made.
Plastic packaging since 1940s
o has seen the most significant growth since then, of all the packaging
materials, due to the development of low-cost processes and materials

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with a wide range of different properties and the ability to tailor those
properties to suit a range of different needs.
o plastics have replaced the more traditional materials such as glass and
metal in some applications, such as:
the change from glass to polyethylene terephthalate (PET)
containers for bottled water and soft drinks
the change from glass to high-density polyethylene (HDPE)
containers for milk
the change from metal cans to flexible plastics pouches for
pet foods, soups and sauces
But still, some notable brands of bottled water retain glass for
its high-quality image and the vast majority of canned foods
remain in the traditional food can.
Advantages of Plastics:
o Brought reduction in pack weight, often with associated reductions in
the total cost of the packed products
o Another significant packaging development relying on plastics is a reelformed carton typified by the Tetra Pack and Combibloc containers.
Wood - has been used for barrels for bulk products such as butter, and is still
used for crates and boxes for fresh produce and for heavy engineering items
such as machinery parts. The most significant use of wood in packaging is
probably in the form of pallets, still the most common way of moving goods
from manufacture to seller
Other materials used in packaging include cork (wine bottles, albeit challenged
by plastics) and textiles such as jute, used for sacks and bags. Jute sacks are
used for agricultural products, due to their breathability, and for commodity
food products such as sugar and rice.
Jute bags are available as shopping bags and gift bags, often by companies
wanting to project a green image by using this natural fibre

SOME EXAMPLES OF PACKAGING INNOVATIONS

COCA COLA
1894 - Mississippi shop owner Joseph Biedenharn bottled Coca-Cola in a common glass
bottle called a Hutchinson after he was impressed by its sales.
1916 - Birth of the contour bottle so its not easily confused with copycat brands.
1923 Six packs were introduced to encourage people to take their drinks home and
were a huge hit.
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1955 Packaging innovations shops started selling Coca cola in various sizes including
larger 10, 12 and 26 ounce versions.
1960 Trademark no.1 for the contour bottle with the word Coca Cola.
2009 With a going green wave Coca Cola launched the innovative plat bottle in the US
made of completely recyclable PET with 30% plant material and in 2011 the
concept went global

HEINZ
-Henry J. Heinz began packing foodstuffs on a small scale at Sharpsburg, Pennsylvania
-1869 Henry sold horseradish in a cart from his mothers garden.
-Henry Heinz went around selling his ketchup and was the first person to come up with
an idea of having cardboard spoon packed in the box.
-Heinz in 2013 was worth 23BLN

TYPES OF PACKAGING
Consumer Packaging
-Designed for consumer convenience and appeal, marketing consideration
display. The main emphasis is on marketing.
Industrial Packaging
-Focuses on the handling convenience and protection during transportation.
The main emphasis is on logistics.
CATEGORIES OF PACKAGING
Primary packaging
Surrounds the product and features labelling
Primary or sales packaging forms a sales unit for the user or final consumer
It includes also the packaging which surrounds the product when the
consumer takes it home
Examples:
Individual bags, plastic bags, eco-bags, paper bags

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Secondary packaging
Box or crate into which a number/group packs of primary packages are
placed for ease of manual movement of product.
Some secondary packaging also used to display products
Examples:
Shrinkwrap film, Thermoformed Plastic Trays
Transit/Tertiary packaging
The base pallet, strapping or wrapping used to bundle/collate the boxes or
crates for transport and distribution
Examples:
Roll Cages
Shipping Containers
Transit packaged products are placed in shipping containers for long-distance
transportation and distribution.
Examples:
Cargo Trucks, Closed Vans.
ENVIRONMENTAL PERSPECTIVE: Responsible Use of Resources
Packaging has attracted criticism as a squanderer of valuable resources and an
environmental pollutant.
Packaging and waste

Every year, more than 10 million tonnes of packaging are used.

Many materials used for packaging cannot easily be recycled, and others became
contaminated by food residues and cannot be recycled.
Bottle manufacturers have redesigned milk bottles to be 65% lighter. This uses less
glass and makes the product lighter and less expensive to transport.
Manufacturers have redesigned steel cans to be 61% lighter, saving metals and
making the product lighter and less expensive to transport.

SUSTAINABILITY is the goal of maintaining a human society over time in ways that
are fair and just for all people and do not damage the environment and its biodiversity.
SUSTAINABLE DEVELOPMENT
a plan for the development of communities that balances the importance of a
vibrant economy and sustainability
the 3 elements of sustainable development the environment, society and the
economy are competing interests.
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SUSTAINABLE COMMUNITIES - places where people lead lines of quality and dignity
without damaging the ecological system.
UNEP United Nations Environment and Development Programme . Human being
is central to its efforts to promote sustainable development
WEAK SUSTAINABILITY
This model accepts that many aspects of development serve the economy, society,
or the environment alone.
It suggests that technology can be a substitute for a damaged environment.
STRONG SUSTAINABILITY
The environmental element of sustainable development is viewed as the common
ground where the society and the economy interact and develop.
Development cannot damage the environment; a healthy environment is
fundamental to a just and fair society and a vibrant economy now and in the
future.
OUR PART AS ENGINEERS
Engineers play a crucial role in improving living standards throughout
the world. As a result, engineers can have a significant impact on
progress towards sustainable development

World Federation of Engineering Organization (2002)

We cant solve problems by using the same kind of thinking we used

when we created them

Albert Einstein

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ONE PLANET LIVING

10 principles for one planet living that designers can use to plan places and products
that promote sustainable development:
1. Zero Carbon
The activity must produce net zero carbon dioxide emissions. Net zero
means that the activity produces no carbon dioxide, or takes measures to remove
the carbon dioxide it produces.
2. Zero Waste
All materials must be used cleanly and recycled cleanly in a continuous
cycle; or they must be composted to re-enter ecological cycles.
3. Sustainable Transport
The movement of materials and products must be done in ways that are
good for people and the environment.
4. Local & Sustainable Materials
Meet consumer demands by using materials that are locally sourced and use
locally available technologies for recycling and reuse.
5. Local & Sustainable Food
Promote and consumes foods that support regional agriculture and food
industries, and minimize their use of non-renewable natural resources in the form
of fossil fuels used for transport and fertilizers.
6. Sustainable Water
Water use that promote human health and prevents water pollution,
depletion of fresh water, and harm o aquatic and marine ecosystems.
7. Natural Habitats and Wildlife

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The harvesting or mining of natural resources, and the construction of

transport routes, factories, warehouses and retail centers should not damage or
degrade natural habitats or harm wildlife.
8. Culture & Heritage
Economic activities should honor and protect the culture and heritage of the
communities they affect, and local knowledge should be used to make decisions.
9. Equity & Trade Fair
Everyone involved in the development, distribution, sales and recycling of
products must be treated and paid fairly and have opportunities for a dignified life.
10.
Health & Happiness
Beyond the consumption of goods and services to meet basic human needs,
there is no correlation between consumption (wealth) and happiness.
DESIGNING FOR SUSTAINABILITY
Designing for Weak Sustainability
Consider the economic, social and environmental strengths and weaknesses
of their designs, but compromise to minimize potential environmental harm.
Designing for Strong Sustainability
Consider the economic, social and environmental strengths and weaknesses
of their designs, but do not compromise and achieve environmental protection as a
design priority.
CYCLIC SOLAR-SAFE DESIGN CRITERIA
Practical design criteria for judging the strengths and weaknesses of a designs
sustainability were developed by Edwin Datschefski in 1998.
1. CYCLIC the product must be made from organic materials that can be recycled
or composted repeatedly.
2. SOLAR the product must use solar or other renewable energy throughout its
development, distribution, use and recycling.
3. SAFE the product must be nontoxic to humans and other organisms, and no toxic
chemicals can be used in manufacturing or recycling.
4. EFFICIENT the production and use of the product should require 90% less
material, energy and water compared to similar products manufactured before
1990.
5. SOCIAL the product and its development and manufacture must not jeopardize
the rights, health or livelihood of individuals or communities.
SUSTAINABLE PACKAGING

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Sustainable packaging is packaging that is functional, cost effective and meets

sustainability principles or design criteria
PRECAUTIONARY PRINCIPLE
This is an obligation for designers to prove that a product, through its manufacture,
use or disposal poses no negative consequences for people or the environment.
STRATEGIES FOR SUSTAINABLE PACKAGING
1. Manufacture with renewable and compostable materials
Examples:
o Bioplastics made from corn, potato, wheat, or dairy polymers
o Paper and cardboard from sustainable managed forests
o Cellulose film
2. Manufacture with recycled and recyclable materials
Examples:
o Paper and cardboard made from recycled fiber or moulded pulp
o Recycled and recyclable plastics like HDPE and PET
3. Design for Reuse
Examples:
o Reusable and recyclable crates and pallets
o Re-sealable plastic containers
o Return system for customer refills
4. Design for recycling
Examples:
o Packaging made from a single material (including labels and closure system)
o Packaging made from materials that are commonly collected for recycling
o Packaging with prominent recycling symbols
5. Eliminate inks, paints and adhesives that are toxic
Examples:
o Print with inks that do not contain toxic compounds (volatile organic
compounds VOCs)
o Use paints and inks that do not contain heavy metals or other toxic
compounds
o Use adhesives that do not contain toxic compounds
6. Eliminate secondary packaging
Example:
o Use only primary packaging and transit packaging
7. Reduce the volume of the materials used
Examples:
o Inflatable pouches to fill package voids
o Refills in pouches
o Lightweight bottles and cans
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