Learning Objectives

SE2127 Packaging Materials, 7.5 credits Study period 3, spring semester 2011

Department of Solid Mechanics in cooperation with Department of Fibre and Polymer Technology and Innventia AB

Examiner: Sören Östlund

Learning objectives

After the course, the student should be able to describe the components of the packaging value chain, and dttdemonstrate how these in fluences the des ign o f pac kages discuss important applications in packaging technology using correct terminology from physics, mechanics and chemistry select suitable material and technology for manufacturing of a particular type of packaging explain the properties of a packaging material based on the structure and chemistry of the material relate the results from mechanical testing of packaging materials to relevant fundamental solid mechanics parameters, and demonstrate the value of modelling and numerical calculations for design of packages

1 Course content

• The packaging value chain – Packaging logistics – Packaging ergonomics • Solid mechanics and the finite element method for packaging design • Manufacturing of packaging • Wood fibre based packaging materials – Converting and end-use properties – Design of paper and paperboard packaging • Plastics – Design of plastic packaging – Barriers • Optical, printing and closing properties • Glass and metal packaging

Facts

• Credits: 7.5 ECTS credits • Level: Advanced • Grades: A-F • Language: English • Course structure: – Lectures 38 h, laboratory 16 h, 2 laboratory reports, home assignment, design project • Web pages – https://www.kth.se/social/course/SE2127 – http://www.kth.se/sci/institutioner/hallf/gru/kurser/SE2127/VT11-1

2 Instructors

Sören Östlund Mikael Hedenqvist (MH) soren@kth. se [email protected] tel. 08-790 7542 tel. 08-790 7645

Chris Dominic (CD) [email protected] tel. 08-676 7000

Mikael Magnusson (MM) [email protected] tel. 08-790 7552

Laboratory

• Laboratory 1 is based on the software CAPE PACK for ppgggackaging logistics and will take place in the Student’s Computer Room at Solid Mechanics on Tuesday, February 1 at 13.15-17.00. REPORT • Laboratory 2 is a one-day study visit to Korsnäs - Frövi Paperboard Mill and Packaging Lab on Tuesday, February 8. • Laboratory 3 deals with testing of mechanical properties of paper and paperboard and will take place at Innventia on Tuesday, February 15 at 13.15-17.00. REPORT

3 Design Project

• Design, in groups of (2)3 students, a package made from a paperboard plastic composite materials. This design should include analysis of strength and stiffness, as well as artistic design, printing, manufacturing, logistics and cost considerations. • The design project will be assessed regarding content, analysis, written and oral presentation, and will affect the final grade. • Well ahead of to the oral presentation, each group should give the examiner a short status report (preliminary design review) on the project work in order to clarify possible misunderstandings and to check details in the analysis.

Assessment of Design Project

• Preliminary design review • Short pppaper A full text pppaper is not ex pected , but the short pppaper should be written as a complete report. You can write the short paper in English or Swedish at your own choice, but the presentation should be in English. • Presentation on Friday, March 12. You should preferably present your design using Power Point. A computer and projector will be available. Each group will only have approximately 10 minutes for their presentation.

4 Examination

• Written exam (TEN1, 4 credits) Monday 14/3, 14-18 in V35 • Laboratory (LAB1, 2 credits) • Design project (ÖVN1, 1,5 credits)

• Final grade is given by a combination of TEN1, LAB1 and ÖVN1.

Grading

The final grade on the course is given by a combination of TEN1, LAB1 and ÖVN1. The score on the paper testing laboratory and the design project is added to the score on the written exam (when passed) to give the overall score that is used to give a grade on the course. The maximum score on the written exam is 60 and a score of 30 is required to pass the exam. The laboratory reports can give an additional score between ‐1 and 3, and the design project can give an additional score between ‐3 and 6. As a result they can change the final grade of the course both upwards and downwards (but not below E in case you have passed the written exam).

5 Literature I

• (PBoP) Pocket book of packaging • (FoPT) Walter Soroka, Fundamentals of packaging technology, 3rd Edition, Institute of • packaging professionals, Naperville, Illinois, USA, 2002. • (BOA) Paperboard Reference Manual, Iggesund Paperboard AB (1993) • (CCC7) Twede, D. and Selke, S. E. M., Cartons, Crates and Corrugated Board – Handbook of Paper and Wood Packaging Technology (Chapter 7), DEStech Publications, Inc., Lancaster, Pennsylvania, USA, 2005. •(LJU) Pulp and Paper Chemistry and Technology - Volume 4, Paper Products Physics and Technology, Chapters 1, 2, 3, 4, 9, 10, 11, 12, 66. • (FRAC) Östlund, S. and Mäkelä, P., Fracture properties, KTH, 2011. • (HPT) R. E. Mark, C. C. Habeger, Jr., J. Borch and M. B. Lyne (Editors), Handbook of Physical Testing of Paper (Chapter 11), 2nd Edition, Marcel Dekker, New York, NY, USA, 2002.

Literature II

• (BPM) Barrier packaging materials, M. S. Hedenqvist, Chapter 26, 547- 563, in Environmental Degradation of Materials, Ed. M. Kutz, William Andrew Publ., Norwich, NY ()(2005). • (LOG) Johansson, K., Olsmats, C., Tiliander, L. and Lorentzon- Karlsson, A., Packaging Logistics, Packforsk, Kista 1997, pages 9-15, 33-45. • (CDO) Chris Dominic Packaging Networks – A Study on Swedish Packaging Industry. Emergent structures in Supply/Demand Chain Management. • Supply/Demand Chain Management Summary of published papers • (MET) Metal Packaging, Metal Packaging Manufacturers Association, www.mpma.org.uk (2006). • Magnusson, M. S. and Östlund, S., Problems with Selected Solutions, KTH, 2011.

6 A folder containing 3‐12 will be sold at in the student office of the Department of Solid Mechanics for SEK 150. Additional material will be handed out during the lectures for free.

The book, 2 (FoPT) Walter Soroka, Fundamentals of packaging technology, 3rd Edition, Institute of Packaging Professionals, Naperville, Illinois, USA, 2002, will be provided by the department during the course for SEK 500. If you want to keep the book after the course, the price is SEK 700; otherwise you will have to return the book in undamaged conditions and you will get your SEK 500 back.

Reading advice

It is suggested that the lecture notes form the basis for individual studies. In the literature the concepts covered at the lectures are covered in more detail, sometimes at several locations, and by finding and using this information it should be possible to get a thorough understanding of the concept.

Please, note that the assessment of the course content is fdfocused on conceptltual undtdiderstanding rather than repeating facts, and knowledge of the underlying fundamentals is important.

7 Course evaluation

• A web-based evaluation of the course will be made after the written examination. • Excerpts from last year’s course evaluation • THE STUDENTS SHOULD EDIT THEIR REPORTS AND COMMENT ON THE FEED-BACK FROM THE INSTRUCTOR ON THE REPORT FROM THE PAPER AND BOARD MATERIALS TESTING LABORATORY. • DEVELOP AND INTRODUCE A COMPUTATIONAL HOME ASSIGNMENT ON LAMINATE THEORY. • ADD 2 HOURS OF TEACHING TIME IN ORDER TO INCREASE FLEXIBILITY IN THE COURSE PLANNING. • TAKE AWAY AT LEAST TWO ITEMS IN THE LITERATURE LIST AND CONCENTRATE ON THE PARTS OF THE LITERATURE THAT IS APPRECIATED AND USE LECTURE NOTES FOR OTHER PARTS. ONLY SUCCEEDED WITH ONE.

Program – weeks 1, 2

1 Tuesday 18/1, 13-15, SÖ Course introduction. FoPT Ch. 1 and 2 E34 Overview of packaging materials LJU Ch. 10 and applications. PboP, (pp. 4-43) PkiPackaging idindustry, va lue c hihain, primary, secondary and tertiary packaging, trends. 2 Thursday 20/1, SÖ Paper and paperboard based BOA (pp. 11-36, 51- 10-12, D35 packaging, overview of different 57) types of materials. LJU Ch. 10 HPT (pp. 564-576) 3 Friday 21/1, 8-10, CD Packaging logistics, functional LOG, CDO D35 demands, transport testing.

4 Tuesday 25/1, 13-15 CD Packaging logistics, functional LOG, CDO D33 demands, transport testing. Introduction to CAPE PACK. 5 Wednesday 26/1, SÖ Paper physics, fundamentals of LJU Ch. 1 and 2 8-10, E32 solid mechanics for paper BOA (p. 84-112) materials. 6 Friday 28/1, 8-10, E34 SÖ Paper physics, laminate theory LJU Ch. 2, 11

8 Program – weeks 3, 4

7 Monday 31/1, 15-17, MM Tutorial 1 Examples: D33 Paper stress-strain curve 1.1.1, 1.1.8 Laminate theory program 1.2.1, 1.1.2, 1.2.13 HOME ASSIGMENT 1.2.3, 1.2.4 & 1.1.3 Tuesday 1/2, 13-17, CD Laboratory 1 CAPE PACK Solid Mechanics Student Computer Room 8 Thursday 3/2, 8-10, SÖ Manufacturing of paperboard and FoPT Ch. 5 and 15 D33 corrugated board, quality BOA (p. 31-44) parameters. CCC Ch 7 HPT (pp. 564-576) 9 Monday 7/2, 8-10, E33 SÖ Manufacturing of paperboard and LJU Ch. 9, 10 corrugatedbd boar d pac kag ing, BOA (p. 157 -225) converting operations: printing, FoPT Ch. 4, 6, 15 and creasing, folding, gluing 18 Intro to DESIGN PROJECT. Tuesday 8/2, 8-17 Laboratory 2 Company visit 10 Friday 11/2, 8-10, E53 MH Polymer based materials and FoPT Ch. 9-11 packages, overview of different types of materials.

Program – weeks 5, 6

11 Monday 14/2, 8-10, MH Barrier materials I BPM, FoPT Ch. 14 E33 Tuesday, 15/2, 13-17, Laboratory 3 Experimental Innventia AB , determination of some Drottning Kristinas mechanical properties väg 61 of paper and board.

12 Thursday 17/2, MH Barrier materials II Handed out material 15-17, E34 BPM 13 Tuesday 22/2, 13-15, MH Plastic packaging – Other FoPT Ch. 13-14 E33 properties 14 Thursday 24/2, 8-10, SÖ Design of paper and board LJU Ch 10 E34 packaging: stacking, analytical BOA (pp. 119-128) methods. FPTCh15FoPT Ch. 15, 17 Company software such as HPT (pp. 576-652) Billerud Box Design, Korsnäs Example: 1.3.3 Optipack and EUPS. 15 Friday 25/2, 8-10, E33 SÖ Design of paper and board FoPT Ch. 17 packaging: dynamic loads and LJU Ch. 4, p. 144 shocks, mechanosorptive creep

9 Program – weeks 7, 8

16 Monday 28/2, 15-17, SÖ Design of paper and board HPT E34 packaging, advanced concepts, LJU Ch. 2, 11, 12 FEM, fracture mechanics FRAC 17 Tuesday 1/3, 13-15, MM Tutorial 2 Examples: D35 1.1.9, 1.1.10, 1.1.11, 1.3.5 18 Tuesday 8/3, SÖ Sackpaper. FoPT Ch. 7, 8 & 13-15, E53 Glass and metal packaging. p. 505-509, MET Environmental issues, life cycle FoPT Ch. 1 and 2 analysis, packaging ergonomics. LJU Ch. 66 The future of paper and paperboard packaging. 19 Thursd ay 10/3 , 13-15, SÖ, PifPresentation of DESIGN D41 MH, PROJECTS CD Monday 14/3, Written examination 14-18, V35

After Lecture 1 you should be able to

• describe what packaging is • give examples of efficient packaging systems • describe how the industrial revolution lead to modern packaging • discuss the relations between packaging and the development of a country • describe the two major divisions within the packaging industry • give examples of packages made from the most common packaging materials

10 Literature

• Lecture notes • Fundamentals of packaging technology – Chapters 1-2 • Pulp and Paper Chemistry and Technology - Volume 4, Paper Products Physics and Technology - Chapter 10 • Pocket book of packaging – Pages 4-43

Packaging, everybody know what it is?

11 What is packaging?

• A coordinated system of preparing goods for transport, distribution, storage, retailing and use. • Packaging is a – complex – dynamic – scientific –artistic – contiltroversial business function • Needs a PRODUCT!

Definition Packaging * “Packaging” shall mean all products made of any materials of any nature to be used for the containment, protection, handling, delivery and presentation of goods, from raw materials to processed goods, from the producer to the user or the consumer. “Non-returnable” items used for the same purposes shall also be considered to constitute packaging.

* Directive 94/62/EC on packaging and packaging waste

12 Packaging functions range from technical to marketing

Technical Functions Marketing Functions • contain • communicate •protect • display • preserve • inform • measure • promote •dispense (sv. dela ut, i.e. medicin) •sell • transport • motivate •store

Typical protect, transport and storage problems • Vibration • Mechanical shock • Abrasion • Deformation • High/low temperature • RltiRelative hum idity • Water • Tampering

13 Packaging - a part of a system -

Product

Packaging

Distribution environment

Functions of packaging systems

1. Product flow - Handling - Transport - Storage

2. Protection - Mechanical - Barrier

3. Runnability - Stiffness - Flatness

4. Environment - Material savings - Environmental concern

5. Communication - Information - Promotion

14 Different levels of a packaging system

Consumer/Sales packaging – primary packaging

Retail/Group packaging – secondary packaging

Transport packaging – tertiary packaging

Pallet

Packaging in the distribution chain

INDUSTRIAL PRODUCTS

Waste RAW Disposal PACKAGING CON SUMER PR ODUC T S END- MATE- PRODUCER/ MANUFAC- USER

RIALS CONVERTER RETAILER TURERS SALER WHOLE- BurningBur- ning

MATERIAL RECYCLING REUSE

REQUIREMENTS AND DEMANDS

PACKAGING DESIGN

15 Different levels along the chain

MANUFACTURER/ WHOLESALERWHOLE- RETAILER END-USER/ PACKING SALER CONSUMER

TERT

SEK

PRIM

Filling of Building up of Breaking down of Handling primary package Transport Storage package system manual X% package system manual X%

The modern packaging industry

metal cans photography glass bottles fillers marketing paper cartons case packers legal plastic containers date coders consumer testing flexible materials consultants raw materials converters machinery services Suppliers

The packaging industry

Users consumer industrial Institutional

food automotive food pharmaceutical machinery non-food toys bulk food military hardware chemicals medical devices personal care

16 What is an efficient packaging?

for for environment human

Effective packaging

for logistics

17 Packaging & Unit load © IKEA of Sweden AB

Example of packaging logistics

IKEA of Sweden

Glimma Tea lights Forecast 15,000,000 bags of 100 tea lights

Packaging & Unit load © IKEA of Sweden AB New Glimma - Old Glimma

18 Packaging & Unit load © IKEA of Sweden AB Glimma today Glimma future

(Photo is of the test prototype)

360 bags of tea lights 30 % less unit load If one pallet takes 5 min to unpack almost 200 working days in the stores will be saved 252 bags of tea lights

Packaging & Unit load © IKEA of Sweden AB In store

• Fast unpacking time • Easy to handle • Could be used as multiple sale solution • More commercial • Less corrugated board visible • Less space/100 pack = more space for other products

19 Packaging & Unit load © IKEA of Sweden AB IKEA

Outbound gods will be reduced with 300 truc ks 30 % less pallets to store in the distribution chain 30 % less pallets to handle Reduce cost Safe transport

History of packaging Primitive packaging • We do not know what the first package was – Containment and carrying devices – Fabricated sacks, baskets and bags made from materials of plant or animal origin – Hollow glass objects in about 1500 B.C. – Markinggp of olive oil amphora in Greece about 250 B.C.

20 From Rome to Renaissance

•Glassblow pipe invented in about 50 B.C. • Paper made in China in about 105 A.D. •Printingfrom woodcuts in about 700-800 A.D.

Industrial revolution

• Rural agricultural workers migrated into cities • IiInexpensive mass-proddduced goo dbds became available to a large segment of the population • Factory workers needed products and food • Many new shops and stores opened • Some industries located in non-agricultural areas

21 The evolution of new packaging roles

• RURAL COMMUNITIES – Barrels • CITY DWELLERS – Smaller quantities required • Shops adapt the bulk delivery system • First pre-packaged products – medicines, cosmetics, teas, liquors and other expensive products • Individual packaging – quality producers wished to identify their particular product, for example Schweppes (1792) Perrier (1863) Colgate (1873)

The evolution of new packaging roles

• Early packages or wrappings for higher cost gods applied the evolving printing and decorating arts • Plastic packages occur in the early 1900s – Cellulose films (1911) – Cellophane (1927) • In d epart ment st ores with th ousand s of prod uct s staff people had little knowledge of the products – The package had to inform the purchaser – The package had to sell the product

22 Packaging in the late 20th century

• 1950s – fast food outlets appear – convenience and prepared food packages – plastics available as packaging material • 1970s – child-resistant closures, tamper (sv. manipulera) evident closures, labelling laws – microwave food, yoghurt, bottled water • Last decades of the 20th century to now – ageing population – smaller families, single person house-holds – convenient and fast for the urban inhabitant

Modern packaging

• High increase in number of goods/products – PkiPackaging force dtthld to the role o f purc hase mo tititivation rather than just presenting the product – Marketers aimed at features and advantages beyond the product itself – New concern is removal of debris generated by consumer socitiety an did impac t on eco logy – Sustainable development of packages

23 Packaging and the modern industrial society

• Packages are a requirement for everyday enjoyment of geographicall y and seasonall y spec ific foo d • Central processing allows value recovery of what would normally be waste. – Use of by-products (i.e. chicken feathers used as fill material, gelatine, animal food) – Packaging materials recycled • Economical manufacture of durable goods requires good packaging, c.f. TV sets, computers, furniture etc.

Science of packaging is in a continuous state of change Science of packaging is closely connected with everything we do in society . For example … Oil: 1) bulk to service stations into glass jars 2) metal cans 3) foil/fibre composite cans 4) plastic bottles Milk: 1) glass bottles 2) plastic bottles 3) flexible bags 4) aseptic paperboard cartons

24 World packaging

• Development of the packaging level is an iditindicator o fthf the wea lthfthlth of the coun try • Packages – reduce food prices – preserve, protect and transport food

Value of packaging materials usage in different branches SEK/billions

25 Most frequently used packaging materials

The total turnover of the global packaging market is more than 500 billion dollars

Glass Others

Metals Machinery

Paper Board Corrugated Plastics Source: WPO

26 Usage (percent by weight) of different packaging materials in a typical shopping basket year 2000

Steel Aluminum Wood Glass Paper

Plastics

Paperboard

Corrugated

Which materials are used for storage of CD discs?

• Stiff plastics • Soft plastics • Paperboard • Paperboard/plastics composites • Metal • Wood

27 Packaging of carbonated drinks

•Glass – beer, soft drinks, champagne • Plastics – soft drinks, water, cider, beer • Metal – beer • Paperboard –?

Milk in plastic bottle or paperboard packaging?

• When asked about drink choices at school, 51% of those surveyed said that they would choose milk over other beverage options when milk was presented in a plastic bottle. When milk was presented in a paper carton, only 24% of the students said they would choose milk over the other options. • Students described the milk in plastic bottles as cool, trendy, stylish, new and fun to drink. They described the paperboard carton as old fashioned. • Kids drink more milk when the right package is offered.

28 Cans • Metal • Glass • Paperboard – Tetra Recart

Transport packaging

• Wood • Corrugated board

29 Paper and Paperboard

Inherent weaknesses of paper and board in packaging applications

30 Fail in a brittle manner Failure load of shopping bags

Paper bag Plastic bag

Reference 1000 N 250 N On wet surface 250 N 250 N Rapid loading 500 N

Poor creep properties (particularly in varying moisture climates)

31 Difficult to form into complex shapes

Past Now Future

Paper based composites

32 Plastics

Plastics based composites

33 Metals

Glass

34 After Lecture 1 you should be able to