Fundamentals of Packaging Technology Seminar Course Outline Semester 1 Day One • Course Introduction • Course Overview 1-3 Market Research • Course Logistics • Why perform market studies • Market study tools 1-1 Perspective on Packaging • Broad based studies • Demographic Workshop: Part One • Focused studies • A definition of packaging • Updating persona through market • The historical evolution of packaging research and packaging materials • The industrial revolution and packaging 1-4 Graphic Design • Growth of modern packaging roles • Demographic Workshop: Part Two • The modern packaging industry • Technical and communication roles compared 1-2 Package Development • The importance of demographic and Process psychographic information • Management of the packaging function • The modern retail environment • The package as the purchase motivator • Project Scope and objectives • Fundamental messages: Cords of • The package development process familiarity and points of difference • The package design brief • Equity and brand names • Specifications • Emotional aspects of color • Basics of graphic design: balance, unity, direction, typography and Day Two illustrations 1-5 Introduction to Printing 1-6 Printing Methods and Printing Methods • Preparing the artwork, prepress proofing Flexographic and Related Relief Printing Processes • Package printing methods and printing presses • Nature and production of the printing plate • Line art, color selection and Pantone Matching System • Configuration of the printing station • Halftone art, screens and screen sizes • Advantages and limitations of flexography • Process art, moire patterns • Offset letterpress (dry offset) and • Color bleeds, trap, special colors applications Fundamentals of Packaging Technology Seminar Course Outline Semester 1 Day Two, Cont. Lithography Gravure • Nature and production of the printing • Nature and production of the printing plate plate • Configuration of the printing station • Configuration of the printing station • Advantages and limitations of lithogra- • Advantages and limitations of gravure phy • Principal packaging applications of • Principal packaging applications of gravure lithography Special Decorating Techniques • Screen, heat transfer, hot stamp and pad printing, reflective metallics and surface gloss Day Three 1-7 Color Perception 1-9 Labels and Labeling • Physics of color • The functions of a label • The human perception of color • Types of labels • Additive and subtractive color synthetics • Label forms • Ink as a modifier of light • Label materials • The four process printing colors • Affixing labels • Standard color viewing conditions • The visual comparison of colors 1-8 Electronic Product Coding • EPC advantages through the supply chain • EAN/UPC symbologies • UPC structure • RFID tags • RFID readers • RFID advantages For details and registration: • RFID limitations www.iopp.org/fundamentals Fundamentals of Packaging Technology Seminar Course Outline Semester 2 Day One Please bring a calculator 2-1 Paper and Paperboard • Dimensioning, grain direction • Fiber sources and fiber quality • Die-boards and paperboard cutting and • Furnish make-ups creasing • Fourdrinier and cylinder-type paper • Folding carton manufacture machines • Set-up boxes, designs, applications and • Machine direction and cross direction limitations • Coatings, calendaring and other treat- 2-3 Corrugated Fiberboard ments • Containerboard grades and standard • Paper characterization flute sizes • Paper and paperboard grades and • General applications of standard flutes applications • Mullen Test and edge crush tests (ECT) 2-2 Folding Cartons • Using McKee formula to estimate box • General paperboard construction classes compression strength • General design considerations • Carrier rules and regulations • Tube-style folding cartons: basic designs • Corrugated board manufacture and variations • Single, double and triple wall boards • Tray-style cartons: basic designs and • Microflute and wave flute comparisons variations Day Two Please bring a calculator 2-4 Corrugated Boxes • General industry tolerances • Regular slotted container (RSC) produc- • Wax and other treatments tion and styles • Die cut container production and style 2-5 Box Compression examples Strength Workshop • Bliss box styles • Standard compression strength measure- • Decorating by direct printing (post ment printing) • Difference between compression • Preprint, litho labeling and litho strength and stacking strength laminating options • Impact of humidity, time, pallet pattern • Scoring allowances and overhang • Dimensioning corrugated containers and pads • Using Fibre Box Association stacking strength factors Fundamentals of Packaging Technology Seminar Course Outline Semester 2 Day Two, Cont. • Calculating required compression • Vibration sources, relative movement strength damage • Determining required ECT values to • Resonance, stack resonance, load meet required stack strength skewing • Stacking HDPE bottles • Unit loads and unit load efficiency • Tracking and acting on distribution 2-6 Distribution Environment losses • Industry guidelines and practices • Package transport and distribution hazards • Pallet issues • A systems approach to distribution pack- • Recommended minimum and aging maximum container dimensions • Sources of shock inputs and effects • Recommended load stability • Good shipping practices Day Three 2-7 Protective Packaging 2-8 Pre-Shipment Testing • Understanding G factors • Purpose • Damage boundary curves • ISTA test procedures • Cushioning against shock • ASTM D4 169 test procedures • Selecting cushioning materials • Planning a pre-shipment test • Using dynamic cushioning tables • Spring-mass relationships and isolating 2-9 Industrial Packaging inputs 2-10 Wood Packages For details and registration: www.iopp.org/fundamentals Fundamentals of Packaging Technology Seminar Course Outline Semester 3 Day One 3-1 Introduction to Polymers 3-3 Packaging Polymers • Structure of HDPE, LDPE, LLDPE and 3-2 Polymer Chemistry mPE • Polymers, plastics and polymerization • Polyethylene density and property trends • Polymer classifications • Structure and general properties • Terminology and abbreviation of polypropylene, poly(vinyl) and poly(vinylidene chloride), polystyrene, • Copolymers and properties poly(vinyl alcohol), poly(vinyl acetate) • A review of basic chemical concepts and ethylene-vinyl acetate, polyamide, • Polarity, solubility, permeability and poly(ethylene terephthalate), other lesser barrier used polymers • Coefficient of friction and adhesion • Thermosets and thermoplastics compared; thermoset applications • Glass transition and melt temperatures • Thermal history and crystallinity 3-4 Property Comparisons • Oriented plastics and shrink plastics • General properties of packaging polymers • Hydrocarbons and polyethylene • Factors affecting barrier properties • Oxygen and moisture vapor barrier comparisons Day Two • Classes of polymer additives 3-5 Extrusion Molding • Basic form-fill-seal machines • Plasticating extruders • High barrier constructions • Cast and blown plastic film and sheet • Wet bond, dry bond, and extrusion • Co-extruded and oriented plastic films laminating • Video presentation: Analytical and • Specifying plies, caliper, and roll Physical Testing orientation • Example laminate constructions 3-6 Flexible Packaging 3-7 Thermoforming • Aluminum foil properties and applications • Extruded profiles and typical packaging • Vacuum metallizing process applications • Metallized paper and film applications • Common thermoforming methods and materials • Structural, barrier, sealing and aesthetic properties • Thermoform packaging applications Fundamentals of Packaging Technology Seminar Course Outline Semester 3 Day Two, Cont. 3-8 Injection Molding • The injection molding process • Injection molds, tooling costs • Sprues, runners, gates and undercuts • Part characteristics and packaging applications Day Three 3-9 Blow Molding 3-11 Closures • The extrusion blow molding process • Closure selection criteria • Parisons and parison programming • Container finish standards and thread • The injection blow molding process styles • Injection stretch blow molding • Closure dimension designations • Extrusion and injection blow molding • Closure liner functions and types compared • Common plastic closure designs • General bottle design considerations • Metal continuous thread, lug, roll-on, press-on and crown closures 3-10 Bottle Design Criteria • Child-resistant and tamper-evident • General design elements designs • Decorating options • Special bottle designs • Environmental stress cracking For details and registration: www.iopp.org/fundamentals Fundamentals of Packaging Technology Seminar Course Outline Semester 4 Day One 4-1 Environmental Issues • Measuring sustainable packaging— • Defining packaging’s role in the solid Wal-Mart’s sustainable scorecard waste issue • No single “sustainable solution” • Proportion of packaging in the waste • Creating sustainable packaging strate- stream gies, yet implementing them one step at • The four “R’s” hierarchy: reduce, reuse, a time. recycle and recover 4-2 Adhesives • Environmental concerns and the con- sumer • Mechanical and specific theories of • The packaging professional’s role in the adhesion environmental issue • Surface tension and dyne level • Adhesive viscosity • Starch, dextrin, and casein adhesives 4-1A Sustainable Packaging and their applications • The concept of cradle-to-cradle product • Emulsion adhesives: advantages, appli-