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PACKAGING TECHNOLOGY
INDEX
S. No. Topic
01 Definition
02 Types Of Packaging
03 Importance of Packaging
04 Packaging History
05 Work Flow
06 Standard Operating Procedure
07 Sampling Plan (Mil.Std 105e)
08 Acceptable Quality Limit (AQL)
09 Art work Development
10 Properties of Packaging Films
11 Definitions
12 Extrusion Coating
13 Wrapper Process
14 Issue in Wrappers
15 Kraft paper
16 Properties Of Paper
17 Cartons Process and its issue
18 Box Process and its issue
19 Test of packaging materials
20 Packaging Equipment’s
21 Anatomy of Barcode
22 Packaging Symbols
23 Wrapping Machine
24 Packaging Film (Single & Laminated) Properties
Packaging:
Definition Packaging is the technology of enclosing or protecting products for distribution, storage, sell, and use. Packaging also refers to the process of designing, evaluating, and producing packages. Packaging can be described as a coordinated system of preparing goods for transport, warehousing, logistics, sale, and end use. Packaging contains, protects, preserves, transports, informs, and sells. In many countries it is fully integrated into government, business, and institutional, industrial, and personal use. Types of Packaging
Primary packaging is the material that first envelops the product and holds it. This usually is the smallest unit of distribution or use and is the package which is in direct contact with the contents.
The wrapper which is directly contact with the product.
Wrapper include in primary.
Secondary packaging is outside the primary packaging, and may be used to prevent pilferage or to group primary packages together.
Boxes etc.
Tertiary or transit packaging is used for bulk handling, warehouse storage and transport shipping. The most common form is a palletized unit load that packs tightly into containers.
Cartons, Jars etc.
TYPES
Aseptic
processing Primary
Liquid whole eggs or dairy
products
Trays Primary Portion of fish or meat
Bags Primary Potato chips, apples, rice
Boxes Secondary
Corrugated box of primary
packages: box of cereal cartons,
frozen pizzas
Cans Primary Can of tomato soup
Cartons, coated
paper Primary
Carton of eggs, milk or juice
cartons
Flexible
packaging Primary Bagged salad
Pallets Tertiary
A series of boxes on a single pallet
used to transport from the
manufacturing plant to a
distribution center
Wrappers Tertiary Used to wrap the boxes on the
pallet for transport
Important Functions of Packaging
Physical protection – The objects enclosed in the package may require protection from, among other things, mechanical shock, vibration, electrostatic discharge, compression, temperature, etc.
Barrier protection – A barrier to oxygen, water vapor, dust, etc., is often required. Permeation is a critical factor in design. Some packages contain desiccants or oxygen absorbers to help extend shelf life. Modified atmospheres or controlled atmospheres are also maintained in some food packages. Keeping the contents clean, fresh, sterile and safe for the duration of the intended shelf life is a primary function. A barrier is also implemented in cases where segregation of two materials prior to end use is required, as in the case of special paints, glues, medical fluids, etc. At the consumer end, the packaging barrier is broken or measured amounts of material are removed for mixing and subsequent end use.
Containment or agglomeration – Small objects are typically grouped together in one package for reasons of storage and selling efficiency. For example, a single box of 1000 pencils requires less physical handling than 1000 single pencils. Liquids, powders, and granular materials need containment.
Information transmission – Packages and labels communicate how to use,
transport, recycle, or dispose of the package or product. With pharmaceuticals, food, medical, and chemical products, some types of information are required by government legislation. Some packages and labels also are used for track and trace purposes. Most items include their serial and lot numbers on the packaging, and in the case of food
products, medicine, and some chemicals the packaging often contains an expiry/best-before date, usually in a shorthand form. Packages may indicate their construction material with a symbol.
Marketing – Packaging and labels can be used by marketers to encourage potential buyers to purchase a product. Package graphic design and physical design have been important and constantly evolving phenomena for several decades. Marketing communications and graphic design are applied to the surface of the package and often to the point of sale display. Most packaging is designed to reflect the brand's message and identity.
Security – Packaging can play an important role in reducing the security risks of shipment. Packages can be made with improved tamper resistance to deter manipulation and they can also have tamper-evident features indicating that tampering has taken place. Packages can be engineered to help reduce the risks of package pilferage or the theft and resale of products: Some package constructions are more resistant to pilferage than other types, and some have pilfer-indicating seals. Counterfeit consumer goods, unauthorized sales (diversion), material substitution and tampering can all be minimized or prevented with such anti-counterfeiting technologies. Packages may include authentication seals and use security printing to help indicate that the package and contents are not counterfeit. Packages also can include anti-theft devices such as dye-packs, RFID tags, or electronic article surveillance tags that can be activated or detected by devices at exit points and require specialized tools to deactivate. Using packaging in this way is a means of retail loss prevention.
Convenience – Packages can have features that add convenience in distribution, handling, stacking, display, sale, opening, reclosing, using, dispensing, reusing, recycling, and ease of disposal
Portion control – Single serving or single dosage packaging has a precise amount of contents to control usage. Bulk commodities (such as salt) can be divided into packages that are a more suitable size for individual households. It also aids the control of inventory: selling sealed one-liter bottles of milk, rather than having people bring their own bottles to fill themselves.
PACKAGING HISTORY:
The Evolution of Packaging:
Product packaging plays several important functions which enable commerce and trade. The functions of modern day packaging go beyond containing, protecting and preserving products. It also includes functions to communicate, promote and transact products. Packaging provides several visceral cues designed to affect consumer’s perception of the product and influence their behavior. These functions are considered normal today, but it took over 150 years for product packaging to evolve into a carefully designed artifact that integrates multiple functions of commerce into a thin film wrapped around products. Growing competition and continuous technological innovations have shaped the evolution of packaging since 1860s. As we researched key technology and material innovations during this vast period, it became evident that these developments revolved closely around cultural phenomenon and consumer behaviors prevalent around given time periods. So we sectioned our analysis across 6 time periods and mapped the technological developments against cultural developments. This approach provided unique lenses to look at the history of packaging and revealed very interesting perspectives on where things stand today and how we can design better for the future of packaging.
Early Age Packaging Materials
The conclusive summary of historic development of packaging above
suggests a lot of patterns across several decades. Lets dive deep into
each of those time periods to have a better understanding of these
patterns. It is interesting to see how the innovations, while trying to
meet consumer needs, periodically shaped consumer behaviors too.
As a result of the Industrial Revolution, there were significant
innovations in improving manufacturing processes and materials.
Most materials used for storing products included wood crates,
barrels, cloth, glass — were primarily rigid and expensive. But
manufacturers of high value goods saw packaging as a reflection of
the quality of their products, and hence there was a palpable interest
in finding new and cheaper ways to make a trade more appealing.
1. Glass
In 1200 B.C. glass was pressed into molds to make cups and bowls. The techniques to blow glass continued to evolve and split molding was developed in 17th century allowing for irregular shapes. Since 19th century, glass is primarily used to package medicines, spirits, liquids,
In 1830s, tin boxes were used for selling cookies, chocolates, and tobacco products. Soon after, first soft metal tubes were produced in 1841 to be used for artist paints and they gained instant popularity.
3. Paper
In 1690, first paper mill in the U.S. was built near Philadelphia. At that time paper was hand-made out of parchment and rags, both of which were expensive and limited in supply.
In 1796, Lithography was invented Alois Senfelder in Munich. This enabled printing of black-and-white illustrations on printed labels. One-color lithographed or letterpress labels were widely used on glass bottles, metal boxes and early paperboard boxes. Color printing or chromolithography was invented in 1837 and became popular soon after manufacturers realized its potential.
First paper making cylinder machine was installed in 1817 by Thomas Gilpin in Delaware used to make paperboards and other forms of paper used in packaging. This gave birth to ‘flexible packaging’. Mechanization made paper plentiful but cost limited its use until paper could be made commercially from wooden pulp in 1850s. The invention of paper bag making machine in by Francis Wolle in 1852 further pushed use of paper in packaging.
1860s, 1870s, 1880s: The Era of Dual Use Packaging
The second wave of Industrial Revolution began during this time and
with major developments in railroads, trade suddenly flourished.
Materials and processes during this time were still expensive and
laborious. During this time packaging was primarily seen as a way of
storage, and reserved for only high value goods like jewelry, gift items,
shoes, and premium foods. As the materials were indispensable, they
were structurally designed to serve a function after product use. Thus,
dual use packaging was a solution to command high price and assure
ingenuity of the manufacturing quality.
More innovations during this period:
1866 — First printed metal boxes were made for Dr. Lyon’s tooth powder. Metal tear-strip was also invented during this time. Further innovations in sealing the packaging to preserve goods, continued during this period.
1867 — Process for deriving cellulose fiber from wood pulp was developed. Wood being cheap and plentiful, this fiber source rapidly replaced cloth fibers as the primary source of paper fiber. Today, virtually all paper has wood pulp as the source of cellulose fiber.
1870 — First registered U.S. trademark was awarded to the Eagle-Arwill Chemical Paint Company, thus establishing a goodwill between manufacturer and the consumer.
1879 — Robert Gair accidently invented paperboard cartons when a
metal rule normally used to crease bags shifted in position and cut the
and other high value goods.
2. Metals
In 1200 A.D. the process of tin plating was invented in Bohemia. Tin was the first metal that economically allowed use of metals in packaging, soon it was used to make tin cans and tin foils. In early 1800s Nicholas Appert, found that food sealed in tin containers and sterilized by boiling could be preserved for long periods. Over a period of time, this established metal packaging as a food grade packaging material.
bags. Gair concluded that cutting and creasing paperboard in one
operation would have advantages; the first automatically made carton,
now referred to as “semi-flexible packaging,” was created. Such folding
cartons or “tubular cartons” dominate the dried, processed food
market.
Packaging Shape as an Identity — Coca-Cola
In early 1900s, Coca Cola found that a straight-sided bottle wasn't distinctive enough and that Coca-Cola was becoming easily confused with ‘copycat’ brands. Glass manufacturers were approached to come up with a unique bottle design for Coca-Cola. The Root Glass Company of Terre Haute, Indiana, designed with the famous contour shape, which won enthusiastic approval from Coca-Cola in 1915 and was introduced in 1916. The new bottle design instantly became an integral part of the brand identity and is today one of the most recognized icons in the world — even in the dark.
More innovations during this period:
1890 — Michael Owens invented first automatic rotary bottle-making machine. Suddenly, glass containers of all shapes and sizes became economically attractive for consumer products, and from the early 1900s until the late 1960s glass containers dominated the market for liquid products.
1894 — Thompson and Norris produced the first double-faced corrugated boxes that prevented material from stretching during transportation. Corrugated boxes played an essential role in developing mass distribution throughout the 20th century.
1920s, 1930s, 1940s: The Era of “Silent Salesman”
In the early part of the 19th century, retailers played an important role
in making a trade happen. Food items were sold in loose, and needed
wrapping and weighing. This meant that consumer had to wait while
their orders were made up. But the rise of cheap and clean packaging
solutions had solved this problem to a large extent and retailer’s role in
facilitating a trade started to marginalize. This allowed for huge retail
chains to come in where products were displayed on the shelf, and
consumer themselves had to make a purchase choice. The big chains
had a price advantage, and were slowly gaining momentum.
But immediately after The Great Depression, supermarkets became a
dominant force and marked a major shift in the consumer behavior.
Manufacturers once again turned to product packaging to be the silent
salesman — differentiating from competition and affecting a sale.
Increasing Visual Appeal — Flexography
Most packaging till this period leaned on distinct typographic treatments to create a visual identity. Due to limitations of letterpress printing, product packaging could only be embraced with illustrative painted imagery to define the contents, it was not truly an interpretation or an honest impression of the product contents. It was after the invention of aniline printing technology in late 1920s that packaging materials afforded visual information with a higher degree of accuracy, reproducing impressions of actuality realistically. The aniline printing used aniline dye on rubber blocks and the technique allowed printing on any kind of substrate including corrugated boards, milk cartons, paper bags, folding cartons and metallic films. This technique later on came to be known as
Flexography, and is now the default for package printing.
More innovations during this period:
1920s — Nutritional value of canned foods gradually approached that of the fresh product. For consumers, the choice between fresh or canned food increasingly became a question of taste, preference, and convenience.
1924 — DuPont bought licensed exclusive rights to make and sell Cellophane in U.S. The cellophane sheet was a clear, transparent protective layer wrapped over primary packaging, to prevent product from moisture and extend its shelf life.
1931—Aluminum foil was packaged in appropriate sizes and thicknesses, in both rolls and sheets a decade after first aluminium foil laminated carton was produced. It started being used as an institutional wrap primarily for use by hotel, restaurant, and hospital kitchens.
1930s and 1940s — The years preceding World War II, amidst a climate of escalating industry consolidation, were also a time of tremendous innovations for synthetics like vinyl, ethylene, and acrylic. U.S. government massively invested in building industrial infrastructure for this new sector. And these innovations lead to discovery of PVC, Nylon, Teflon, Polystyrene, Polyethylene, each of which transformed several industries and heralded the rise of Plastic Age in years to follow.
1950s, 1960s, 1970s: Convenience As The Motivation
Post World War II, U.S. experienced massive economic growth over next three
decades as its gross national product grew more than nine times the value of
$100 billion in 1940. During the time, even the poorest Americans were affluent
compared to world standards. As a result of this, everyone was able to afford
most luxuries available at the time. This lead to an exuberant growth in
consumerism, and everyone wanting to have a modern and convenient lifestyle.
Most development of the moldable metals and plastics, happened much earlier
than this period, but its exploits were primarily limited to military use. But after
WWII, the consumer market exploded with the continuous innovations in
aluminium and plastics. Owing to mega efforts of giants like DuPont, Dow
Chemicals, and the likes — shinier, sturdier, cleaner, more flexible, and modern
looking materials were available at cheaper price compared to traditional
materials. This provided impetus to re-invent existing packaging solutions and
plastics and metal cans took over majority of consumer packaging, while paper
was limited in use and glass reserved for high value products only.
Explosion of the Toxins — Plastics
DuPont and Dow Chemical’s heralded the rapid rise of plastics as they were used for textiles, tires, toys, paints, electronics, and as packaging material, affecting all aspects of life. Alan Pendry captured the versatility of plastics in his award winning short film The Shape of Plastics, in 1962. While the widespread use of plastics made a lot of economic sense, its environmental effects were soon apparent. In absence of regulations, it was difficult to keep a check on manufacturers. U.S. government passed National Environmental Protection Act in 1970 and form EPA as an authority to tackle environmental issues and form necessary regulations.
More innovations during this period:
1950 — Polyethylene was invented to be used as cable shielding material, but soon it outgrew its original use and was used to make products such as food and garbage bags, packaging films, and milk containers. In less than a decade, the demand for PE grew from 5 million pounds to 1.2 billion pounds at the end of 1960.
1960 — Reynolds and Alcoa made all-aluminium cans out of one piece of metal. This solved the problem of weights of cans, now only a lid needed to be attached. This provided impetus for invention of rip-off closure and the pop-top lids on aluminium cans.
1977 — Polyethylene Terephthalate (PETE) invented as material for beverage packaging is today one of the most commonly used plastics.
Packaging machines may be of the following general types:
Accumulating and collating machines
Blister packs, skin packs and vacuum packaging machines
Bottle caps equipment, over-capping, lidding, closing, seaming and sealing machines
Box, case and tray forming, packing, unpacking, closing and sealing machines
Cartoning machines
Cleaning, sterilizing, cooling and drying machines
Coding, printing, marking, stamping, and imprinting machines
Converting machines
Conveyor belts, accumulating and related machines
Feeding, orienting, placing and related machines
Filling machines: handling dry, powdered, solid, liquid, gas, or viscous products
Inspecting: visual, sound, metal detecting, etc.
Label dispenser
Orienting, unscrambling machines
Package filling and closing machines
Palletizing, depalletizing, unit load assembly
Product identification: labeling, marking, etc.
Sealing machines: heat sealer
Slitting machines
Weighing machines: check weigher, multihead weigher Wrapping machines: stretch wrapping, shrink wrap, banding Form, fill and seal machines.
STANDARD OPERATING PROCEDURE OF PACKAGING
SAMPLING, TESTING, CLEARANCE:
Receiving Intimation for inspection and sampling:
Store provides daily receiving of in-coming materials of
24hours receiving in the early first half on next working
day through e-mail.
In case of urgent material requirement, concerned
departments intimate to QA for urgent sampling and
further material status.
In case of late receiving, concerned department
intimates QA earlier in working hours.
Procedure for Sampling and Inspection:
Materials are inspected as per daily receiving and
samples are drawn of each item as per approved
sample plan, refer SOP “Sampling Plan & AQL of
Packaging Materials”.
In case of any deviation / unusual observation QA
Inspector / Officer / Executive reports to immediate
Head(s) and concerned departments immediately.
Procedure for Testing and analysis:
All in-coming materials are tested as per work instructions.
Assure that COA (certificate of analysis) must be submitted by supplier with every incoming delivery.
Material analysis report of testing parameters is filled against standard specifications and QA status with comments to be updated on ERP in respective organization and Status stickers to be pasted on items within 2 working days.
In case of any deviation observed QA shall report all testing / analysis results against standard specifications of each material to immediate Head(s) and concerned departments.
In case of HOLD /REJECTED material QA shall intimate all concerns through e-mail / other communication means and paste Yellow and Red stickers respectively on Hold/ Rejected lots.
In case of Rejection of any material QA issue a Rejection Certificate refer SOP “Rejection Approval Criteria “duly signed by QA Officer / Executive / AM / Sr. Manager for Dispose off , return back to supplier or sale out as per management decision for the subject material.
In case of HOLD, additional sampling, retesting and machine / line trial will be conducted by QA and sometimes R&D personnel as well (if required).
As per further results of re-sampling / machine trial, decision is made for the utilization or rejection of the subject HOLD material.
In case of conditional acceptance of any material either penalty or warning is given to the supplier against deviation / problem observed during sampling / inspection /testing /machine trial as per policy.
SAMPLING PLAN (MILITARY STANDARD 105e) USED IN INDUSTRY FOR SAMPLING OF
MATERIALS:
General Requirements:
Sample Size Unit:
In general lot size no’s shall be considering of main packing/supply unit like: For Packaging
materials packing units are Reels, Cartons, and Bundles of boxes etc.
4.2.2 Packaging Materials:
For Wrappers, Poly-hi shrink, Bopp, PVC, Aluminum foil at least 1 meter pcs
/reel.
Boxes, Jars, Tins, Sticker, Poly bags. Caps Seal are taken in form of No’s/Pcs.
Cartons are in form of Pcs/No’s.
Glue is 100 ml.
Hot melt wax is 100 gm.
Procedure:
Packaging materials sampling is carried out as per sampling Plan reference
Annexure II.
Packaging testing is then performed with reference to related material
standard & specifications respectively.
The material are then accepted when comply with specification & standards
else rejected.
Rejection due to variation in physical attributes are subjected to follow AQL’s
reference Annexure – III, IV &V for RM/PM defect categorization and rejection
level with respect to lot size.
At In process stage the Semi Finished Products at Hilal 1 & 2 are tested for
Micro analysis as per Sampling plan.
Switching Rule of Inspection:
Start the sampling from normal level with respect to sampling plan. Sampling as per sample size should be in such a way that the whole lot
presence must be covered by dividing the sample size to whole lot randomly. In case of following conditions the sampling level can be switched to Reduced
inspection from normal. Production steady 10 consecutive lots accepted Approved by responsible authority
Similarly when below conditions observed the reduced inspection shall be
switch to normal inspection level. Lot rejected Irregular production Lot meets neither accept nor reject criteria. Other conditions warrant return to normal inspection.
The normal inspection shall also switch to tightened inspection when experience 2 out of 5 consecutive lots rejected.
Similarly in case of 5 consecutive lots accepted the tightened inspection can be switched to normal level and in case of 3 lots rejected on tightened inspection the supplier will be consider for black list.
Definitions
Term/word/statement Meaning/Description
AQL It is defined as the maximum number of defects per unit of
product that for the purpose of sampling inspection can be
considered satisfactory/acceptable. The Acceptable Quality
Limit, commonly referred to as AQL, is a method widely used
to measure a production order sample to find whether or
not the entire product order has met the specifications.
Defects classification Are divided into 3 Critical, Major & Minor as below.
Critical A defect that can compromise product safety, purity, or
identity that may be harmful to the consumer.
Major A defect that jeopardizes the integrity or function of the
package.
Minor A defect that does not affect product safety, purity, or
identity, or package integrity of functions
Reference Used:
S.
No
Description
1. Military Standard Sampling procedure and tables for inspection by attributes Mil
–STD-105E 10th May 1989. (Single Sampling Plan)
FLOW CHART OF SAMPLING PLAN:
Start
Reduced Normal Tightened
Production Steady 10 Consecutive Lots
accepted Approved by responsible
authority
2 out of 5 consecutive lots rejected
Lot rejected Irregular production Lot meets neither accept
nor reject criteria Other conditions warrant
return to normal inspection
5 consecutive lots accepted
Lot size Code letter
Sample size
GENERAL INSPECTION LEVEL
1(REDUCED) 2(NORMAL) 3(TIGHTENED)
2 to 8 A 2 2 2 3
9 to 15 B 3 2 3 5
16 to 25 C 5 3 5 8
26 to 50 D 8 5 8 13
51 to 90 E 13 5 13 20
91 to 150 F 20 8 20 32
151 to 280 G 32 13 32 50
281 to 500 H 50 20 50 80
501 to 1200 J 80 32 80 125
1201 to 3200
K 125 50 125 200
3201 to 10000
L 200 80 200 315
10001 to 35000
M 315 125 315 500
35001 to 150000
N 500 200 500 800
150001 to 500000
P 800 315 800 1250
500001 to 10,00,000
Q 1250 500 1250 2000
10,00,000 over
R 2000 800 2000 2000
After tightened
inspection, if three
consecutive lots
rejected, the
AQL (Acceptable Quality Limit): (FOR BOXES)
AQL (Acceptable Quality Limit): (FOR WRAPPERS):
AQL (Acceptable Quality Limit): (FOR CARTONS):
Class 0 (0%) Class 1 (Critical) = 0.15% Class 2 (Major) = 1.5% Class 3 (Minor) = 4.0%
Wrong Artwork
Wrong Text & Barcode
Wrong/right grain of board
Wrong Printing color
Dimension difference
Low Box Board Strength
Grammage Variation
Improper Creasing
High Moisture
Flaps size deviation
Improper side and clutch pasting
Inappropriate clutch lock
Weak Perforation
Un related things (physical hazards)
Mis-Registration
Quantity variation in cases
Embossing (if in artwork)
Flaps lock cut problem
Box Binding
Wrong orientation of flap
Scratches
Stickiness
Class 0 (0%) Class 1 (Critical) = 0.15% Class 2 (Major) = 1.5% Class 3 (Minor) = 4.0%
Wrong Artwork
Wrong Structure
Wrong Winding Direction
Variation in Inner Core
Diameter
De-lamination (Weak peel
strength)
Dimension difference
Reel Slitting size deviation
Misprinting
Colour variation
Photo cell mark missing
Liquid contamination
Variation in Reel outer
diameter
Excessive joints (More than 2)
Static Charge
Stickness
Mis- registration
Grammage (low/high)
Thickness (low/high)
Undesirable smell
Damaged edges
Damaged Core
Wrinkles
Uneven winding
Loose / Tight winding
Packing
Outer Core diameter
Class 0 (0%) Class 1 (Critical) = 0.15% Class 2 (Major) = 1.5% Class 3 (Minor) = 4.0%
Wrong Artwork
Wrong Text & Barcode
Wrong Printing Colour
Wrong panel printing
Water absorbing outer liner
No. of plies deviation
Short dimensions
Low box Compression
Strength
Tearing of outer paper
Improper Creasing
High Moisture
Flaps size deviation
Improper side pasting
Grammage deviation
Un related things (physical
hazards)
Liner separation (Lesser
binding)
Misprinting
Quantity variation in bundles
Tearing of inner paper
Two side pasting,
Sharp edges
Carton binding
AQL INSPECTION (FOR CRITICAL) 0.15%
Lot size Code letter
Sample size for reduced
maximum rejects
allowed for
reduced
Sample size for Normal
maximum rejects
allowed for
normal
Sample size for
Tightened
maximum rejects
allowed for
tightened
2 to 8 A 2 0 2 0 2 0
9 to 15 B 2 0 3 0 3 0
16 to 25 C 2 0 5 0 5 0
26 to 50 D 3 0 8 0 8 0
51 to 90 E 5 0 13 0 13 0
91 to 150 F 8 0 20 0 20 0
151 to 280
G 13 0 32 0 32 0
281 to 500
H 20 0 50 0 50 0
501 to 1200
J 32 0 80 0 80 0
1201 to 3200
K 50 0 125 0 125 0
3201 to 10000
L 80 1 200 1 200 1
10001 to 35000
M 125 1 315 1 315 1
35001 to 150000
N 200 2 500 2 500 1
150001 to
500000 P 315 3 800 3 800 2
500001 to
10,00,000 Q 500 4 1250 5 1250 3
10,00,000 over
R 800 5 2000 7 2000 5
AQL INSPECTION (FOR MAJOR) 2.5%
lot size Code
letter
Sample
size for
reduced
maximum
rejects
allowed
for
reduced
Sample
size for
Normal
maximum
rejects
allowed
for
normal
Sample
size for
Tightened
maximum
rejects
allowed
for
tightened
2 to 8 A 2 0
2 0
3 0
9 to 15 B 2 0
3 0
5 0
16 to 25 C 2 1
5 0
8 0
26 to 50 D 3 1
8 0
13 0
51 to 90 E 5 2
13 1
20 1
91 to 150 F 8 3
20 1
32 1
151 to
280 G 13
4 32
2 50
1
281 to
500 H 20
5 50
3 80
2
501 to
1200 J 32
7 80
5 125
3
1201 to
3200 K 50
9 125
7 200
5
3201 to
10000 L 80 12 200 10 315 8
10001 to
35000 M 125 - 315 14 500 12
35001 to
150000 N 200 - 500 21 800 18
150001
to
500000
P 315 - 800 21 1250 18
500001
to
10,00,000
Q 500 - 1250 21 2000 18
10,00,000
over R 800 - 1250 21 2000 18
AQL INSPECTION (FOR MINOR) 4%
lot size Code
letter
Sample
size for
reduced
maximum
rejects
allowed
for
reduced
Sample
size for
Normal
maximum
rejects
allowed
for
normal
Sample
size for
Tightened
maximum
rejects
allowed
for
tightened
2 to 8 A 2 0 2 0 3 0
9 to 15 B 2 1 3 0 5 0
16 to 25 C 2 1 5 0 8 0
26 to 50 D 3 2 8 1 13 1
51 to 90 E 5 3 13 1 20 1
91 to 150 F 8 4 20 2 32 1
151 to
280 G 13 5 32 3 50 2
281 to
500 H 20 7 50 5 80 3
501 to
1200 J 32 9 80 7 125 5
1201 to
3200 K 50 12 125 10 200 8
3201 to
10000 L 80 - 200 14 315 12
10001 to
35000 M 125 - 315 21 500 18
35001 to
150000 N 200 - 500 21 800 18
150001
to
500000
P 315 - 800 21 1250 18
500001
to
10,00,000
Q 500 - 1250 21 2000 18
10,00,000
over R 800 - 1250 21 2000 18
ART WORK DEVELOPMENT PROCEDURE
Design Input/Idea Raised
Evaluation
( advantges costing & marketing
point of view)
Sent to R&D for text/information
verification
Review by QA
Uploading the artworks on server.
Provide Artwork & CD to Vendor for
Epson making.
Epson Approval
Feedback & Approval Not Physable Rejected
OK
Artwork Development by Creative
Design Approval by
Marketing & DirectorNot OK
Correction
OK
Verify & sign Epson by Marketing,
Creative, Export, R&D & QA
respectively Correction requried
Submission of Epson by vendor
Cylinder Making & Print Proof
sample submission by vendorPrint Proof Approval
Preparation of Shade
Card and submission
OK
Not OK resubmit by vendor
PROPERTIES OF PACKAGING FILMS:
S.NO. STRUCTURE MICRON BURNING TEST
1 BOPP 20 SLIGHLTY BLACK SMOKE , DRIPPING
LIKE WAX,
2 MOPP 18, 20 SLIGHLTY BLACK SMOKE , DRIPPING
LIKE WAX,
3 MCPP 25 BLACK SMOKE, BREAK AND THAN
DROP, SHRINK AFTER BURNING
4 WCPP 25 BLACK SMOKE, BREAK AND THAN
DROP, SHRINK AFTER BURNING
5 PET 12
HEAVY BLACK SMOKE, BREAK AND
THAN DROP, NO DRIPPING, SHRINK
AFTER BURNING, RAPIDLY BURNING,
SPARK DURING BURNING
6 PVC 170
HEAVY BLACK SMOKE,SLOW BURNING,
SLIGHLTY SPARK DURING BURNING,
BLACK SHAPED AFTER BURNING, NO
BREAKAGE OBSERVED
7 ALU.FOIL 7, 20 SLIGHTLY WHITE SMOKE, NO DRIPPING
& SHRINKAGE, WHITE AFTER BURN
8 LDPE 55, 60 SLIGHLTY WHITE SMOKE , DRIPPING
LIKE WAX, SLOW BURNING
S.NO. STRUCTURE MICRON DENSITY VISUAL TEST TEAR TEST
1 BOPP 20 0.9 CRYSTAL CLEAR EASY TO
TEAR
2 MOPP 18, 20 0.9 SILVER EASY TO
TEAR
3 MCPP 25 … SILVER STRETCH BEFORE
TEAR
4 WCPP 25 … WHITE MILKY STRETCH BEFORE
TEAR
5 PET 12 1.38 CRYSTAL CLEAR EASY TO
TEAR
6 PVC 170 1.28 CRYSTAL CLEAR SLIGHTLY
RESIST
7 ALU.FOIL 7, 20 2.71 SILVER EASY TO
TEAR
8 LDPE 55, 60 0.92 HAZYNESS/CLOUDNESS STRETCH BEFORE
TEAR
PROPERTIES
S.NO. FILMS W.V.T.R
1 PVDC 0.05
2 HDPE 0.3
3 P.P 0.4
4 LDPE 1.2
5 PET 1.3
6 PVC 4
7 NYLON 24
8 E.V.O.H ABSORB WATER
PROPERTIES
S.NO. FILMS O.T.R
1 ETHYLENE VINYL ALCOHOL 0.02
2 PVDC 0.2
3 NYLON 3
4 PET 5
5 HDPE 110
6 P.P 150
7 LDPE 480
NEW PACKAGING FILMS
BIAXIALLY ORIENTED POLYAMIDE:
POLYAMIDE PROPERTIES DIS ADVANTAGE
MOSTLY USED IN CURED
MEAT AND CHEESE PRODUCT
WITH OPE+P.E
SUPERNYL AND SANTONYL
MAINLY LAMINATED WITH
P.E, PET, CPP.
DENSITY 1.13
GOOD HEAT RESISTANCE ,
MELTING POINT 220 •C
HIGH TENSILY STRENGTH
RESISTANCE TO FAT AND OIL
BARRIER PROPERTIES OF GASES IS
GOOD IN DRY CONDITIONS BUT
NOT GOOD IN HIGH HUMIDITY
GOOD PRINTIBILITY
THICKNESS RANGE 10 TO 30
MICRON
WATER
TRANSMISSI
ON RATE IS
HIGH.
EVOH PROPERTIES DISADVANTAGE
EVOH RESINS ARE
HYDROLYSED CO POLYMER
OF ETHYLENE AND VINYL
ACETATE
EVOH ARE USUALLY
EMBEDDED IN POLY OLIFIN
LAYER WITH A GOOD WATER
BARRIER
P.E+EVOH+P.E AND
P.A+EVOH+P.E MOSTLY USED
IN READY MEALS, BAKERY
PRODUCTS, PASTA
HIGH MECHANICAL STRENGTH
ELASTICITY
SURFACE HARDNESS
LOW HAZINESS
HIGH RESISTANCE TO OIL
EXCELLENT BARRIER TO
ODOURS
GOOD GAS BARRIER PROPERTY
IN DRY CONDITIONS
UNDER INFLUENCES
OF HIGH HUMIDITY
GAS BARRIER
PROPERTIES
DETERIORATE
BAREX PROPERTIES
MOSTLY USED IN BEVERAGE BOTTLE
LAMINATES WITH PAPER/ALU/BAREX WE CAN USED IN SPICES AND LEMON JUICES
GOOD CLARITY HIGH IMPACT
STRENGTH RESISTANCE TO OIL
AND FATS
PVDC PROPERTIES DIS ADVANTAGES
Another name is
Saran
Vinylidene chloride is
co polymerized with
vinyl chloride
Slightly yellowish cast
in heavy section
Density (1.68)
Good gas (oxygen)
permeability
Good water vapor
barrier 0.1
gm/meter/24hr
Good odor barrier
Soft and transparent
films
Difficult to handle on
printing
Must be stored in a
cool placed otherwise
shrinkage can cause
HDPE (PROPERTIES) DIS ADVANTAGES
Good tensile strength
Good chemical resistance
Films is colorless
Prevent from mechanical
damage
High tear resistance
High moisture barrier
Tensile strength 4.45 MPa
Heat sealing
Heavier than LDPE
Bad UV light resistance
ALUMINUM FOIL PROPERTIES DIS ADVANTAGE
The first use of foil in the
United States was in 1913 for
wrapping Life Savers, candy
bars, and gum.
The first aluminum foil rolling
plant, "Dr. Lauber, Neher &
Cie." was opened in
Emmishofen, Switzerland.
In 1911, Bern-based Tobler
began wrapping its chocolate
bars in aluminum foil,
including the unique
triangular chocolate bar,
Toblerone.
Annual production of
aluminum foil was
approximately 800,000 tones
(880,000 tons) in Europe and
600,000 tones (660,000 tons)
in the USA in 2003.
Approximately 75% of
aluminum foil is used for
packaging of foods,
cosmetics, and chemical
products, and 25% used for
industrial applications.
Sodium silicate solutions is
used for bonding with paper
It is usually printed by
flexography and gravure is
sometime used.
Aluminum foils thicker than
25 µm are impermeable to
oxygen and water.
As aluminum foil acts as a
complete barrier to light
and oxygen (which cause
fats to oxidize or become
rancid), odors and flavors,
moisture, and bacteria, it is
used extensively in food
and pharmaceutical
packaging.
7mic foil has water vapor
transmission rate is about
0.2 gm per meter square
per 24hr at 38©
Chemical and greases
resistance is good
It is unaffected by sun light
and temp about 550 ºf.
Density = 2.7
High cost
METALLIZED FILM PROPERTIES
Vaporizing molten metal and
depositing it onto a cold polymer web.
the process take place in a vacuum
chamber
Two most common substrates are PET
and OPP
Good moisture barrier
Good gas barrier
Prevent from light
Cheaper than aluminum
Thickness of the deposited layer is
about 30nm
Glossy metal appearance
1. BOPP PROPERTIES DIS ADVANTAGE
When polypropylene film is
extruded and stretched in both the
machine direction and across
machine direction it is called
biaxial oriented polypropylene.
Biaxial-Oriented Polypropylene
(BOPP) films have become a
popular, high growth film on the
world market because of a unique
combination of properties such as
better shrinkage, stiffness,
transparency, seal ability, twist
retention and barrier.
high melting point (169
•c)
low density (0.9)
low cost
high tear resistance
toughness
clarity
Good moisture barrier
Micron (BOPP,MOPP)=
18,20
MCPP = 25
Sealing temp = 176.6 ©
Low aroma barrier
Degraded by UV
Attacked by chlorinated
solvents and aromatics.
Must be stored in a cool
placed otherwise
shrinkage can cause
PET PROPERTIES DIS ADVANTAGES
(C10H8O4)n
It was a British discovery
It is still the most well-
known name used for
polyester film.
The PET bottle was
patented in 1973 by
Nathaniel Wyeth.
PET in its natural state is a
colorless, semi-crystalline
resin.
In its un oriented states is
usually combined with
other films
When it is used alone , it
should always be the
oriented
Good Gas barrier
Good barrier to alcohol
It is strong and impact-
resistant.
Melting point 205 •c.
1.37 density
High transparency
Good print ability
Sealing temp = 135 ©
MICRON = 12
Not good moisture barrier
Low aroma barrier
Noisy films
Not good tear strength
P.E PROPERTIES DIS
ADVANTAGES
Discovered in
England in the
early 1930
Straight chain of
hydrocarbons
Two main types
: LDPE and HDPE
Printing by
gravure and
flexography
Soft and
flexible
Good moisture
barrier
Low cost
Good chemical
resistance
MICRON = 65
Sealing temp =
135
Density = 0.93
Slightly haziness
Difficult to get
adhesive on it ,
because its
surface is non
polar
Chemical resistance
Ability of a material to retain utility and appearance following contact with chemical agents. Chemical resistance implies that there is no significant chemical activity between the contacting materials.
Co-extrusion (COEX)
Simultaneous extrusion of two or more different thermoplastic resins into a
sandwich-like film with clearly distinguishable individual layers.
Corona treatment
A treatment to alter the surface of plastics and other materials to make them more receptive to printing inks.
Degradation
A change or break-down in a material's chemical structure.
De-lamination
Separation or splitting of laminate layers caused by lack of or inadequate
EXON PROPERTIES
Vacuum deposited aluminum
Transparent multilayer poly propylene
core
Broad sealing range
Good moisture barrier
Good light barrier
Good gas barrier
Easy to convert
Metal appearance
Flavor and aroma barrier
15 micron
13.7 grammage
73.3 yield
Optical density 2.3
Water transmission rate = 0.3
gm/meter square/24hr
PVC PROPERTIES DIS ADVANTAGES
It was first discovered by
Henri Victor
Vinyl is made by
chlorination of ethylene
to produce vinyl chloride,
which is then
polymerized with a
benzyl per oxide to
produce PVC
When it is oriented it is
the most popular shrink
films
Two types : plasticized
and un plasticized
Good toughness
Resistance to oil
Machine ability is good
Good gas barrier
Good moisture barrier
Sealing temp = 107.2
Micron = 170
Density = 1.40
Sunlight can have a degrading
effect
Vapors from heat sealing can
be harmful if inhaled
LDPE PROPERTIES DIS ADVANTAGES
Density 0.91 to 0.93
Molecular weight
distribution is narrower
Good tensile strength
Good tear strength as
compare to HDPE
Good moisture barrier but
not good as HDPE
Good chemical resistance
Good seals
High melting point
Poor gas barrier as compare
to HDPE
DEFINITIONS:
Aluminum foil
A thin gauge (.285-1.0 mil) aluminum foil laminated to plastic films to provide oxygen, aroma and water vapor barrier properties.
Barrier
In packaging, this term is most commonly used to describe the ability of a material to stop or retard the passage of atmospheric gases, water vapor, and volatile flavor and aroma ingredients. A barrier material is one that is designed to prevent, to a specified degree, the penetrations of water, oils, water vapor, or certain gases, as desired. Barrier materials may serve to exclude or retain such elements without or within a package.
Biaxial orientation
Orientation of plastic films in both machine and cross machine (transverse) directions by stretching. Biaxial stretched films are generally well balanced in both directions and much stronger in terms of tear strength.
Cast film
Plastic film produced from synthetic resins (such as polyethylene) by the cast process. In this process, the molten resin is extruded through a slot die onto an internally cooled chill roll.
adhesion, or by mechanical disruption such as peeling or shearing forces.
Directionality
The tendency for certain materials to have properties imparted by the flow direction through a machine.
Ethylene-vinyl acetate (EVA)
A polar copolymer of ethylene and vinyl acetate, retaining some of the properties of polyethylene but with increased flexibility, elongation, and impact resistance. EVA is frequently specified as the extrusion coating on polypropylene, aluminum foil and poly (ethylene terephthalate), to provide good heat-seals at high converting rates, or as the adhesion layer in some laminates.
Ethylene-vinyl alcohol (EVOH)
Can be regarded as a copolymer of polyethylene in which varying amounts of the -OH functional group have been incorporated. A typical packaging EVOH is about 20 to 35% ethylene. EVOH is one of the best polymeric oxygen barriers available to packagers. However, its susceptible to water requires that for most applications it be laminated or co-extruded into a protective sandwich with materials that will keep the EVOH layer away from water.
Extrusion
The process of forming a thermoplastic film, container, or profile by forcing the polymer melts through a shaped orifice.
Extrusion coating
A process where a film of molten polymeric material is extruded onto the surface of a substrate material and cooled to form a continuous coating.
Extrusion lamination
A laminating process in which individual layers of multi-layer packaging materials are laminated to each other by extruding a thin layer of molten synthetic resin (such as polyethylene) between the layers.
Film
Generally used to describe a thin plastic material usually not more than 75 micrometers (0.003 inch) thick.
Flexible packaging
A package or container made of flexible or easily yielding materials that, when filled and closed, can be readily changed in shape. A term normally applied to bags, pouches, or wraps made of materials ranging in thickness from 13 to 75 micrometers (0.0b0á to 0.003 inch) such as paper, plastic film, foil, or combinations of these.
Flexographic printing
A method of printing using flexible rubber or photopolymer printing plates in which the image to be printed stands out in relief. Fluid ink metered by an engraved roll is applied to the raised portions of the printing plate and then transferred to the substrate.
Gas transmission rate (GTR)
The quantity of a given gas passing through a unit area of the parallel surfaces of a film, sheet, or laminate in a given time under the test conditions. Test conditions may vary and must always be stated.
Gauge
Thickness. In North America, film thickness, measured in mils, is usually given in gauges. A 100 gauge shrink film is one mil, or 1/1000 of an inch, thick. In Europe, the film thickness metric is the micron. A quick equivalency equation is: 1 mil = 25.4 microns.
Gravure printing
Gravure is abbreviated from the term rotogravure. During gravure printing an image is etched on the surface of a metal cylinder and chrome plated for hardness. The ink fills the cells and is transferred onto the printing substrate.
Gusset
The fold in the side or bottom of the pouch, allowing it to expand when contents are inserted
HDPE
High density, (0.95-0.965) polyethylene. Have much higher stiffness, higher temperature resistance and much better water vapor barrier properties than LDPE, but it is considerably hazier.
Heat-seal coating
An adhesive coating applied to a packaging material that is capable of being activated by heat and pressure to form a bond.
Heat-seal layer
A heat sealable innermost layer in plastic packaging films and laminates. Can be either adhesive laminated or extrusion coated onto a non-sealable film (or foil).
High barrier
Describes a material or package that has very low gas permeability characteristics; that is, it offers a great deal of resistance to the passage of a gas through its volume.
Laminate
(A) noun a product made by bonding together two or more layers of material. (b) Verb To unite layers of material to produce a multilayer material.
Laminated film
An adhered combination of two or more films or sheets made to improve overall characteristics. Also multilayer film.
Light resistance
The ability of material to withstand exposure to light (usually sunlight or the ultraviolet part of the light spectrum) without change of color or loss of physical and/or chemical properties.
LLDPE
Linear low density polyethylene. Tougher than LDPE and has better heat-seal strength, but has higher haze.
Mach inability
The ability of a film to run on packaging equipment.
Machine direction (MD)
The direction that film moves through the packaging equipment.
MDPE
Medium density, (0.934-0.95) polyethylene. Have higher stiffness, higher melting point and better water vapor barrier properties.
Metalize
Applying a thin coating of metal to a nonmetallic surface by chemical deposition or by exposing the surface to vaporized metal in a vacuum chamber.
MET-OPP
Metalized OPP film. It has all the good properties of OPP film, plus much improved oxygen and water vapor barrier properties, (but not as good as MET-PET).
MET-PET
Metalized PET film. It has all the good properties of PET film, plus much improved oxygen and water vapor barrier properties. However, it is not transparent. See also VMPET.
Moisture vapor transmission rate (MVTR)
A depreciated term, usually measured at 100% relative humidity, expressed in grams/100 square inches/24 hours, (or grams/square meter/24 Hrs.) See WVTR.
Nylon
Polyamide resins, with very high melting points, excellent clarity and stiffness. Two types are used for films - nylon-6 and nylon-66. The latter has much higher melt temperature, thus better temperature resistance, but the former is easier to process, and it is cheaper. Both have good oxygen and aroma barrier properties, but they are poor barriers to water vapor.
Polyethylene film (PE)
Made in high density, low density, linear low density and metallocene variations. By far the largest volume packaging film family.
Poly (ethylene terephthalate) film (PET)
Polyester, (Polyethylene Terephtalate). Tough, temperature resistant polymer. Biaxial oriented PET film is used in laminates for packaging, where it provides strength, stiffness and temperature resistance. It is usually combined with other films for heat seal ability and improved barrier properties.
Tear resistance
The ability of a film to resist the propagation of a tear.
Tensile strength
The amount of pull a film can withstand without tearing apart or stretching.
Thermoforming
A method of forming plastics where a plastic sheet is heated to a point where it is soft and formable.
Transverse direction (TD)
The direction perpendicular to the machine direction.
Vapor barrier
A layer of material through which water vapor will pass only slowly, or not at all.
Water vapor transmission rate (WVTR)
A measure of the rate of water vapor transmission through a material. Usually measured at 100% relative humidity, expressed in grams/100 square inches/24 hours, (or grams/square meter/24 Hrs.) See MVTR.
OPP
Oriented PP (polypropylene) film. A stiff, high clarity film, but not heat sealable. Usually combined with other films, (such as LDPE) for heatsealability. Can be coated with PVDC (polyvinylidene chloride), or metalized for much improved barrier properties.
Optics
The visual properties of a film, such as clarity, gloss, haze, opacity, etc.
Orientation
The process of mechanically stretching plastic film or parts in order to produce a straightening and alignment of the molecules in the stretch direction. If done in one direction, the material is said to be uniaxial or monoaxially oriented. if done in two directions, the film is biaxial oriented.
(OTR)
Oxygen transmission rate. Varies considerably with humidity, therefore it needs to be specified. Standard conditions of testing are 0, 60 or 100% relative humidity. Units are cc./100 square inches/24 hours, (or cc/square meter/24 Hrs.) (cc = cubic centimeters)
Polypropylene film (PP)
Unoriented film is soft and clear but brittle at low temperatures. This property as well as stiffness, strength and clarity is improved by orientation.
PVDC
Polyolefin
Family name for the polymers (plastics) derived by ethylene and propylene, such as polyethylene (PE) and polypropylene (PP)
Polyvinylidene chloride. A very good oxygen and water vapor barrier, but not extricable,
therefore it is found primarily as a coating to improve barrier properties of other plastic films,
(such as OPP and PET) for packaging. PVDC coated and ’saran‘coated are the same.
EXTRUSION COATING PROCESS:
Extrusion coating is the coating of a molten web of synthetic resin onto a substrate material. It is a versatile coating technique used for the economic application of
various plastics, notably polyethylene, onto paperboard, corrugated fiberboard, paper, aluminum foils, cellulose, Non-woven’s, or plastic films.
Process
Coating
The actual process of extrusion coating involves extruding resin from a slot die at temperatures up to 320°C directly onto the moving web which may then passed through a nip consisting of a rubber covered pressure roller and a chrome plated cooling roll. The latter cools the molten film back into the solid state and also imparts the desired finish to the plastic surface. The web is normally run much faster than the speed at which the resin is extruded from the die, creating a coating thickness which is in proportion to the speed ratio and the slot gap.
Laminating
Extrusion laminating is a similar process except that the extruded hot molten resin acts as the bonding medium to a second web of material.
Co-extrusion
Co-extrusion is, again, a similar process but with two, or more, extruders coupled to a single die head in which the individually extruded melts are brought together and finally extruded as a multi-layer film.
PRINTED WRAPPERS PROCESS FLOW>>>>
Class 0 (Critical) (Major) (Minor)
Wrong Artwork
Wrong Structure
Wrong Winding
Direction
Variation in Inner
Core Diameter
De-lamination
(Weak peel
strength)
Dimension
difference
Reel Slitting size
deviation
Misprinting
Color variation
Photo cell mark
missing
Liquid
contamination
Variation in Reel
outer diameter
Excessive joints
(More than 2)
Static Charge
Stickiness
Mis- registration
Grammage
(low/high)
Thickness
(low/high)
Undesirable smell
Damaged edges
Damaged Core
Wrinkles
Uneven winding
Loose / Tight
winding
Packing
Outer Core
diameter
Raw Material (Films)
Receiving
Printing
Lamination
Curing
Slitting/Cutting
Packing
Dispatch
KRAFT PAPER:
Kraft paper or kraft is paper or paperboard (cardboard) produced from chemical pulp produced in the kraft process.
Sack Kraft Paper, or just sack paper is a porous kraft paper with high elasticity and high tear resistance, designed for packaging products with high demands for strength and durability.
Pulp produced by the kraft process is stronger than that made by other pulping processes; acidic sulfite processes degrade cellulose more, leading to weaker fibers, and mechanical pulping processes leave most of the lignin with the fibers, whereas kraft pulping removes most of the lignin present originally in the wood. Low lignin is important to the resulting strength of the paper, as the hydrophobic nature of lignin interferes with the formation of the hydrogen bonds between cellulose (and hemicellulose) in the fibers.
Kraft pulp is darker than other wood pulps, but it can be bleached to make very white pulp. Fully bleached kraft pulp is used to make high quality paper where strength, whiteness and resistance to yellowing are important.
Manufacture
Wood pulp for sack paper is made from softwood by the kraft process. The long fibers provides the paper its strength and wet strength chemicals are added to even further improve the strength. Both white and brown grades are made. Sack paper is then produced on a paper machine from the wood pulp. The paper is microcrepped to give porosity and elasticity. Micro-crepping is done by drying with loose draws allowing it to shrink. This causes the paper to elongate 4% in the machine direction and 10% in the cross direction without breaking. Machine direction elongation can be further improved by pressing between very elastic cylinders causing more microcrepping. The paper may be coated with polyethylene (PE) to ensure an effective barrier against moisture, grease and bacteria. A paper sack can be made of several layers of sack paper depending on the toughness needed.
Kraft paper is produced on paper machines with moderate machine speeds. The raw material is normally softwood pulp from the kraft process.
Maintaining a high effective sulfur ratio or sulfidity is important for the highest possible strength using the kraft process.
The kraft process can use a wider range of fiber sources than most other pulping processes. All types of wood, including very resinous types like southern pine, and non-wood species like bamboo and kenaf can be used in the kraft process.
Qualities
Normal kraft paper is strong and relatively coarse. It has high tensile strength. The grammage is normally from 40–135 g/m2.
Sack kraft paper, or just sack paper is a porous kraft paper with high elasticity and high tear resistance, designed for packaging products with high demands for strength and durability.
Absorbent kraft paper is made with controlled absorbency, i.e., a high degree of porosity. It is made of clean low kappa hardwood kraft and has to have a good uniformity and formation.
Spinning kraft paper is an especially strong type of kraft paper with relatively low grammage (40 g/m2). This paper requires the best possible machine direction strength and cross machine elongation. This is done by high fiber orientation on the papermachine.
Hunting cartridge paper is a kraft paper used in shotgun shells. This paper needs a high tensile strength in the machine direction, which is the axial direction of the cartridges. In the cross direction, the cartridge is supported by the gun-pipe, but a sufficient elongation is needed. The body of the cartridge is wound of a kraft paper of 80–120 g/m2, which is further covered by an outer sheet of 60–80 g/m2 with colour and printing.
Candy wrapping paper or twisting paper are thin 30–40 g/m2 kraft papers and is mostly flexo or offset printed. These papers requires a good strength, with highly oriented fibers. Twisting paper is mostly opaque and often supercalendered.
Applications
Kraft paper (plastic hazard free) is used paper sacks for cement, food, chemicals, consumer goods,flour bags etc.
Kraft papers are used in paper grocery bags, multiwall sacks, envelopes and other packaging.
Kraft paper is an inexpensive material for lining particle boards.
Properties of Paper
Basis Weight (GSM)
Brightness, Whiteness and Color
Bulk Dimensional Stability
Folding Endurance (Double Folds)
Formation Gloss
Machine and Cross Direction
Moisture
Opacity Porosity
Sizing / Cobb
Smoothness
Stiffness Stretch (Elongation)
Tearing Resistance
Temperature and Humidity: Conditioning of Paper
Thickness Wax Pick No. (Surface Strength)
Wire side and Felt side
Basis Weight (GSM) The weight or substance per unit area is obviously fundamental in paper and paper board products. The Basis weight of paper is the weight per unit area. This can be expressed as the weight in grams per square meter (GSM or g/M2), pounds per 1000 sq. ft. or weight in kgs or pounds per ream (500 sheets) of a specific size. REAM WEIGHT is a common term to signify the weight of a lot or batch of paper. Control of basis weight is important as all other properties are affected. Variations in moisture content in paper affect the grammage. Brightness, Whiteness and Colour Brightness is defined as the percentage reflectance of blue light only at a wavelength of 457 nm. Whiteness refers to the extent that paper diffusely reflects light of all wave lengths throughout the visible spectrum. Whiteness is an appearance term. Colour is an aesthetic value. Colour may appear different when viewed under a different light source. Brightness is an arbitrarily defined, but carefully standardized, blue reflectance that is used throughout the pulp and paper industry for the control of mill processes and in certain types of research and development programs. Brightness is not whiteness. However, the brightness values of the pulps and pigments going into the paper provide an excellent measure of the maximum whiteness that can be achieved with proper tinting. The colour of paper, like of other materials, depends in a complicated way on the characteristics of the observer and a number of physical factors such as the spectral energy distribution of the illuminant, the geometry of illuminating and viewing, the nature and extent of the surround and the optical characteristics of the paper itself. Bulk Bulk is a term used to indicate volume or thickness in relation to weight. It is the reciprocal of density (weight per unit volume). It is calculated from caliper and basis weight. Sheet bulk relates to all other sheet properties. Decrease the bulk or in other words increase the density, and the sheet gets smoother, glossier, less opaque, darker, lower in strength etc.
Dimensional Stability
An important consequence of the absorption and de-absorption of
moisture by paper is the change in dimension that usually
accompanies changes in moisture content. Such changes in dimension
may seriously affect register in printing processes and interfere with
the use of such items as tabulating cards. Uneven dimensional
changes cause undesirable cockling and curling. Dimensional changes
in paper originate in the swelling and contraction of the individual
fibres. It has been observed that cellulosic fibers swell in diameter
from 15 to 20% in passing from the dry condition to the fibre
saturation point. It is impossible to be precise about the degree of this
swelling because paper-making fibres differ considerably in this
property, and because the irregular cross-section of fibres creates
difficulty in defining diameter. Change that occurs in the dimensions
of paper with variation in the moisture content is an important
consideration in the use of paper. All papers expand with increased
moisture content and contract with decreased moisture content, but
the rate and extent of changes vary with different papers.
Folding Endurance (Double Folds)
Folding endurance is the paper's capability of withstanding multiple
folds before it breaks. It is defined as the number of double folds that
a strip of 15 mm wide and 100 mm length can withstand under a
specified load before it breaks. It is important for printing grades
where the paper is subjected to multiple folds like in books, maps, or
pamphlets. Fold test is also important for carton, box boards,
ammonia print paper, and cover paper etc. Folding endurance is a
requirement in Bond, Ledger, Currency, Map, Blue Print and Record
Papers.
Formation
Formation is an indicator of how the fibres and fillers are distributed
in the sheet. Formation plays an important role as most of the paper
properties depend on it. Paper that is poorly formed will have weak,
thin spots and thick spots. These will affect properties like caliper,
opacity, strength etc. Paper formation also affects the coating
capabilities and printing characteristics of the paper.
Gloss It is the specularly and diffusely reflected light component measurement against a known standard. Gloss is important for printing such things as magazine advertisements. The level of gloss desired is very dependent on the end use of the paper. Gloss and smoothness are different properties and are not dependent on each other. Machine and Cross Direction Paper has a definite grain direction due to greater orientation of fibres in the direction of travel of the paper machine. This grain direction is known as machine direction. The cross direction is the direction of paper at right angles to the machine direction. Some of the properties vary with the MD and CD and hence the values are reported in both the directions. While sheeting the paper, machine and cross direction are to be kept in mind and the sheet cutting to be done to suit the end use requirements. Examples: 1. all printing papers are to be cut in long grain (The biggest dimension in the grain direction). 2. Book papers fold better and the book stays open better if the sheets are out so that the machine direction runs up and down the pages. 3. Wrap around labels for metal cans and bottles are to be cut with the machine direction vertical to obtain greater flexibility about the can. Long grain and Short grain: The sheet is in long grain if the larger dimension is parallel to grain (MD) direction. The sheet is said to be in short grain if the larger dimension is parallel to cross direction (CD). Moisture Most physical properties of paper undergo change as a result of variations in moisture content. Water has the effect of plasticizing the cellulose fibre and of relaxing and weakening the inter fibre bonding. The electrical resistance and the dielectric constant of paper both vary with moisture content. The absorption and reflectance of certain bands of infrared and microwave radiation by paper are affected by its moisture content. The amount of water present in a sheet of paper is usually expressed as a percent. The amount of water plays an important role in calendaring, printing and converting process. Moisture control is also significant to the economic aspect of paper making. Poor moisture control can adversely affect many paper properties.
Opacity
Opacity is the measure of how much light is kept away from passing
through a sheet. A perfectly opaque paper is the one that is
absolutely impervious to the passage of all visible light. It is the ratio
of diffused reflectance and the reflectance of single sheet backed by a
black body. Opacity is important in Printing Papers, Book Papers, etc.
Porosity Because paper is composed of a randomly felted layer of fibre, it follows that the structure has a varying degree of porosity. Thus, the ability of fluids, both liquid and gaseous, to penetrate the structure of paper becomes a property that is both highly significant to the use of paper. Paper is a highly porous material and contains as such as 70% air. Porosity is a highly critical factor in Printing Papers Laminating Paper, Filter Paper, and Cigarette Paper. Bag Paper, Ant tarnish Paper and Label Paper. Porosity is the measurement of the total connecting air voids, both vertical and horizontal, that exists in a sheet. Porosity of sheet is an indication of absorptive or the ability of the sheets to accept ink or water. Porosity can also be a factor in a vacuum feeding operation on a printing press.
Sizing / Cobb
Because paper is composed of a randomly felted layer of fibre, it's
structure has a varying degree of porosity. Thus, the ability of fluids,
both liquid and gaseous, to penetrate the structure of paper becomes
a property that is both highly significant to the use of paper. The need
to limit the spreading of ink resulted in "sizing" the paper with
gelatinous vegetable materials which had the effect of sealing or
filling the surface pores. Later, the term "sizing" was applied to the
treatment of paper stock prior to the formation of the sheet, with
water-repellent materials such as rosin or wax. Resistance towards
the penetration of aqueous solution / water is measured by Sizing or
Cobb values.
Smoothness
Smoothness is concerned with the surface contour of paper. It is the
flatness of the surface under testing conditions which considers
roughness, liveliness, and compressibility. In most of the uses of
paper, the character of the surface is of great importance. It is
common to say that paper has a "smooth" or a "rough" texture. The
terms "finish" and "pattern" are frequently used in describing the
contour or appearance of paper surfaces. Smoothness in important
for writing, where it affects the ease of travel of the pen over the
paper surface. Finish is important in bag paper as it is related to the
tendency of the bag to slide when stacked. Smoothness of the paper
will often determine whether or not it can be successfully printed.
Smoothness also gives eye appeal as a rough paper is unattractive.
Stiffness
Stiffness is the measure of force required to bend a paper through a
specified angle. Stiffness is an important property for box boards,
corrugating medium and to certain extent for printing papers also. A
limpy and flimsy paper can cause feeding and delivery problems in
larger sheet presses. A sheet that is too stiff will cause problems in
copier machines where it must traverse over, under, and around feed
rollers. Bond papers also require certain stiffness to be flat in
typewriters etc.
Stretch (Elongation)
Stretch is the amount of distortion which paper undergoes under
tensile stress. Stretch elongation is usually expressed, as percent
stretch to rupture. Stretch can be related to the paper's ability to
conform and maintain conformance to a particular contour, e.g.
Copier paper, multicolor offset printing papers, liquids packing
cartons base papers etc. It is an important property in sack Kraft
papers which are used for cement bags etc. Stretch is higher in cross
direction than machine direction.
Tearing Resistance
Tearing resistance indicates the behavior of paper in various end use
situations; such as evaluating web run ability, controlling the quality
of newsprint and characterizing the toughness of packaging papers
where the ability to absorb shocks is essential. fibre length and
interfibre bonding are both important factors in tearing strength. The
fact that longer fibres improve tear strength is well recognized. The
explanation is straight forward; longer fibres tend to distribute the
stress over a greater area, over more fibres and more bonds, while
short fibres allow the stress to be concentrated in a smaller area.
Temperature and Humidity: Conditioning of Paper
conditioning of paper is also of importance in many printing and
converting operations. In addition to the effect of moisture content
on physical properties, it also determines the buildup of static of the
paper sheet subjected to pressure and to friction. The tendency for
paper to develop static becomes greater with increasing dryness.
Cellulosic fibres are hygroscopic i.e. they are capable of absorbing
water from the surrounding atmosphere. The amount of absorbed
water depends on the humidity and the temperature of the air in
contact with the paper. Hence, changes in temperature and humidity,
even slight changes, can often affect the test results. So, it is
necessary to maintain standard conditions of humidity and
temperature for conditioning.
Thickness
Thickness or Caliper of paper is measured with a micrometer as the
perpendicular distance between two circular, plane, parallel surfaces
under a pressure of 1 kg./ CM2. Caliper is a critical measurement of
uniformity. Variations in caliper can affect several basic properties
including strength, optical and roll quality. Thickness is important in
filling cards, printing papers, condenser paper, saturating papers etc.
Wax Pick No. (Surface Strength) This indicates the surface strength of the paper. This test is important for all uncoated printing papers.
Wire side and Felt side Also referred as wire side and top side. The side which is in contact with the paper machine wire during paper manufacture is called the wire side. The other side is top side. Certain properties differ between wire and felt side and it is customary to measure these properties on both the sides. In case of paper to be printed on one side only, best results are obtained by printing on felt side. Postage stamps are printed on wire side and then gummed on felt side, where the smoothness is helpful for attaining an even application.
CARTON PROCESS FLOW>>>>
Class 0 (Critical) (Major) (Minor)
Wrong Artwork
Wrong Text & Barcode
Wrong Printing Color
Wrong panel printing
Water absorbing
outer liner
No. of plies deviation
Short dimensions
Low box
Compression
Strength
Tearing of outer
paper
Improper Creasing
High Moisture
Flaps size deviation
Improper side pasting
Grammage deviation
Un related things
(physical hazards)
Liner separation
(Lesser binding)
Misprinting
Quantity
variation in
bundles
Tearing of inner paper
Two side pasting,
Sharp edges
Carton binding
BOX PROCESS FLOW>>>>
Class 0 (Critical) (Major) (Minor)
Wrong Artwork
Wrong Text & Barcode
Wrong/right grain of
board
Wrong Printing color
Dimension
Difference
Low Box Board
Strength
Grammage Variation
Improper Creasing
High Moisture
Flaps size deviation
Improper side and clutch
pasting
Inappropriate clutch lock
Weak Perforation
Un related things
(physical hazards)
Mis-Registration
Quantity variation in
cases
Embossing (if in artwork)
Flaps lock cut problem
Box Binding
Wrong orientation of flap
Scratches
Stickiness
Receiving of Sheets
Printing
Film Lamination
Die cutting
Breakage o f Boxes
Grinding, Gluing, Pasting
Packing
Test for Packaging items:
Test for Boxes:
Grammage Dimension Moisture Tearing strength Stiffness test Colour test Creasing test Weight of box Bursting strength Thickness Box compression test
Test for Cartons:
Grammage Dimension Moisture Tear test Bursting test Puncture test Edge crush test Thickness Fluting check Carton compression test
Test for Wrapper:
Grammage Wax (if paper) Dimension Tear test Co friction test Tensile test Peel off Heat seal test Sealing strength test
Water Vapor Permeability Analyzer
Application To test the water vapor transmission rate (WVTR) of packaging materials, such as plastic film, composite film, coextrusion film, aluminum-plated film, aluminum foil, infusion bag, sheets, paper, paper board, solar battery panel, cellophane, ceramics and porcelain, and various containers such as bag, pouch, bottle, can, bowl, box, widely used in the industries of food, pharmaceuticals, personal care, household, electronics and so on.
Working Principle Electrolytic detection sensor method. Fix the test sample in the middle of test chamber to separate the chamber into upper room and lower room. When humid gas flows in upper room and dry gas in lower room, the water molecules in upper room penetrate through the sample into the dry gas, and electrolytic sensor system detect and analyze the water content and calculate the water vapor transmission rate. Features 1. Temperature control: International advanced electromagnetic technology, program controlled, and no need of external accessories. Precision: 0.1℃. 2. Humidity control: Dual gas flow method, with broad range, high precision and stable flow. 3. Standard gas calibration and standard film calibration. 4. Auto judgment and auto stop. 5. Leakage protection; over range protection; auto save data when power is cut off; incorrect operation warning. 6. Wholly automatic, software easy to use. Curves of transmission rate, water vapor density, humidity and temperature, auto record and continuous display. Can easily monitor interaction of parameters and the whole testing process. 7. Highly modularized. Setting, testing, baseline, calibration, report etc are independent. Powerful data analysis. Easy to operate. 8. Built-in computer, can work without external computer. 9. Support quick test, applicable to evaluation test. 10. Two chambers can work independently at the same time for two different samples. 11. Software upgrade, data backup and fault diagnosis through USB port. Specifications Test range 0.001~100 g/(m2•24h) Test precision 0.001 g/(m2•24h) (film and sheet) Temperature range 15~45℃(5~55℃ optional) Temperature precision ±0.1℃
Humidity range 0﹪RH, 30~90%RH, 100%RH Number of samples 1~2 pieces Test area 50.24cm2 Sample size Φ100mm Sample thickness ≤ 2mm Carrier gas 99.999% N2 (user provide) Carrier gas pressure ≥ 0.1Mpa
Instrument size 610mm x 550mm x 400mm
Oxygen Permeability Analyzer Application To test the oxygen transmission rate (OTR) of packaging materials, such as plastic film, composite film, coextrusion film, aluminum-plated film, aluminum foil, infusion bag, sheets, paper, paper board, solar battery panel, cellophane, ceramics and porcelain, and various containers such as bag, pouch, bottle, can, bowl, box, widely used in the industries of food, pharmaceuticals, personal care, household, electronics and so on. Working Principle Coulometric sensor method. Fix the test sample in the middle of test chamber to separate the chamber into upper room and lower room. When oxygen flows in upper room and nitrogen in lower room, the oxygen molecules penetrate through the sample into the lower room, and coulometry sensor system detect and analyze the oxygen content and calculate the oxygen transmission rate. To test container, oxygen is outside and nitrogen is inside of the container. Features 1. Adopts international advanced electromagnetic temperature control technology can control temperature rising and lowering without any external accessory. 2. The humidity control adopt double air humidity control method, humidity control area is large and with high accuracy. 3. Has two calibration methods: standard gas calibration and standard film calibration. 4. Has the functions of double cavity pressure control and automatic pressure balance. 5. Can judge and stop automatically. 6. Has leakage auto protection function. 7. The software operation is easy, all testing program is automatic. It records and continuously displays the curves of the permeation rate, oxygen concentration, humidity and temperature. It can monitor the mutual influence between the parameters. 8. Has good ability of data analysis, easy to operate Specifications Test range 0.02 ~ 16500 cm3/(m2•24h) (max possibility: 260000 cm3/(m2•24h)) Temperature range 15°C~45°C (5°C~50°C optional) Temperature accuracy ±0.1°C Gas supply pressure 0.1~0.2MPa Environment temperature 23°C Sample size Φ100mm Test area 50.24cm2 Sample thickness ≤ 2mm Number of samples 2 pieces Carrier gas port 1/8 inch Instrument size 630mm x 560mm x 350mm Power supply AC 220V 50Hz
Instructions
1 Study the bar code. The first digit indicates the type of product.
2 Digits 2 through 6 are the manufacturer's identification number, which is chosen by the Uniform Code Council.
3 The manufacturer creates digits 7-11 to differentiate its products from other manufacturer's products.
4 The last digit is the check digit, which corrects erroneously keyed bar codes. To check the validity of the hand-keyed bar code, cashiers use a multiplication algorithm to get a sum equal to the check digit.
HOW TO READ BARCODE WITH THE HELP OF LINES
DIGIT CODE
0 3211
1 2221
2 2122
3 1411
4 1132
5 1231
6 1114
7 1312
8 1213
9 3112
• Note that bar codes are made up of both white
and black lines. The white spaces in between
the black lines are part of the code.
• Understand that there are four different
thicknesses to the lines. Henceforth, the
skinniest line will be referred to as "1," the
medium-sized line as "2," the next largest line as
"3." and the thickest is "4."
• If we consider 0 digit and we make their code
with the help of line so first we read from the
left side. The white thick line is equal to 3
numbers as we discuss above. Than we read
black which is equal to 2 and than white and
black which is equal to 1 digit. The code will be
3211.
• We read whole barcode by the help of above
method.
ANOTHER WAY TO READ BARCODE
DIGIT CODE
0 0001101
1 1100110
2 1101100
3 0111101
4 1011100
5 1001110
6 0101111
7 1000100
8 1001000
9 1110100
• Note that bar codes are made up of both
white and black lines. The white spaces in
between the black lines are part of the code.
• Note that black skinniest line is equal to 1 and
also white skinniest line is equal to 0. If three
black lines attached together so we read as
111 and just like this we read other lines.
SYMBOLS MEANING SYMBOLS MEANING
Do not use hand hooks
Handle with care
This way up
Do not roll
Keep away from sunlight
Content should be stored at 10 to 20 •c
Keep away from water
If you are not happy with the quality of the
product than call on customers service
numbers
Centre of gravity
Suitable for vegetarian
Do not clamp as indicated
Symbol suggest that customers should aware
that the product could contain wheat, gluten
and nut
Recyclable
Used dustbin
90 perc recyclable so used recycle bin
Do not stand on carton
Clamp as indicated