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DTKFCPL Dr. Kuchroo June 25, 2003

PRINCIPLES OF PACKAGING
Dr. T. Kuchroo

The packaging in food has become an important tool in marketing of a consumer
food product. Packaging not only provides shelf life and appearance to the product
but also helps us to create pull in the market place. In the present marketing
scenario food packaging has become vital tool in promotion and aesthetic quality of
the product. To choose a packaging material for a product it is essential to
understand the parameters required for designing shelf-life and printability. It is
important to note various qualifications of packaging material and their chemical and
physical characteristics which are important not only for food laws but also should
have the ability to protect the product flavour, taste and should not impart any
chemical change. The packaging materials vary in their behaviours and are used
accordingly in packaging of various food products.

A food package is a structure design to contain a food product in order -

1. To make it easier and safer to transport
2. To protect the product against contamination
3. To protect product against damage or degradation and
4. To provide a convenient measure of dispersing the product

The addition of printing or other decoration to the exterior of the package serves

1. To identify the contents as to type and quality
2. To identify the manufacturers brand and grade
3. To attract Buyers attention
4. To persuade the buyer to purchase
5. To instruct the purchaser on how to use the product.

The packaging is normally defined by market and the selection is based on cost and
requirements. The selection involves many factors:

i) Pack Size
ii) Nature of Product
iii) Barrier properties
iv) Temperature extremes to be encountered
v) Regiment of open device or reclosure
vi) Shelf life
vii) Stackability , in use condition
viii) Ease of disposing
ix) Competitive Pack
x) Dealer Pack, Shipper

Within each package form or category other more specific question need to be
answered

1. How many piles should the laminate have?
2. What is the function of the each ply?
3. Which ply should be closest to the product?
4. What thickness should be used?
5. How should the pouch be formed and sealed?
6. What outer protection ( Box shipper) is needed?
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DTKFCPL Dr. Kuchroo June 25, 2003
There have been many packaging materials invented and tried from last two decades
for different products. These materials need to qualify for the following
characteristics

1. Shelf life
2. Transit
3. Compactness
4. Easy to handle
5. Printability

Shelf life- The shelf life of the product shall depend upon the chemical composition
of the product and the packaging material used. There are two broad characteristics
of the products:
a) Products which have a tendency to absorb moisture
b) Products which have a tendency to leave moisture
Both these properties need different packaging materials unless the products falling
in second category are not modified to achieve the properties similar to group `a.
Moisture barrier properties are very important in packaging material. The packaging
material also should have the capacity to avoid air ingress in product. Oxygen from
air in particular has direct impact on oxidative stability of the product. Fat goes
under oxidation in presence of air and form peroxides and other carbonyl compounds
which give off odor to the product.

Transit- The packaging material should be able to provide protection to the product
and should be able to withstand the transit journey. There are different materials
having different properties in this regard.

Compactness - The packaging material should provide compactness to the product
to be able to avoid breakage or shape degradation.

Handling-The material should have the capability to have ease in handling and
should be able to withstand various packaging techniques.

Printability - The material should have the capability to have ease in printing and
should help the product to improve the image. Different packaging materials have
different printing quality.

Based on the above physical parameters various packaging materials are in use.
Some of them are explained below

RIGID PACKAGING MATERIALS AND PACKAGE FORMS
Glass containers
Glass containers are one of the stalwart of food packaging. Glass is made from
limestone, sand, soda ash and alumina. Colorants are added as per the
requirements. It is an excellent protection barrier to solids, liquids and gases. It is
the excellent protection against odor and flavor contaminants. The chief
disadvantages as a packaging material are weight and fragility and it is not easily
disposable. The transparency of the glass provides excellent product visibility and
attractive finish. Glass containers include Bottles, jars, tumblers, Jugs, carboys, vials,
and ampules. The other important factor in selecting glass container for food is color
which can influence the type of light reaching the food and its ability to resist
thermal shock. Special glasses have been developed to withstand the temperature
shock.
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DTKFCPL Dr. Kuchroo June 25, 2003



Metal containers
Metal containers are manufactured from soldered tin plate but more recently
aluminium cans have been introduced. Today there are several options available like
Standard tinplate, light weight tinplate, double reduced tinplate, tin free steel
(coated) vacuum deposited aluminium on steel and aluminium.

Can coatings are now considered as vital components especially for food and
beverages. Coatings must be non toxic and free from odors and taste. They must not
deteriorate or come loose from the can wall during food storage. Interior coatings
made from acrylics, butadiene, epoxy amines, epoxy esters, epoxy phenolics,
oleoresins, phenolics and vinyls depending upon the type of food and process

Several type of food products and type of steel base

Class of Food Characteristics
Required

Typical example Steel base
Most strongly
corrosive
Highly or moderately
acidic
Apple juice, berries etc Type L
Moderately
corrosive
Acidified vegetables Apricots, figs, grape
fruit
Type MS, MC
Mildly corrosive Low acid products Peas, Corn, Meat, etc Type MR, or
MC
Non- corrosive Mostly dry or non
processed
Dehydrated soups,
frozen fruits,
shortenings
Type MR, or
MC


Composite container
A composite container is made from two or more constituent materials. It usually
consists of paperboard body with metal or plastics ends. Two basic types are
available-Spiral wound containers are made in cylindrical shapes where two or more
plies of board are glues together around the material. Convolute-wound composites
are produced by straight winding. Body materials used are clip board and Kraft
paper. Lining used are vegetable parchment, wax laminates, aluminium foil and
polyethylene coated paper. Composite cans are closed by a snap or a lid, plug the lid
or lever lid.

Aerosol containers
Aerosol containers are used to dispense a product by means of pressurized gas or
liquid that is held in the same container. The container must be gas tight or may be
constructed from steel can, aluminium cans, glass or plastics or combination.


Rigid Plastic packages
A wide variety of rigid plastics can be used in the form of thermoformed injection
molded and the blow molded containers. Thermo formed containers are formed by
exposing the plastic sheet to heat and forming into female around male mold.
Vacuum or pressure forming and several other techniques are used. The plastics
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DTKFCPL Dr. Kuchroo June 25, 2003
used for thermoformed trays are poly carbonate, poly ethylene, poly vinyl chloride,
poly ester, polystyrene, poly propylene, cellulose acetate and acrylonitrile.


The specific plastic selected depends upon the foods to be packaged and storage
requirements. All thermo formed trays are covered with heat sealable or snap-on lids
made of plastic film or aluminium foil laminate. Injections molded are used in high
volume application for jars, bottle and tubes. Most widely used plastics are
polystyrene, poly propylene and acryl nitrite. Blow molding is generally used to
produce containers where the neck diameter is small in contrast to overall container
diameter. Plastics used are Poly vinyl chloride, polypropylene, PVC, Polystyrene, poly
acetyl, cellulose acetate etc.

Solid and corrugated fiberboard containers
Solid and corrugated fiberboard containers are used to fabricate shipping cartons and
cases used extensively in wholesale and industrial shipping. They are not usually
used as direct containers for foods but are extensively employed as outer shippers
for packaged foods. Both are made from heavy fibrous Kraft paperboard. Solid
fiberboard is made by gluing several piles of paperboard together by using asphalt or
special resin adhesive such as urea formaldehyde.

There are five major types of corrugated paperboards; unlined, single-faced, double-
faced, double walled and triple walled. Just two are used for wrapping and the others
are used where exceptional strengths and rigidity are essential. Double faced
corrugated is the most commonly used for boxes liners and partitions.

A B C E(flute)
Flutes/fort 35-37 50-52 41-45 90-96
Flute
height(in)
0.185 0.105 0.145 0.085
Thickness(in) 3/16-7/32 4/32 5/32 5/64

Each flute has particular properties with respect to load support in each of three
possible directions

Aluminum containers
Containers fabricated from plain aluminum foil have different degrees of rigidity
depending upon thickness, tamper, alloy and container design, some are rigid and
are easily deformed and others are more delicate and hence they are included in
semi rigid. Aluminium containers provide extreme convenience in preparation and
serving of foods they withstand extremes of temperatures. Aluminium protects the
food against moisture, gases and light. Folded end cartons have wrinkle free sides
and bottoms. Formed containers are made with male and female dies have wrinkled
side walls and flanges with smooth flanges flat web materials can be hermetically
scaled as closures.


Flexible Packaging Material
Flexible packages are made from combination of flexible materials. There are millions
of possible combinations.

Paper
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DTKFCPL Dr. Kuchroo June 25, 2003
Paper remains an important factor in flexible packaging because it contributes
strength, stiffness, smoothness and low cost. In flexible packaging the basic paper
used contains bond, tissue, litho, Kraft, glassine parchment and grease proof.

Bond papers are uncoated sheets made of bleached chemical pulps in weights and
ranging from 9.07 to 31.75 Kg. They are supplied with wide variety of finishes and
may be purchased with the high weight and tear strength and printing and
laminating grades.

Tissues are light weight papers made of semi and fully bleached chemical pulps in
basis weight ranging from 3.62 to 9.07 Kg with open or closed fiber formation.
Special treatments may be added as such as wet strength and mild resistance.

Litho papers are sheets coated on one or both sides in basic weights ranging from
13.15 through 27.22 kg. They are not strong enough as bonds but have better
surface for printing and are preformed for labels etc.

Kraft papers are extremely strong and may be used in bleached or unbleached
forms. Basic weight range from 11.34 to 36.28 kgs. Kraft papers are graded
according to wood pulps used. The strength of Kraft paper depends upon the quality
of wood pulp used provides the strength to the paper accordingly.

Glassine papers are super calendered chemical pulp sheets in basic weights ranging
from 6.8 to 20.4 Kgs. They have a high resistance to air and grease. Genuine
glassine pulp is beaten much larger than imitation grade and therefore the genuine
glassiness have highest resistance to grease.

Parchment papers are made up of bleached chemical pulp which is immersed in a
bath of sulphuric acid. The good grease resistance and high wet strength. Both
parchment and grease proof papers have a rougher and more opaque appearance
than glassiness. They are supplied ranging from 6.8 to 12.3 Kg

Films
A film is thin plastic flexible sheeting having a thickness of 0.0254 cm or less. Te first
commercial flexible film was cellophane. Cellophane is manufactured from highly
purified cellulose derived from bleached sulphite pulp. The cellulose is treated with
sodium hydroxide solution and carbon di sulphide to produce "xanthanal which
when dispersed with sodium hydroxide, produce viscose. The viscose is extruded
through a slot into acid salt baths generate cellulose film. It is then processed and
various coatings and modifications are made to develop several grades of
cellophane, nitrocellulose coated cellophane after non blocking moisture vapor
resistance (MVT) slip and flexibility and heat seal ability. Saran coated offers
protection from oxygen and Better MVT.

Polyethylene
Polyethylene is the largest volume, simple film used in flexible packaging industry.
High pressure polyethylene is obtained by exposing ethylene to temperature
between 150 *C and 200 * C at a pressure of about 1200atm in presence of traces
of oxygen. This film is known as Low density poly ethylene. Low pressure high
density poly ethylene is produced at temperature between 60*c and 160 * C and
pressure of 40 Atm with alkyl metal catalysts. Its greatest benefit is its ability to
fusion or heat seal ability.

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DTKFCPL Dr. Kuchroo June 25, 2003
Poly propylene is produced by polymerization of polypropylene. It is more rigid,
stronger and lighter than polyethylene. The film has low water vapour permeability,
good resistance greases, high temperature stability and poor gas barrier.

Polyesters are condensation products of poly alcohol with a di-acid or its anhydride.
They offer excellent tensile strength, tear resistance and good ageing properties.

The polyvinyl chloride films are prepared by polymerizing vinyl chloride in presence
of suitable catalysts. By the addition of plasticizers, flexible films are obtained.

Amylose film is made from corn starch. The film is edible and is very soft, slightly
hazy, stretchable and water soluble. The film has poor moisture barrier. It is
satisfactory as a gas and flavour barrier.

Ionomers based on low density poly ethylene, the ionic bonds in ionomers serve to
increase overall bond strengths and yield superior oil, grease and solvent resistance.
At normal temperature Surlyn A is tougher and is more sensitive to water
absorption. Its high melting strength makes it Surlyn A extremely suitable for
extrusion coating, vacuum forming and skin packaging.

Ehtylene- Vinyl Acetate Co polymers (EVA) results from the co-polymerization of high
pressure (low density) polyethylene and vinyl acetate. EVA is more flexible; however
it is more permeable to water vapor and gases. Impact strength is excellent and the
film is clearer than polythene. EVA is thermally unstable at high heat but very stable
and versatile at lower temperature and has a wide heat-seal range. The polar nature
of side groups present in the co-polymer causes blacking characteristics.

Polypropylene co polymers offers excellent water and gas strength properties,
however its cold temperature impact strength is poor. In an effort to overcome this
defect, a second monomer usually ethylene is introduced into polypropylene
structure. Poly propylene co polymers are used for shrink wrapping.


MECHANICAL PROPERTIES OF PACKAGING FILMS.

Film
material
Tensile
strength
Elongation
%
Tearing
strength(
G mil)
Bursting
strength
1 mil
thick
(P.S.I)
Folding
endurance
Number
of
foldsx10 3
Heat
seal
Cellophane
plain
104-186 14-36 275-426 ..... .... .....
N C - Coated 70-150 10-50 2-10 55-65 OW 15 93.3-
148.8
Sam Coated 70-130 25-50 2-15 ..... .... 107.2-
176.6
Polyethylene
coated
50 and
over
15-25 16-50 40-50 good 110-
148.8
Cellulose
acetate
50-139 25-45 2-25 50-85 0.25-0.4 176-
232
Polyethylene
Low density 13.5-25 200-800 150-350 48 Very high 121.1-
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DTKFCPL Dr. Kuchroo June 25, 2003
176.6
High density 24-61 150-650 15-300 .... .... 135-
176.6
Polyester 170-237 70-130 10-27 45-50 20 135-
204.4
Polypropylene 45-100 400-600 32-1750 Very
high
.... 162.7-
204.4
Polystyrene
(oriented)
80-120 3-20 20-30 23-60 ... 121.1-
162.7
Vinylidene
saran
80-200 40-80 10-100 20-40 250 93.3-
176.6
Nylon 138-170 200 50 No burst .... 204-
232




Co extruded films
Films called structured films are produced by a process of co extrusion.
(Simultaneous extrusion through complex dies) Both flat die and blown structural
films are being manufactured. One of the first commercial products was
polyethylene- polypropylene. Film designed for broad WMP. Another structure used is
a co-polymer-homo polymer-copolymer polypropylene film.

These films are being used for different purposes. The composition of the films
depends upon the end use. These are five layer films now available which are
personally being used in packing oil and other greasy products and provide an
excellent shelf life to the product. The common co-extrusion films are varying from 3
to 5 layer combination

The five layer films have shown superior properties.

a) High tensile strength and improved burst strength
b) NO Flex crack
c) Light barrier properties for UV stabilization
d) Symmetrical film without curl for smooth running in automatic FPS
machine.
e) Permanent printability
f) Very good gas barrier properties
g) Leak proof sealing and high seal tack strength
h) Aroma retaining properties
i) Can withstand hazardous transportation in cardboard boxes
j) Easy to handle and low cost material against conventional materials


Co-extrusion technology based on co-extruded films up to 3 layers is now a
common usage in our country for many years. The films having 2-3 layers using
common polymer link LDPE, HDPE etc. The usage of Nylon 6 has become successful.
The available structure of 3 layer film is PA 6/ bonding/surlyn. The typical five layer
structure suitable for packing oil, butter oil etc.

LDPE/Bonding/PA6/Bonding/HDPE Or LDPE/Bonding/Pa6/Bonding/Surlyn
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DTKFCPL Dr. Kuchroo June 25, 2003

The heat seal properties of these films are better. To achieve better barrier
properties metalizing of film has helped to achieve better shelf life and has provided
product a better get-up. Various combinations of film laminate here achieved similar
properties. For products which are more solid in nature like snax, powder, biscuits
etc.

Various combination of film laminates are in use depending upon the end use.
i) Metallized polyester laminated to LDPE or HDPE or LDHD
ii) Plain polyester laminated to LDPE or LDHD
iii) Plain BOPP laminate to LDPE or LDHD
iv) Polyester/ Foil/ Poly
v) Paper/Poly
vi) Metallized polyester/ paper/poly
vii) Metallized BOPP to LDPE or LDHD

The metalized films provide additional characteristics to the films towards the aroma
and oxygen barrier properties for packing tea, coffee and sugar. For pharmaceutical
packing, aluminium foil laminated to LDPE, glassine etc. is used to laminate to
provide better seal ability and barrier properties. The total foil in itself is an excellent
barrier. Coating and after substitutes serve only to add strength, decoration and heat
seal ability.

The most important laws which govern the packaging is to cognizance of all chemical
components of the supply, whether these components enter the food by direct
addition or by indirect means. For example, by virtue of migration from a food
packaging material.

A food additive is actually any substitute that can become component of food by
direct or indirect means unless that is known to be safe or is prior sanctioned. All
substances that can become a component of food are presumed to be additives
unless declared by law; all other substitutes i.e. non-food additives new prior
sanctioning. These substances are listed separately by law in each country.

It is not within the scope of the article to consider legislation relating to various laws
required to be followed in manufacture of the packaging material. The laws are
different in different countries. It is essential to understand that packing material to
follow the regulation enacted by FDA in each country.