1、Packaging DefinitionsPackaging is a means,not an end in itself1“Packaging is the science,art and technology of enclosing or protecting products for distribution,storage,sale,and use”“Packaging can be described as a coordinated system of preparing goods for transport,warehousing,logistics,sale,and en
2、d use”“Packaging contains,protects,preserves,transports,informs,communicates,sells and enables usage”Functions and roles of packagingPackaging is a means,not an end in itself2Historical rolePastPresentFuturecontainsprotects(physically)transportspreservessells(shelf appeal)communicatesinformsenables
3、usage(convenience)promotesreuseacts(intelligent)interactsis environmentally soundPackaging MatrixComplex combination of criteria in a 3 dimensional matrix3Consumer SafetyRegulatory/Legal requirementsProduct informationShelf appealBranding/PromotionCost/EconomyEcology/EnvironmentMachinability/Line ef
4、ficiencyTrade requirementsConvenienceProduct protectionDistribution/logisticPrimary packagingTertiary packagingSecondary packagingMaterialStructural designPrinting&DecorationGraphic designPackaging MatrixEach product will be packed in several packaging articles4Primary packagingTertiary packagingSec
5、ondary packagingPackaging LevelsTerminology5Primary packagingSecondary packagingTertiary packagingPackaging LevelsTerminology and examples6Primary packagingSecondary packagingTertiary packaging=SRP or Display=Packaging Assembly=Transportation Unit=SKU=Food Contactand/or Sales Unit=Pallet=Unit LoadPa
6、ckaging Levels7Some demands on packaging are common to all levels,e.g.ecology,machinability,cost However some demands are specific to each levelPrimary packagingSecondary packagingTertiary packaging4-Palletisation requirements1-Food Contact2-Requirements in Consumer Unit:PIF,EZO,Reclose3-Trade guida
7、nce=SRP or Display=Packaging Assembly=Transportation Unit=SKU=Food Contactand/or Sales Unit=Pallet=Unit LoadPackaging LevelsSome demands on packaging are common to all levels,e.g.ecology,machinability,cost However some demands are specific to each level 8Primary packagingSecondary packagingTertiary
8、packaging4-Palletisation requirements1-Food Contact2-Requirements in Consumer Unit:PIF,EZO,Reclose3-Trade guidance=SRP or Display=Packaging Assembly=Transportation Unit=SKU=Food Contactand/or Sales Unit=Pallet=Unit LoadPrimary:Food Contact4 cases of product in“Food Contact”with packaging material9Ma
9、terial physically touching the productExamples:-Milkini-Tender(carton tray inside and OPP wrapper)Bag or box when primary pack is:-Twist wrapper(e.g.One-by-One,Imagine)-Non-sealed praline tray(ILM)Retail case for wrapped products(e.g.Mignonette,WTR)Material in“air”contact with productMaterial in con
10、tact with sealed low barrier film containing the productHermetically sealed product with low/insufficient barrier film,permeable to contaminants most vulnerable are highly absorbent products(large surface,mobile,fatty e.g.powders)-PE coated bag(e.g.Pavlides cocoa bev.)-OPP pouch for twisted products
11、 in co-packing(e.g.TCO segments)Material in contact with product in consumption phase after opening-Sealed praline tray-Sealed tablets and bars stored after opening(not eaten in one go-contamination based on time until eaten)Packaging LevelsSome demands on packaging are common to all levels,e.g.ecol
12、ogy,machinability,costHowever some demands are specific to each level 10=food contactand/or sales unit=SRP or display=packaging assembly=transportation unit=SKU=palette=Unit loadPrimary packagingSecondary packagingTertiary packaging4-Palletisation requirements1-Food contact2-Requirements in Consumer
13、 Unit:PIF,EZO,Reclose3-Trade guidanceCU:Packaging Integrity Feature(PIF)All Mondelz International products shall have a PIF 11 Definition:“A PIF is a package seal,feature or addition,applied during original manufacture,which prevents opening the package in the normal manner without destruction or pe
14、rmanent displacement of the feature.”A PIF has to provide evidence of package and seal integrity,but it does not mean that a package is tamper proof.Documentation:Corporate Quality Procedure:7.3-20 Package IntegrityPaper stickerOverwrap filmTear strip sticker(partly)removable stickerCU:Easy opening(
15、EZO)Feature&GraphicAny new package which is launched by Kraft Foods shall have a functional Easy Opening(EZO)and a graphic description of the EZO 12 Definition:A controlled EZO feature enables the consumer to get access to a product he likes to get in a convenient way and without using a device(e.g.
16、tool).Background:As part of the“Creating Consumer Brand Value”strategy the objective of EZO for all Kraft products has been widely communicated.Packages which are easy to open and reclose support the consumer interest in convenient handling.Documentation:Best Practice on EZOPeel n sealVAFPTear tapeC
17、U:Reclose FeatureReclose feature is recommended for multi-serve products 13 Definition:A reclose feature allows the consumer to close a packaging provisionally after first or further openings.It is designed to hold the packaging content inside and give a certain protection to the remaining product.B
18、ackground:If a pack is defined as a multi-portion pack the consumer would normally expect to be able to reclose the pack after usage.In addition,the inclusion of reclose should be aligned to the pack serving size and linked to the H&W policy.Twist off capHinged lidPeel n sealVAFP IICU:Platform speci
19、fic requirementsSome“packaging platforms”are developed at Mondelz and their execution should follow Best Practices.14Peel n SealInvisible SealKraft owned technology EZO system with rigid tray inside PIF die cut BP for film die cut EZO graphics Material structureStick PackVAFPValue Added Flow PackKey
20、 characteristics for VAFP functionality:Laminate&CS specification,CS pattern,Fin seal“T junction”position and film overlap,Gussets,Cutting knives:straight cut,Sealing jaws:cross machine direction,EZO pictogram:graphic and positionKraft concept protected with 3 patents and supplier exclusivityGraphic
21、 appearance on shelfConvenience(easy opening/reclose)Flexibility in box shapes Product protection/freshnessProduct quality over shelf-lifeProtection against tainting(off-tastes)vs.ink and board.Key characteristics:Four standard widths:23,30,35 and 45mmDefined target,minimum and maximum length,depend
22、ing on widthEasy opening featureMaterial structureA key challenge for Assorted Pralines is to create interest/newness/modernity whilst respecting key requirements.Invisible seal can even improve:Packaging LevelsSome demands on packaging are common to all levels,e.g.ecology,machinability,cost However
23、 some demands are specific to each level 15=food contactand/or sales unit=SRP or display=packaging assembly=transportation unit=SKU=palette=Unit loadPrimary packagingSecondary packagingTertiary packaging4-Palletisation requirements1-Food contact2-Requirements in Consumer Unit:PIF,EZO,Reclose3-Trade
24、guidanceTU:Shelf Ready Packaging(SRP)(1)16ExamplesTU:Shelf Ready Packaging(SRP)(2)17In order to comply with the retailers needs and the equipment constraints,any new transportation unit shall follow the SRP Design Guide 9706 which focuses on:Structure(construction),Graphics,Equipment considerations(
25、if applicable)Definition:SRP(Shelf Ready Packaging)=RRP(Retail Ready Packaging)=PAV(prt-vendre)refer to a product that comes in a ready merchandised unit which:is easy to identify,is easy to open,can easily be put onto the shelf,can easily be disposed of,allows an optimisation of shelf replenishment
26、,enhances product availability,visibility and access.Background:Numerous Retail Chains all across Europe demonstrate a fairly high level of SRP implementation.Expected benefits:productivity and business opportunityTU:Shelf Ready Packaging(SRP)(3)18SRP designs:examples Before After CdO mignonettesPac
27、kaging LevelsSome demands on packaging are common to all levels,e.g.ecology,machinability,cost However some demands are specific to each level 19=food contactand/or sales unit=SRP or display=packaging assembly=transportation unit=SKU=Pallet=Unit loadPrimary packagingSecondary packagingTertiary packa
28、ging4-Palletisation requirements1-Food contact2-Requirements in Consumer Unit:PIF,EZO,Reclose3-Trade guidanceUnit Load:Palletisation requirementsThe unit load consists of transportation units(SRP or displays)grouped on a palletfor storage and transport.20 Key focus:Minimize product damage during shi
29、pping and handlingComply with industry guidelines,Maximize supply chain efficiency.Key parameters:1.Pallet dimensions:UK=1000 x1200 mm/Euro=800 x1200 mm2.Unit load height3.Over and under hang4.Area efficiency target max 95%5.Cube efficiency above 80%6.Optimum pallet pattern7.StackabilityMax 50mmMax
30、50mmCapacity optimizedPoor optimized loadPackaging MatrixComplex combination of criteria in a 3 dimensional matrix21Consumer SafetyRegulatory/Legal requirementsProduct informationShelf appealBranding/PromotionCost/EconomyEcology/EnvironmentMachinability/Line efficiencyTrade requirementsConveniencePr
31、oduct protectionDistribution/logisticPrimary packagingTertiary packagingSecondary packagingMaterialStructural designPrinting&DecorationGraphic designPackaging MatrixComplex combination of criteria in a 3 dimensional matrix22MaterialStructural designPrinting&DecorationGraphic designPackaging MatrixCo
32、mplex combination of criteria in a 3 dimensional matrix23MaterialStructural designPrinting&DecorationGraphic designPackaging MatrixComplex combination of criteria in a 3 dimensional matrix24MaterialStructural designPrinting&DecorationGraphic designPaper:cardboard,corrugatedRigid:glass,rigid plastics
33、,metalFlexibles:plastic film,aluminium foilShape,size,cold seal pattern,creases(technical drawing)Offset,flexo,gravure,Embossing,varnish,gold stampingMainlyDesignagencyIn the pack technical specificationPackaging MatrixComplex combination of criteria in a 3 dimensional matrix25MaterialStructural des
34、ignPrinting&DecorationGraphic designPaper:cardboard,corrugatedRigid:glass,rigid plastics,metalFlexibles:plastic film,aluminium foilOffset,flexo,gravure,Embossing,varnish,gold stampingMainlyDesignagencyIn the pack technical specificationShape,size,cold seal pattern,creases(technical drawing)Material:
35、Cardboard(1)From wood to pulp26 Cardboard=paper grammage 150 g/m Modern paper is almost exclusively made from cellulose fibres derived from wood.Wood(like all plant materials)consists of cellulose fibre,hemicellulose and lignin which binds cellulose fibres together.Pulping is a process of breaking/r
36、emoving the lignin in order to separate the fibres.Material:Cardboard(2)Paper characteristics depend on fibre length&pulping process27Fibre lengthPulping processHardwood(poplar,maple)=short fibres(2mm)smooth surfacereduced physical propertiesSoftwoods(pine,spruce)=long fibres(4mm)high tensile,tear,f
37、old and puncture strengthrougher surfacevariations in densityMechanical pulpinghigh yield(because there is still lots of lignin)Presence of lignin makes the fibres hard and rigidLow density,breakableChemical pulpingPreserve fibre lengthHigh density(flexible and soft fibres)High whiteness,brightness,
38、and light stabilityHigh purity,no odour and taint contaminationCombined processessemi-chemical(chemical treatment+refining)thermo-mechanical(wood softened by heat before refining)CTMP(chemical-thermo-mechanical-pulp)Recycled FibresProperties are inherited from the original fibre source,however,each
39、re-pulping degrades and reduces the fibre length reduced physical properties contaminated by water insoluble adhesives,non-removable inks,plastic debris28Material:Cardboard(2)Paper production process(simple version)WoodPaper reelMaterial:Cardboard(3)GradeVisual appearanceCompositionTypical applicati
40、onsVirgin fibresSBS/SBBSolid Bleached Sulphated/BoardGZSulphate,bleached virgin fibresFBBFolding Box boardGC1GC2White backCream backOuter layer GZCore layer fully mechanical or chemothermo mechanical pulpGC3 Cream backMade of recycled light or unprinted deinked food grade cardboardRecycled pulpWLCWh
41、ite lined chipboardTriplexGTOuter layers GZ/GCCore layer fully recycled fibresWLCWhite lined chipboardDuplexGD1 Numbering due to board densityTop layer GZCore layer fully recycled fibreGD2GD3Top layer GZ/GCCore layer fully recycled fibre29Cardboard classification,properties and main applicationsBest
42、 QualityLowest QualityILM 300gILM 50gGD2Material:CorrugatedPhysical properties depend on structure,fluting and liner type30ABCEFFlute sizes:Structure:types of combined boardsTriple wallDouble wallSingle wallSingle faceKraft liner(virgin)vs.Test liner(recycled)Material:CorrugatedExamples31 Bulk trans
43、portation Displays Shelf Ready Pack Consumer unitMaterial:PlasticsMain polymers used in packaging32Polyethylene terephthalateHigh density polyethylenePolyvinyl chlorideLow density polyethylenePolypropylenePolystyreneThermoformingFilm extrusioninjectionBlown film extrusion ThermoformingThermoformingI
44、njection blow mouldingInjection blow mouldingFilm extrusion ThermoformingInjection blow mouldingMaterial:PlasticsMain technologies around plastics33ThermoformingFilm extrusionmale formfemale formHeating platesresinresin extrudercast roll MDOTDOreels before convertingMaterial:PlasticsMain technologie
45、s around plastics34In-mould labellingInjection mouldingEjector UnitMoving PartFixed PartHeated BarrelHopperExtrusion screwPrint vs.IMLMaterial:PlasticsMain technologies around plastics35Extrusion blown filmsExtrusion blow mouldingMaterial:Glass36Glass is used to pack a variety of products e.g.Drinks
46、 Powders Cosmetics Pharmaceuticals Food Inert Absolute gas and moisture barrier Transparency Rigidity Adjustable light transmission with colors Heat resistance Recyclability/Reusability Value perceptionCharacteristics:Recipe of glass:All ingredients can entirely be replaced by culletThree main color
47、s:Flint glassGreen glassAmber glass Other colors are possibleGlass main applications and propertiesMaterial:GlassGlass production37Raw material mixingMelting and formingCold endBlow and Blow ProcessPress and Blow ProcessMoulding toolMaterial:MetalMetal used in packaging are Aluminium and Steel38Meta
48、l is applied in two forms in packaging:Aluminium(Al)Steel(Fe)PrintPETAdhesiveAluminumAdhesivePEFlexible films as barrier layer(Al)Cans(Al and Fe)Membranes(Al)Closures(Al and Fe)Magnetism Corrosion No migration of gases and liquids No light transmission Heat resistant Metallic appearance Rigidity Dea
49、d folding behaviourCharacteristics:Applications:Packaging MatrixComplex combination of criteria in a 3 dimensional matrix39MaterialStructural designPrinting&DecorationGraphic designPaper:cardboard,corrugatedRigid:glass,rigid plastics,metalFlexibles:plastic film,aluminium foilOffset,flexo,gravure,Emb
50、ossing,varnish,gold stampingMainlyDesignagencyIn the pack technical specificationShape,size,cold seal pattern,creases(technical drawing)Structure:ShapesBase shapes for carton boxes40PrismsPolygonsCurvesBiggest growing area in market during the 10 last yearsParallelepipedsMinimalist shapes back into
