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Packaging Demands

Packaging Demands

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 different consumer demands. In particular, this includes the choice of suitable material which has to ensure product safety, be sustainable, easy to transport and store and also have a persuasive impact on potential customers seeking to make purchase decisions. Especially where food is concerned, and cardboard are very much in demand. though India is one of the largest producers of foods and agrobased products estimated at rs 500 billion, 20 billion of these get wasted due to non availability of processing and packaging. over the years, the industry has undergone tremendous change and with technological advancements, the process continues. • Consumer Packaged Goods • The adaptability of plastic packaging allows it to meet a variety of needs for consumer goods. As packaging moves from design phase through recovery/disposal, the varying types of plastics and their unique properties offer many choices for the decisions that are made along the way: Colour, Weight, Size,Shape,Utility,,Protection,and more. Plastics help bring home more product with less packaging. Plastic packaging in general is lightweight and strong. Different plastics can be moulded, extruded, cast, and blown into seemingly limitless shapes and films or foams. This resourcefulness often delivers while using minimal resources, creating less waste, consuming fewer resources, and creating fewer CO2 emissions than alternative materials. Plastics make packaging more efficient, 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 against corrosion and avoid the tedious sequences using anti-corrosive packaging. Materials such as VCI bubble film, paper, oil, chips, and that are used as a part of anticorrosive packaging helps to prevent goods from exposing to various climate zones. Moreover, this packaging can be used in the scenarios such as export of goods over long distances, long-term storage of metal goods, and metals that are sensitive for corrosion. • Pharma Packaging • Pharma Packaging, also known as the , is the packaging processes used for pharmaceutical operations involving production through distribution channels to the end consumer. The packaging of Pharma products provides containment, drug safety, identity convenience of handling and delivery. The major role of pharmaceutical packaging is to provide life-saving drugs, surgical devices, blood and blood products, nutraceuticals, powders, liquid and dosage forms, solid and semisolid dosage forms. This kind of packaging is involved in dosing, dispensing etc. Forms of packaging in pharma industry: Blister packs, , Timed Dosing. • Types of packaging used in pharma • – for bottles, syringes, , and cartridges. Plastic – for bottles, tubes, foils and . Cardboard – for . Paper – for . Metal – Metals like aluminium for tubes, caps, blister, pressurized cylinders etc. Rubber – for closures. • Trends in Plastics Packaging are: • Changing consumer habits • Increased urbanization and growing young population • Increased use of home and personal care products • Developments in the field of polymer science • Increased investment in food processing and production in china, and Increased preference of plastic pouches, by consumers and retailers. • FLEXIBLE PACKAGING • Flexible packaging can be made with flexible materials that can be packed, sealed and can retain the freshness of its content. Be it moulding the packages into a variety of shapes or preserving the flavour and safety of food or logistical aspects, all are covered under the flexible packaging. This is the major benefit that makes flexible packaging the first choice for food packaging. The package can last for a very long time; if it is stored in the right conditions. Flexible packaging is environmentally friendly as it uses less 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 and extended by providing heat seal, barrier protection, ease of use, press-to-seal and high- quality print finishes. This type of packaging produces a fraction of waste during the printing process, overall reducing landfill discards. Improvements in productions processes have reduced water and energy consumption, greenhouse gas and emissions and volatile organic compounds. Finally, lighter-weight flexible packages result in less transportation- related energy and fossil fuel consumption, and environmental pollution. • Industrial packaging : Industrial packaging is used to protect, ship and store a wide range of goods. Typically, industrial packaging is used at the production site, right after production, although it can be used at any point in the supply chain. This type of packaging is usually used on products that are sensitive and rely heavily on stability or that are hazardous or that are bulky or products that have components that are sensitive to each other. Industrial packaging materials can include: Wood, such as, wood board, derails board, plywood, skids, wooden , wooden boxes and more. Formed stainless steel and other metals. Corrugated cardboard, fibreboard, and more. Various plastic forms and more. . ASEPTCIC PROCESSIG is a processing technique wherein commercially thermally sterilized liquid products (typically food or pharmaceutical) are packaged into previously sterilized under sterile conditions to produce shelf-stable products that do not need refrigeration. Aseptic processing is a processing technique wherein commercially thermally sterilized liquid products are packaged into previously sterilized containers under sterile conditions to produce shelfstable products that do not need refrigeration • There are two specific fields of application of aseptic packaging technology- • 1. Packaging of pre-sterilised and sterile products. E.g. Milk and dairy products, puddings, desserts, fruit and vegetables. • 2. Packaging of non-sterile products to avoid infection by microorganism E.g. Fermented dairy products like yoghurt. Aseptic packaging technology is fundamentally different from that of conventional food processing by . • 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 • Boxes, Bags and Pouches, Cups and Trays, Bottles and , Metal Cans, Plastic Cans, 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 • Sterility check. • Advantages of Aseptic Packaging: • Convenience Aseptic packages are portable, lightweight, and shatterproof and easily transportable Food Safety The aseptic process and carton together ensure that the liquid food or beverage inside is free from harmful bacteria and contaminants. No refrigeration required Long shelf life More nutrition Compared with canning, products can retain more nutrients as well as natural taste, colour and texture Low Packaging to product ratio Limitations • Plant Installation cost is high as compare to canning • Gas transmission rate of Aseptic / 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 is formed, filled and then sealed continuously in a sterile(germ free) environment. Since it is mainly used in the pharma industry. It is also known as Blow Fill Seal pharmaceutical seal machine. Blow- Fill-Seal (BFS) technology is a manufacturing technique used to produce small, (0.1mL) and large volume, (500mL +) liquid-filled containers. Originally developed in Europe in the 1930s, it was introduced in the United States in the 1960s, but over the last 20 years it has become more prevalent within the pharmaceutical industry and is now widely considered to be the superior form of aseptic processing by various medicine regulatory agencies including the U.S. Food and Drug Administration (FDA) in the packaging of pharmaceutical and healthcare products. • The basic concept of BFS is that a container is formed, filled, and sealed in a continuous process without human intervention, in a sterile enclosed area inside a machine. Thus this technology can be used to aseptically manufacture sterile pharmaceutical liquid dosage forms. The process is multi-stepped: first, pharmaceutical- grade plastic resin is vertically heat extruded through a circular throat to form a hanging called the parison. This extruded tube is then enclosed within a two-part mould, and the tube is cut above the mould. The mould is transferred to the filling zone, or sterile filling space, where filling needles (mandrels) are lowered and used to inflate the plastic to form the container within the mould. Following the formation of the container, the mandrel is used to fill the container with liquid. Following filling the mandrels are retracted and a secondary top mould seals the container. All actions take place inside a sterile shrouded chamber inside the machine. The product is then discharged to a non-sterile area for labeling, packaging and distribution. • Blow-fill-seal technology reduces personnel intervention making it a more robust method for the aseptic preparation of sterile pharmaceuticals. BFS is used for the filling of vials for parenteral preparations and infusions, eye drops, and inhalation products. Generally the plastic containers are made up of and polypropylene. Polypropylene is more commonly used to form containers which are further sterilised by autoclaving as polypropylene has greater thermostability. • Injection Modelling and Fill, Seal • Two-step process that molds vials then transfers them to the filling line to be filled and heat sealed. (No risk of contact between product and heat) Added flexibility that ranges from small batches at 1,500 vials per hour to full-scale production at 15,000 vials per hour. Smaller dimensions mean machines fit in most existing contract filling environments. Improved end-user experience. Easily switch out or replace damaged, worn, or old parts. Less than half of the cost of traditional BFS machines with the same production capacity. More environmentally friendly and no excessively wasted plastic material. Provides the option for 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 and heat) Only capable of full-scale production at roughly 10,000 vials per hour without being able to stop the machine. 3 working shifts necessary once started. Large dimensions with a recommended minimum room size of 500-600 square feet. Halted production time due to the changeover of molds. Higher initial financial investment and overall cost. Large amount of plastic waste is cut from the parison and then disposed of. Extremely complex set up, maintenance, and operating instructions that require 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 and heat) Only capable of full-scale production at roughly 10,000 vials per hour without being able to stop the machine. 3 working shifts necessary once started. Large dimensions with a recommended minimum room size of 500-600 square feet. Halted production time due to the changeover of molds. Higher initial financial investment and overall cost. Large amount of plastic waste is cut from the parison and then disposed of. Extremely complex set up, maintenance, and operating instructions that require highly skilled and well-trained personnel. • The major difference between and blow moulding is the kind of product produced. Typically, blow moulding is designed to produce hollow, singular containers, such as bottles. On the other hand, injection moulding is used to produce solid pieces, such as plastic products. • Advantages of blow moulding: Production In large Quantities. Blow Moulding is a process that can help the companies to produce large number of uniform units in a short period of time, Production of an Array of different products, Automation, Low Cost. Disadvantages: The Requirement of Precision Generates Waste, Petroleum Usage, Affects the Environment. • Containerization is a system of intermodal freight transport using intermodal containers (also called shipping containers and ISO containers). The containers have standardized dimensions. They can be loaded and unloaded, stacked, transported efficiently over long distances, and transferred from one mode of transport to another—container ships, rail transport flatcars, and semi-trailer trucks—without being opened. The handling system is completely mechanized so that all handling is done with cranes and special forklift trucks. All containers are numbered and tracked using computerized systems. Containerization did away with the manual sorting of most shipments and the need for warehousing. It displaced many thousands of dock workers who formerly handled break bulk cargo. Containerization also reduced congestion in ports, significantly shortened shipping time and reduced losses from damage and theft. Containers can be made from a wide range of materials such as steel, fibre-reinforced polymer, aluminium or a combination of all. Containers can be made of weathering steel to minimize maintenance needs. • Classification of containers: The containers are classified into various types depending upon their Characteristics. These are follows Depending upon its functions: a) less container 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 weight container = below 18 tonnes b) Medium weight container = 18 to 25 tonnes c) Heavy weight container = above 25 tonnes. • Types of containers: • 1. End loading: Fully enclosed, equipped with end – doors, suitable for general cargo. It is basic intermodal container. • 2. Side loading: fully enclosed, equipped with side door for use in stowing and discharge of cargo. • 3. Open top: used for carriage of heavy, bulky or machinery items where loading or discharge of the cargo through end or side door is not practical. Most open top containers are equipped with fabric covers. Some open top versions are filled with removal hatch – panel covers of a detachable full size metal roof. • 4. Ventilated: for cargoes which should not be exposed to rapid or sudden temperature changes, ventilated versions are available. • 5. Refrigerator: also known as refer container. Insulated and equipped with a built in refrigeration system, powered by direct electrical connection or by diesel or gasoline generator used primarily for refrigeration of frozen foods. • 6. Dry bulk: designed for carriage of dry bulk cargoes such as 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 or bulky items or machinery & vehicles. Some are equipped with removable sides and fabric covers. • 9. Livestock: containers for livestock carriage. These containers are available for transporting poultry, cattle, and other livestock • WHAT IS ELECTRONIC ARTICLE SURVEILLANCE (EAS) • Electronic article surveillance (EAS) alarm systems are triggered when someone leaves a store or building with a product having an active tag or attached to it. EAS systems are often applied to prevent shoplifting in stores or theft of valuable 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 (radio frequency) systems Systems combined with RFID Systems that are RFID-ready RFID only THANK YOU

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