PACKAGING DEMANDS

Prepared by Mrs.M.Janani

Department of Commerce (International Business)

Government Arts College, Coimbatore – 18.

Reference: Fundamentals of Packaging Technology

Authors: S.Natarajan

M.Govindarajan

V.Kumar

• Packaging manufacturers need to adjust to differentconsumer demands. In particular, this includes thechoice of suitable material which has to ensure productsafety, be sustainable, easy to transport and store andalso have a persuasive impact on potential customersseeking to make purchase decisions. Especially wherefood is concerned, paper and cardboard are very muchin demand. though India is one of the largest producersof foods and agrobased products estimated at rs 500billion, 20 billion of these get wasted due to nonavailability of processing and packaging. over the years,the food packaging industry has undergonetremendous change and with technologicaladvancements, the process continues.

• Consumer Packaged Goods• The adaptability of plastic packaging allows it to meet a

variety of needs for consumer goods. As packaging movesfrom design phase through recovery/disposal, the varyingtypes of plastics and their unique properties offer manychoices for the decisions that are made along the way:Colour, Weight, Size,Shape,Utility,Printing,Protection,andmore. Plastics help bring home more product with lesspackaging. Plastic packaging in general is lightweight andstrong. Different plastics can be moulded, extruded, cast,and blown into seemingly limitless shapes and films orfoams. This resourcefulness often delivers while usingminimal resources, creating less waste, consuming fewerresources, and creating fewer CO2 emissions thanalternative materials. Plastics make packaging moreefficient, which ultimately conserves resources.

• Anti-corrosive Packaging• Anti-corrosion refers to the protection of metal

surfaces from corroding in high-risk (corrosive)environments. Products can be protected againstcorrosion and avoid the tedious sequences usinganti-corrosive packaging. Materials such as VCIbubble film, paper, oil, chips, and bags that areused as a part of anticorrosive packaging helps toprevent goods from exposing to various climatezones. Moreover, this packaging can be used inthe scenarios such as export of goods over longdistances, long-term storage of metal goods, andmetals that are sensitive for corrosion.

• Pharma Packaging

• Pharma Packaging, also known as the drug packaging,is the packaging processes used for pharmaceuticaloperations involving production through distributionchannels to the end consumer. The packaging ofPharma products provides containment, drug safety,identity convenience of handling and delivery. Themajor role of pharmaceutical packaging is to providelife-saving drugs, surgical devices, blood and bloodproducts, nutraceuticals, powders, liquid and dosageforms, solid and semisolid dosage forms. This kind ofpackaging is involved in dosing, dispensing etc. Formsof packaging in pharma industry: Blister packs, Bottles,Timed Dosing.

• Types of packaging used in pharma

• Glass – for bottles, syringes, ampoules, vialsand cartridges. Plastic – for bottles, tubes, foilsand lamination. Cardboard – for boxes. Paper– for labels. Metal – Metals like aluminium fortubes, caps, blister, pressurized cylinders etc.Rubber – for closures.

• Trends in Plastics Packaging are:

• Changing consumer habits

• Increased urbanization and growing youngpopulation

• Increased use of home and personal careproducts

• Developments in the field of polymer science

• Increased investment in food processing andproduction in china, and Increased preferenceof plastic pouches, by consumers and retailers.

• FLEXIBLE PACKAGING

• Flexible packaging can be made with flexiblematerials that can be packed, sealed and canretain the freshness of its content. Be it mouldingthe packages into a variety of shapes orpreserving the flavour and safety of food orlogistical aspects, all are covered under theflexible packaging. This is the major benefit thatmakes flexible packaging the first choice for foodpackaging. The package can last for a very longtime; if it is stored in the right conditions. Flexiblepackaging is environmentally friendly as it usesless material and less wastages to make it.

• BENEFITS OF FLEXIBLE PACKAGING• Adds value and marketability to food and non-

food products alike from ensuring food safety andextended shelf life by providing heat seal, barrierprotection, ease of use, press-to-seal and high-quality print finishes. This type of packagingproduces a fraction of waste during the printingprocess, overall reducing landfill discards.Improvements in productions processes havereduced water and energy consumption,greenhouse gas and emissions and volatileorganic compounds. Finally, lighter-weightflexible packages result in less transportation-related energy and fossil fuel consumption, andenvironmental pollution.

• Industrial packaging : Industrial packaging is used toprotect, ship and store a wide range of goods. Typically,industrial packaging is used at the production site, rightafter production, although it can be used at any pointin the supply chain. This type of packaging is usuallyused on products that are sensitive and rely heavily onstability or that are hazardous or that are bulky orproducts that have components that are sensitive toeach other. Industrial packaging materials can include:Wood, such as, wood board, derails board, plywood,skids, wooden crates, wooden boxes and more.Formed stainless steel and other metals. Corrugatedcardboard, fibreboard, paperboard and more. Variousplastic forms shrink wrap and more. Polypropylene.

ASEPTCIC PROCESSIG

Aseptic processing is a processing techniquewherein commercially thermally sterilized liquidproducts (typically food or pharmaceutical) arepackaged into previously sterilized containersunder sterile conditions to produce shelf-stableproducts that do not need refrigeration. Asepticprocessing is a processing technique whereincommercially thermally sterilized liquid productsare packaged into previously sterilized containersunder sterile conditions to produce shelfstableproducts that do not need refrigeration

• There are two specific fields of application of aseptic packagingtechnology-

• 1. Packaging of pre-sterilised and sterile products. E.g. Milk anddairy products, puddings, desserts, fruit and vegetables.

• 2. Packaging of non-sterile products to avoid infection bymicroorganism E.g. Fermented dairy products like yoghurt. Asepticpackaging technology is fundamentally different from that ofconventional food processing by canning.

• In canning, the process begins with treating the food prior to filling.• Initial operations inactivate enzymes so that these will not degrade

the product during processing.• The package is cleaned, and the product is introduced into the

package, usually hot.• Generally, air that can cause oxidative damage is removed from the

interior.

Types of Aseptic Packs

• Carton Boxes, Bags and Pouches, Cups andTrays, Bottles and Jars, Metal Cans, PlasticCans, Composite Cans are used for packaging.Integrity Check for Aseptic Packaging material

• Teardown test – Sealing strength

• Electrolytic Test – Pinhole testing

• Dye test – For pinholes in laminated cartons

• Sterility check.

• Advantages of Aseptic Packaging:• Convenience Aseptic packages are portable,

lightweight, and shatterproof and easily transportableFood Safety The aseptic process and carton togetherensure that the liquid food or beverage inside is freefrom harmful bacteria and contaminants. Norefrigeration required Long shelf life More nutritionCompared with canning, products can retain morenutrients as well as natural taste, colour and textureLow Packaging to product ratio Limitations

• Plant Installation cost is high as compare to canning• Gas transmission rate of Aseptic bag/ package• Overcooked flavour in some products• Lack of equipment for particulate sterilization, due

especially to settling of solids and thus over processing

• What is a Blow Fill Seal Machine• A Blow Fill Seal machine is a type of Horizontal Form Fill

Seal Machine where a container is formed, filled and thensealed continuously in a sterile(germ free) environment.Since it is mainly used in the pharma industry. It is alsoknown as Blow Fill Seal pharmaceutical seal machine. Blow-Fill-Seal (BFS) technology is a manufacturing techniqueused to produce small, (0.1mL) and large volume, (500mL+) liquid-filled containers. Originally developed in Europe inthe 1930s, it was introduced in the United States in the1960s, but over the last 20 years it has become moreprevalent within the pharmaceutical industry and is nowwidely considered to be the superior form of asepticprocessing by various medicine regulatory agenciesincluding the U.S. Food and Drug Administration (FDA) inthe packaging of pharmaceutical and healthcare products.

• The basic concept of BFS is that a container is formed, filled, andsealed in a continuous process without human intervention, in asterile enclosed area inside a machine. Thus this technology can beused to aseptically manufacture sterile pharmaceutical liquiddosage forms. The process is multi-stepped: first, pharmaceutical-grade plastic resin is vertically heat extruded through a circularthroat to form a hanging tube called the parison. This extrudedtube is then enclosed within a two-part mould, and the tube is cutabove the mould. The mould is transferred to the filling zone, orsterile filling space, where filling needles (mandrels) are loweredand used to inflate the plastic to form the container within themould. Following the formation of the container, the mandrel isused to fill the container with liquid. Following filling the mandrelsare retracted and a secondary top mould seals the container. Allactions take place inside a sterile shrouded chamber inside themachine. The product is then discharged to a non-sterile area forlabeling, packaging and distribution.

• Blow-fill-seal technology reduces personnelintervention making it a more robust methodfor the aseptic preparation of sterilepharmaceuticals. BFS is used for the filling ofvials for parenteral preparations and infusions,eye drops, and inhalation products. Generallythe plastic containers are made up ofpolyethylene and polypropylene.Polypropylene is more commonly used toform containers which are further sterilised byautoclaving as polypropylene has greaterthermostability.

• Injection Modelling and Fill, Seal

• Two-step process that molds vials then transfers themto the filling line to be filled and heat sealed. (No risk ofcontact between product and heat) Added flexibilitythat ranges from small batches at 1,500 vials per hourto full-scale production at 15,000 vials per hour.Smaller dimensions mean machines fit in most existingcontract filling environments. Improved end-userexperience. Easily switch out or replace damaged,worn, or old parts. Less than half of the cost oftraditional BFS machines with the same productioncapacity. More environmentally friendly and noexcessively wasted plastic material. Provides the optionfor multilayer packaging designs and calibrated drops.

• BLOW FILL SEAL• One-step process that blows and fills vials at the

same time. (Risk of contact between product andheat) Only capable of full-scale production atroughly 10,000 vials per hour without being ableto stop the machine. 3 working shifts necessaryonce started. Large dimensions with arecommended minimum room size of 500-600square feet. Halted production time due to thechangeover of molds. Higher initial financialinvestment and overall cost. Large amount ofplastic waste is cut from the parison and thendisposed of. Extremely complex set up,maintenance, and operating instructions thatrequire highly skilled and well-trained personnel.

• BLOW FILL SEAL• One-step process that blows and fills vials at the

same time. (Risk of contact between product andheat) Only capable of full-scale production atroughly 10,000 vials per hour without being ableto stop the machine. 3 working shifts necessaryonce started. Large dimensions with arecommended minimum room size of 500-600square feet. Halted production time due to thechangeover of molds. Higher initial financialinvestment and overall cost. Large amount ofplastic waste is cut from the parison and thendisposed of. Extremely complex set up,maintenance, and operating instructions thatrequire highly skilled and well-trained personnel.

• The major difference between injection mouldingand blow moulding is the kind of productproduced. Typically, blow moulding is designed toproduce hollow, singular containers, such asbottles. On the other hand, injection moulding isused to produce solid pieces, such as plasticproducts.

• Advantages of blow moulding: Production In largeQuantities. Blow Moulding is a process that canhelp the companies to produce large number ofuniform units in a short period of time,Production of an Array of different products,Automation, Low Cost. Disadvantages: TheRequirement of Precision Generates Waste,Petroleum Usage, Affects the Environment.

• Containerization is a system of intermodal freight transport usingintermodal containers (also called shipping containers and ISOcontainers). The containers have standardized dimensions. They canbe loaded and unloaded, stacked, transported efficiently over longdistances, and transferred from one mode of transport toanother—container ships, rail transport flatcars, and semi-trailertrucks—without being opened. The handling system is completelymechanized so that all handling is done with cranes and specialforklift trucks. All containers are numbered and tracked usingcomputerized systems. Containerization did away with the manualsorting of most shipments and the need for warehousing. Itdisplaced many thousands of dock workers who formerly handledbreak bulk cargo. Containerization also reduced congestion in ports,significantly shortened shipping time and reduced losses fromdamage and theft. Containers can be made from a wide range ofmaterials such as steel, fibre-reinforced polymer, aluminium or acombination of all. Containers can be made of weathering steel tominimize maintenance needs.

• Classification of containers: The containers areclassified into various types depending upontheir Characteristics. These are followsDepending upon its functions: a) lesscontainer load((LCL) b) Full container Load(FCL) c) Open top. Depending on its length: a)20 Ft container = 20x8x8.5 b) 40 Ft container =40x8x8.5 c) 45 Ft container = 45x8x8.5.Depending on its weight: a) Less weightcontainer = below 18 tonnes b) Mediumweight container = 18 to 25 tonnes c) Heavyweight container = above 25 tonnes.

• Types of containers:

• 1. End loading: Fully enclosed, equipped with end– doors, suitable for general cargo. It is basicintermodal container.

• 2. Side loading: fully enclosed, equipped with sidedoor for use in stowing and discharge of cargo.

• 3. Open top: used for carriage of heavy, bulky ormachinery items where loading or discharge ofthe cargo through end or side door is notpractical. Most open top containers are equippedwith fabric covers. Some open top versions arefilled with removal hatch – panel covers of adetachable full size metal roof.

• 4. Ventilated: for cargoes which should not be exposed torapid or sudden temperature changes, ventilated versionsare available.

• 5. Refrigerator: also known as refer container. Insulated andequipped with a built in refrigeration system, powered bydirect electrical connection or by diesel or gasolinegenerator used primarily for refrigeration of frozen foods.

• 6. Dry bulk: designed for carriage of dry bulk cargoes suchas chemicals and grains.

• 7. Liquid bulk: tank type containers for carriage of goods• 8. Flat rack: available in a variety of sizes and models, the

flat racks are used for lumber, mill products, large heavy orbulky items or machinery & vehicles. Some are equippedwith removable sides and fabric covers.

• 9. Livestock: containers for livestock carriage. Thesecontainers are available for transporting poultry, cattle, andother livestock

• WHAT IS ELECTRONIC ARTICLE SURVEILLANCE(EAS)

• Electronic article surveillance (EAS) alarmsystems are triggered when someone leaves astore or building with a product having an activetag or label attached to it. EAS systems are oftenapplied to prevent shoplifting in stores or theft ofvaluable properties from e.g. public buildings.There are several types of EAS solutions available.Century Europe’s EAS product range consists of:AM (acoustic-magnetic) systems RF (radiofrequency) systems Systems combined with RFIDSystems that are RFID-ready RFID only

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