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8/13/2019 Dic Kerala Session 03 Pkg Mats 1 Paper & Glass Metals
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SCOPE
PACKAGING MATERIALS
PACKAGING FORMS
SIGNIFICANCE OF PACK FORMS
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WHAT DOES THESE TWO PICTURES REPRESENT?
WOMENS TWO FORMS OF DRESSES
SAREE SALWAR KAMEEZ
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WHAT DOES THESE TWO PICTURES REPRESENT?
MENS TWO FORMS OF PROTECTIVE CLOTHING
SWEATER JACKET
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WHAT DOES THESE TWO PICTURES REPRESENT?
MENS TWO FORMS OF WEAR
DHOTI TROUSERS
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HENCE
DIFFERENTFORMS ARE
POSSIBLE
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WHAT DOES THESE TWO PICTURES REPRESENT?
TWO FORMS OF SNACKS
IDLI DOSA
THIS IS DIFFERENT FROM THE EARLIER
FORMS. THERE THE FORM AND THEMATERIAL WERE DIFFERENT.
HERE TWO FORMS ARE FROM THE SAMEMATERIAL
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SUMMARY
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HENCE FOR A PARTICULAR FUNCTION DIFFERENTFORMS ARE POSSIBLE AND USED
THIS CAN BE FROM THE DIFFERENT MATERIAL OR SAME
MATERIAL.
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MATERIALS VARY DEPENDING UPON NEEDCOTTON IS USED FOR NORMAL USE
SILK IS USED FOR SPECIAL OCCASIONS
FORMS & MATERIALS
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MATERIALS VARY DEPENDING UPON NEEDONE IS CASUAL WEAR
OTHER IS PARTY WEAR
FORMS & MATERIALS
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SUMMARY
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HENCE MATERIAL & FORMS ARE DIFFERENT
YOU CHOOSE FORMS AND MATERIALS DEPENDINGUPON NEED, CHOICE AND AVAILABILITY ETC.
OUR DRESS COVERS AND PROTECTS OUR BODYTHUS IT IS THE PACKAGING FOR OUR BODY.
PACKAGING ALSO COVERS AND PROTECTS PRODUCT.
HENCE THE SAME HOLDS GOOD FOR PACKAGING.
YOU CHOOSE PACKAGING FORMS AND MATERIALSDEPENDING UPON NEED, CHOICE AND AVAILABILITY.THE NEEDS COULD BE PRODUCT, MARKETING, COST,
AVAILABILITY ETC.
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PACKAGING MATERIALS
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PLASTICS
RIGID FLEXIBLE
PLASTICS
RIGID FLEXIBLE
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LET US SEE HOW PRODUCTCHOSES ITS OWN PACKAGING
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PACK SIZE, SHAPE & DESIGNCONSUMER PERCEPTION
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Needs of market segments
Represent different usage situations
Gain more shelf space in retail outlets
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DESIGN & SHAPE HINTS
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Unusual shapes draw greater attention Horizontal (calmness), Vertical (strength), Slanted
lines (upward movement) Curving lines(femininity), Sharp lines(masculinity)
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USE OF COLOUR
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Express people emotions
Add elegance, prestige to products by using polishedreflective surface
Meaning of color varies from culture to culture
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The Use of Color: Red
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RED:DepictsColor of fire and blood:
Associated with energy,Danger.High visibility - stop signs.Stimulates quick decisionsPromots energy drinks.
PINK: romance, love, friendship,denotes feminine.
Red, Pink
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Pleasant, cheerfulfeelings.When overused, has adisturbing effect;A warming effect.
Associated with food.For children's products.Catches attentionFor highlighting.Yellow is seen before other
colors
The Use of Color: YellowYellow
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ORANGE:Combines energy of Red &happiness of yellow.Denotes Sacrifice,happiness,
success,victory.Has very high visibility.
GOLD:prestige.
Gold representsillumination, wisdom,wealth, richness.Symbolizes high quality.
The Use of Color: OrangeOrange & Gold
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BLUEThe color of the sky and sea.Trust, loyalty, wisdom,confidence, intelligence, faith.Masculine.
Water products.Calming effect.
The Use of Color: BlueBlue
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PURPLERoyalty.Luxury.Feminine.CreativityHigh valued products.
The Use of Color: PurplePurple
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Goodness, innocence, purity,luxury, high value products ,authority.Perfection.Safety, purity, divinity,Cleanliness.Positive connotation.Faith and purity.
The Use of Color: WhiteWhite
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Power, elegance, formality.Strength and authority.Prestigious color.Black and gray make the othercolors stand out.
Contrasts well with brightcolors.
The Use of Color: BlackBlack
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BRAIN TEASERS
Suggest colour scheme for1. Halwa2. Green Pepper (Pickled)
3. Banana Chips4. Herbal products5. Female beauty cream
6. After shave lotion
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SCOPE
BRIEF OFMFG, PROPERTIES & APPLICATIONS
PAPER
GLASSMETAL
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WHAT IS PAPER?PAPER IS MADE FROM CELLULOSE FIBER DERIVED
FROM WOOD.
LET US BRIEFLY SEE HOW PAPER IS MADEPAPER BOARD IS THICKER PAPER
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50CELLULOSE
25 HEMICELLULOSE + 25LIGNIN
WOODPAPER
PAPER MANUFACTUREPAPER IS A CELLULOSIC MATERIAL. WOOD HAS 50% CELLULOSE &50% MIXTURE OF HEMI CELLULOSE COMPOUND & LIGNIN WHICH
BIND CELLULOSIC FIBRES TOGETHER
LIGNIN IS A PHENOLIC COMPOUNDWHICH GIVES THE COLOUR TO PAPER AND BINDS
THE HEMI CELLULOUSE & CELLOLOSE
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PAPER MANUFACTURE
WOOD
HARD WOOD
SOFT WOOD
CONIFEROUSTEMPERATE
3.5-4 mm
DECIDIOUSTROPICAL1 1.5mm
FOR PAPER MAKING,THESE FAIBRES ARE SEPERATED FROM EACH OTHER TO BECOME DISCRETE ENTITIES THROUGH A DRASTICACTION AND LATER MATTED
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PAPER MANUFACTUREPULPING SECTION PAPER MAKING SECTION
WOOD
DEBARKINGSOAKING
CHIPPINGDIGESTING
BEATING
FILLERSSIZING
REFINING
STAGE 1MAKE READY
STAGE 2PULPING
STAGE 3STOCK
PREPARATION
FORMATION
PRESSING & DRYING
COATING
STAGE 4SHEETING
STAGE 5FINISHING CALENDERING
WINDING
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STAGE1 MAKE READY
WOOD
DEBARKING
SOAKING
TO STAGE 2
SOAKED TO MAKE IT SOFT
DRY OUTSIDE LAYER (BARK) REMOVED
TREE CUT TO LOGS TIMBER
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STAGE2 PULPING
CHIPPING
PULPING
TO STAGE 3
FROM STAGE 1
(DIGESTER/ COOKING)
MECHANICAL, CHEMICAL & SEMI-CHEMICAL PROCESSES
CUT TO SMAILL PIECES FOR EASY COOKING
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PAPER PULPER
PAPER MANUFACTURE
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PAPER MANUFACTURESTAGE 3 - STOCK PREPARATION
UNBEATEN BEATEN FIBRILLATED
TO STAGE 4ROM STAGE 2 BEATING REFINING SIZING FILLERS
PREPARING FIBERS FOR PAPER MANUFACTURING IS KNOWN ASSTOCK PREPARATION.
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PAPER MANUFACTURE
PAPER MILLS CAN TAKE UP TWO ROUTES1. INTEGRATED
FROM STAGE 1 TO STAGE 52. NON INTEGRATED
FROM 3 TO 5
NON INTEGRATED MUST BRING THE PULP EITHERSLURRY FORM OR SOLID FORM FOR PAPER
MAKING
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STAGE 4 SHEETING
TO STAGE 5ROM STAGE 3 FORMATION PRESSING & DRYING
FORMATION INVOLVES FORMING A SHEET OF THEPULP.
THIS CONTAINS 95 % OF WATER AND 5 % OF PULP.HENCE THIS SHEET NEEDS TO BE PRESSED TOREMOVE THE WATER AND LATER DRIED.
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ABRASIVE PAPERS - Sand paper, Flint paper, Emery paper
ABSORBENT PAPERS. Soft, loosely felted, unsized, spongy such as blottings,filter papers, toweling,
ALKALI-PROOF PAPER. white or colored, which does not discolor when incontact with alkaline materials, such as soap. Careful selection of fibers with no
particular strength requirements. Book papers are sufficiently alkali-proof and
glassine and waxed papers are also satisfactory.
ANTI-TARNISH PAPER. Tissues used for wrap-ping silverware, razor blades,needles, silverware, etc. Freedom from acidity and reducible sulfur compounds.
Copper salts or other inhibitors are sometimes used for silver tissues.
ART PAPER. Coated paper or board with a high finish and smooth surface.
BAG PAPER. Paper used for making bags for use by grocers is normally of kraftpaper, greaseproof for salted nuts; water resistant paper for garbage bags;
bleached paper for candy bags, etc. The term does not denote any one kind of
paper or any special strength requirement.
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BIBLE PAPER. An opaque, light weight, printing paper for use where low bulk is an
essential, as in Bibles, insurance rate books, encyclopedias, etc. Basis weight is generally
from 30
40 GSM. Preferred fiber stock is linen or hemp, very carefully beaten tofibrillate rather than cut it; and titanium dioxide is often used as a filler.
BLOODPROOF PAPER. Strong wrapping paper, hard sized with wax, or otherwise treated,
to render it resistant to blood; used in stores on scales where meat is weighed, and for
separating layers of meat in a package.
BOND. High strength, permanence and durability such as those used for government
bonds and legal papers, business letterheads, forms, etc. The fibers used for the bestgrades of bond paper are from rags, but many grades are made from high-grade bleached
chemical wood pulps.
BREAD WRAPPERS. Thin, waxed paper, made opaque by titanium dioxide and printed
with the desired characters.
CANDY TWISTING TISSUE. A light-weight paper, generally waxed for wrap-ping candy
kisses, taffy, etc.CARBON TISSUE. Tissue with carbon black usually with wax or oily material.
CHECK PAPER. A bond paper often treated with chemicals or dyes to make alteration of
writing difficult or impossible.
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CHROMO PAPER. Any paper or board which is especially suitable for printing with colors;
the term is generally applied to coated papers.
CIGARETTE PAPER. A strong tissue of uniform, close texture, used to cover the tobacco in
cigarettes. It is generally made from linen or flax tow which has been very highly beaten,and usually contains from 15 to 30 per cent of calcium carbonate filler.
COATED. A term applied to any paper or board whose surface has been covered with a
coat of adhesive and mineral pigment. The term is some-times applied to lacquered and
varnished papers.
CURRENCY PAPER. A bond type paper used for printing currency, bonds and government
securities. In the United States it is made from new rag cuttings, is tub sized with glue,loft dried and plate finished. It must have high tensile and folding strength and
exceptional resistance to wear.
DRAWING PAPER. A general term applied to paper used for pen or pencil drawing. There
are numerous grades for different types of work and the fiber composition ranges all the
way from rag stock to groundwood.
DUPLEX. A term applied to papers or boards differing in color, finish, or texture on thetwo sides. Such differences may be obtained on the paper machine, during finishing, or
by pasting.
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FILTER PAPER. An unsized, porous paper used for the separation of solid particles from
fluids or gases. It comes in many grades of porosity, chemical purity and fiber furnish
according to the work it has to do.
FLOCK PAPER. Paper prepared by covering the whole or a part of its surface with an
adhesive and dusting the surface while sticky with powdered fibers of various kinds.
GLASSINE. A very dense, semitransparent paper, generally made from chemical
woodpulp which is beaten to give a high degree of hydration. The paper is grease
resistant, not readily penetrated by air, and if waxed is highly resistant to moisture
vapor. It is used to wrap foods, tobacco, chemicals, etc., and for purposes where
transparency is helpful.
GREASEPROOF. Any paper which has been treated in any way during its manufacture to
make it resistant to the penetration of grease or oil.
UMMED PAPER. Any paper coated on one side with an adhesive, such as fish glue,
dextrin or animal glue. Various kinds of paper are used according to the use
requirements such as labels, sealing tape, etc.NEWSPRINT. The type of paper used in printing newspapers. Fiber composition at least
70 per cent groundwood and the rest unbleached sulfite.
C h f i i i l d f h ki f h
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PARCHMENT. A sheet of writing material made from the skins of goats or other
animals. Vegetable or imitation parchment is made to resemble animal parchment by
passing a sheet of unsized, pure fiber paper through a bath of sulfuric acid and then
washing it very thoroughly and drying. The acid gelatinizes the surface fibers and the
dried surface is grease-proof, has a high wet strength and is very resistant todisintegration by water and many solutions.
STRAWROARD. A board made from straw which has been chemically treated,
generally with lime, and then made into board as usual. It is a coarse, hard board
used for boxes and corrugating purposes.
TISSUE PAPER. In general this term applies to any light, gauzy paper weighing less
than 18 pounds (24 x 36-500). Used for many purposes and sold under various names.
WAXED PAPER. Paper which has been treated with wax either by passing it through a
bath of the wax and at once chilling it by cooling rolls (wet waxing), or by passing
through rolls as soon as waxed so that the wax is driven in and the paper feels dry
(dry waxing).
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GLASS
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WHAT IS GLASS
SUPER COOLED LIQUIDLIQUID WHICH IS COOLED TO A STAGE WHERE
ITS VISCOSITY IS SO GREAT THAT MOLECULES DO
NOT MOVE FREELY ENOUGH TO FORM CRYSTALS
100% RECYCLABLE SUSTAINABLE
INERT ALMOST TO EVERYTHING
GOOD FOR ENVIRONMENT
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WHAT IS GLASS
Silica Sand68%
Soda Ash12%
Limestone10%
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WHAT IS GLASS
CULLET
Recycled glass used
at levels as high as80% when available
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WHAT IS GLASS
HENCE GLASS RECIPE IS
SAND70%
SODA ASH12%
LIMESTONE
10%
ADDITIVES8%
CULLET - 80%
REST20%
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MANUFACTURE
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MANUFACTURE
CULLET SAND OTHER RM
WASHING & SIEVINGCRUSHED TO 15
20 mm dia
SORTING
WEIGHED
MIXER
FURNACE1500 deg C
FOREHEARTH
GOBS CUT OFF
MOULDING
COOLING
ANNEALING LEHR
PROTECTIVE COATINGS
BOTTLES & JARS
SCHEMATIC DIAGRAM OF GLASS MANUFACTURING
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MANUFACTURE
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MANUFACTURE
BLOWING THE BOTTLE OR JAR
o TWO STAGE MOULDING BLANK MOLD FORMS NECK AND INITIAL SHAPE
BLOW MOLD PRODUCE THE FINAL SHAPE
o
BLANK MOLD COMES IN A NUMBER OF SECTIONS: FINISH SECTION CAVITY SECTION (TWO HALVES FOR PARISON REMOVAL)
o GUIDE OR FUNNEL FOR INSERTING GOB
o A SEAL FOR GOB OPENING ONCE GOB IS SETTLED IN MOLD
o BLOWING TUBES THROUGH THE GOB AND NECK
o BLOW MOLD PRODUCE FINAL SHAPE
GOB FORMATION
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GOB FORMATION
VIDEO CLIPS
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VIDEO CLIPS
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GLASS MOULDING PROCESSES
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GLASS MOULDING PROCESSES
TWO TYPES OF PROCESSES
BLOW & BLOW PRESS & BLOW
TWO PROCESSES DIFFER ACCORDING TO THEPARISON PRODUCING.
NARROW MOUTH WIDE MOUTH
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GLASS MOULD SETS
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DECORATIONFROSTING
ETCHING BY HYDROFLURIC ACID (HF) ORSAND BLASTING EXPENSIVE
PRINTING
SCREEN PRINTING
INKS ARE FIRED.APPLIED CERAMIC LABEL
CERAMIC FROSTING
SPRAY WITH CERAMIC PAINT
( GROUND GLASS + OIL MIXTURE)
FIRE
OIL EVAPORATES AND GROUND GLASS
FUSES ON SURFACE.
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METALS
WHAT IS THE MATERIAL?
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WHAT IS THE MATERIAL?
TIN PLATE
WHAT IS THE MATERIAL?
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WHAT IS THE MATERIAL?
ALUMINIUM
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WHAT ARE FORMS
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WHAT ARE FORMS
METAL PACKAGING MATERIALSALUMINIUM TIN PLATE MILD STEEL TUBES CAPS
TRAYS CONTAINERS BOTTLES FOIL
CAPS CONTAINERS CANS PAILS
CLOSURES
DRUMS PAILS
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29/06/2002 TATA TINPLATE 75
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Story of Tincans
The history of packaging couldnot be complete without paying
deserved tribute to the Tincans.
In the late 18thcentury,
Napoleons army, which had
suffered more from malnutrition
than by actual combat, offered
12,000 francs, to anyone whocould develop a way to
preserve foodfor themilitary on the battlefield.
Napoleon Bonaparte
the first customer !
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29/06/2002 TATA TINPLATE 77
A French confectioner,
Nicolas Appert, after 15
years of research, tookhome the prize in 1809. He
discovered that the
application of heat to food
in sealed cans preservedthe food from
deterioration.
Story of Tincans
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29/06/2002 TATA TINPLATE 78
What does canning of food do Heat sterilization process kills food spoilingorganisms.
The steel base of the tinplate cans is the only
media which can sustain this heat. Sealing properties are excellent resulting in
processed food remaining sterile.
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Impermeability of Tin Cans Steel base make tinplate the most tolerant
packaging medium with power to resist insects,
bacteria, shocks and above all, ultraviolet light.
The design of cans make them totally tamper proof.
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Tinplate
MILD STEEL 0.12 mm to 0.60 mm
FeSn2 alloy layer
Free Tin layerTin Oxide
Passivation Film
Oil Film
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ALUMINIUM COLLAPSIBLE
TUBES
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COLLAPSIBLE TUBE PRODUCTION STAGES
IMPACT EXTRUSION
ANNEALING
COATING
DECORATION
PACKAGING
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Metal slug is located on a
shaped striking surface or
anvil
A punch strikes slug with great
force.
Zinc Stearate ( powder) is
used as lubricants to slug to
facilitate extrusion and reduceheat.
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Under enormous impactPressure metal flows like a
LIQUID straight upalong
the outside of the striking
punch forming a round
cylindrical shape.
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The tube height is governed by
the thickness of the initial slug.
Shoulders and tip are formed
as a part of the process.
Tubes with a thin web in the
orifice will start with a solid
slug.
Force of impact work hardens
and makes it stiff.
ANNEALING
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ANNEALING
After extrusion, the tubes are annealed to
remove the work hardening and provide the
softness or limpness needed for good
collapsibility. The degree of hardness that
remains in the annealed condition is needed forthe tube to maintain its shape and to hold the
crimped fold at the closed end.
The non capping end of tube is trimmed to exactdesired length.
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COATINGCoatings are required inside some aluminum
collapsible tubes to prevent corrosion by certainproducts.
Even a superficial amount of corrosion, which might
be tolerated for other applications, is objectionable in
the tubes, because gas produced by the corrosionreaction causes the tube to swell.
Consequently, coatings that provide a high degree of
protection against corrosion are required.
Even the outer surface needs a white surface coating.
DECORATION
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DECORATIONDecoration is needed for collapsible tubes to identify
products packed in them.Tube outside needs a white enamel base coat and
cured before decoation.
The decoration is achieved by use of an artwork.
This is printed by offset flexography using stereos.
The decoration is cured in a oven.
They are then capped.
PACKAGING
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PACKAGINGCollapsible tube is susceptible to denting because of
its softness.These needs to be packed to avoid hitting against
each other as well as from mechanical impacts during
transportation.
Generally they are packed in corrugated boxes withhoney comb partitions.
Boxes and partitions are often reused to reduce cost.
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THINK