Handbook of Paper and Paperboard Packaging Technology E-Book

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 741

Veröffentlichungsjahr: 2012

Beschreibung

The definitive industry reference on the paper and paperboard packaging sector.

Now in a fully revised and updated second edition, this book discusses all the main types of packaging based on paper and paperboard. It considers the raw materials, the manufacture of paper and paperboard, and the basic properties and features on which packaging made from these materials depends for its appearance and performance. The manufacture of twelve types of paper- and paperboard-based packaging is described, together with their end-use applications and the packaging machinery involved. The importance of pack design is stressed, as well as how these materials offer packaging designers opportunities for imaginative and innovative design solutions. Environmental factors, including resource sustainability, societal and waste management issues are addressed in a dedicated chapter.

The book is directed at readers based in companies which manufacture packaging grades of paper and paperboard, companies involved in the design, printing and production of packaging, and companies which manufacture inks, coatings, adhesives and packaging machinery. It will be essential reading for students of packaging technology and technologists working in food manufacturing who are users of paper and paperboard packaging products.

Praise for the First Edition

‘This book is a valuable addition to the library of any forward-looking company by providing in-depth coverage of all aspects of packaging which involve the most ecologically acceptable material, namely paper and paperboard.’—International Journal of Dairy Technology

‘...a welcome contribution to a field where coverage was previously limited to subject-specific books... or to single chapters in textbooks on broader aspects of packaging technology.’—Packaging Technology and Science

Leseprobe

Contents

Contributors

Preface

Acknowledgements

1 Paper and paperboard – raw materials, processing and properties

1.1 Introduction – quantities, pack types and uses

1.2 Choice of raw materials and manufacture of paper and paperboard

1.3 Packaging papers and paperboards

1.4 Packaging requirements

1.5 Technical requirements of paper and paperboard for packaging

1.6 Specifications and quality standards

1.7 Conversion factors for substance (basis weight) and thickness measurements

2 Environmental and resource management issues

2.1 Introduction

2.2 Sustainable development

2.3 Forestry

2.4 Environmental impact of manufacture and use of paper and paperboard

2.5 Used packaging in the environment

2.6 Life cycle assessment

2.7 Carbon footprint

2.8 Conclusion

3 Paper-based flexible packaging

3.1 Introduction

3.2 Packaging needs which are met by paper-based flexible packaging

3.3 Manufacture of paper-based flexible packaging

3.4 Medical packaging

3.5 Packaging machinery used with paper-based flexible packaging

3.6 Paper-based cap liners (wads) and diaphragms

3.7 Tea and coffee packaging

3.8 Sealing tapes

3.9 Paper cushioning

4 Paper labels

4.1 Introduction

4.2 Types of labels

4.3 Label adhesives

4.4 Factors in the selection of labels

4.5 Nature and function of labels

4.6 Label printing and production

4.7 Print finishing techniques

4.8 Label finishing

4.9 Label application, labelling and overprinting

4.10 Label legislation, regulations and standards

4.11 Specifications, quality control and testing

4.12 Waste and environmental issues

5 Paper bags

5.1 Introduction

5.2 Types of paper bags and their uses

5.3 Types of paper used

5.4 Principles of manufacture

5.5 Performance testing

5.6 Printing methods and inks

5.7 Conclusion

6 Composite cans

6.1 Introduction

6.2 Composite can (container)

6.3 Historical background

6.4 Early applications

6.5 Applications today by market segmentation

6.6 Designs available

6.7 Materials and methods of construction

6.8 Printing and labelling options

6.9 Environment and waste management issues

6.10 Future trends in design and application

6.11 Glossary of composite can-related terms

7 Fibre drums

7.1 Introduction

7.2 Raw material

7.3 Production

7.4 Performance

7.5 Decoration, stacking and handling

7.6 Waste management

7.7 Summary of the advantages of fibre drums

7.8 Specifications and standards

8 Multiwall paper sacks

8.1 Introduction

8.2 Sack designs

8.3 Sack materials

8.4 Testing and test methods

8.5 Weighing, filling and closing systems

8.6 Standards and manufacturing tolerances

8.7 Environmental position

9 Rigid boxes

9.1 Overview

9.2 Rigid box styles (design freedom)

9.3 Markets for rigid boxes

9.4 Materials

9.5 Design principles

9.6 Material preparation

9.7 Construction

9.8 Conclusion

10 Folding cartons

10.1 Introduction

10.2 Paperboard used to make folding cartons

10.3 Carton design

10.4 Manufacture of folding cartons

10.5 Packaging operation

10.6 Distribution and storage

10.7 Point of sale, dispensing, etc.

10.8 Consumer use

10.9 Conclusion

11 Corrugated fibreboard packaging

11.1 Introduction

11.2 Functions

11.3 Board properties and test methods

11.4 Manufacturing

11.5 Corrugated fibreboard and sustainability

12 Solid board packaging

12.1 Overview

12.2 Pack design

12.3 Applications

12.4 Materials

12.5 Water and water-vapour resistance

12.6 Printing and conversion

12.7 Packaging operation

12.8 Waste management

12.9 Good manufacturing practice

13 Paperboard-based liquid packaging

13.1 Introduction

13.2 Packaging materials

13.3 Printing and converting

13.4 Carton designs

13.5 Opening, reclosure and tamper evidence

13.6 Aseptic processing

13.7 Post-packaging sterilisation

13.8 Transit packaging

13.9 Applications for paperboard-based liquid packaging

13.10 Environmental issues

13.11 Systems approach

14 Moulded pulp packaging

14.1 Introduction

14.2 Applications

14.3 Raw materials

14.4 Production

14.5 Product drying

14.6 Printing/decoration

14.7 Conclusion

Appendix: Checklist for a packaging development brief

Index

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Library of Congress Cataloging-in-Publication Data

Handbook of paper and paperboard packaging technology / edited by Mark J. Kirwan. – 2nd ed.p. cm.Earlier edition has title: Paper and paperboard packaging technology.Includes bibliographical references and index.

ISBN 978-0-470-67066-8 (hardback : alk. paper) – ISBN 978-1-118-47091-6 (epdf/ebook) –ISBN 978-1-118-47089-3 (emobi) – ISBN 978-1-118-47092-3 (epub) – ISBN 978-1-118-47093-0 (obook)1. Paper containers. 2. Paperboard. 3. Packaging. I. Kirwan, Mark J.TS198.3.P3P37 2013658.7′85–dc23

2012024778

A catalogue record for this book is available from the British Library.

Wiley also publishes its books in a variety of electronic formats. Some content that appears in print may not be available in electronic books.

Front cover illustration courtesy of Smurfit Kappa Group plc.Cover design by Meaden Creative

Contributors

Smith Anderson GroupAnderson Group LtdFife, UKWelton Bibby & Baron LtdRadstock, Somerset, UKCullen Packaging LtdGlasgow, UKDaven ChamberlainEditorPaper TechnologyBury, Lancashire, UKArnoud DekkerInnoTools ManagerSmurfit Kappa Development CentreHoogeveen, The NetherlandsMichael FairleyLabels & Labelling ConsultancyHertfordshire, UKFibrestar Drums LtdCheshire, UKJonathan FowleInnovati Partners, Shepton Mallet,Somerset, UKCatherine Romaine HendersonIntegrated Communication ConsultantsGreer, SC, USAMichael JukesLondon Fancy Box CompanyKent, UKMark J. KirwanPaper and Paperboard SpecialistFellow of the Packaging SocietyLondon, UKMondi Industrial BagsVienna, Austria

Preface

This book discusses all the main types of packaging based on paper and paperboard. It ­considers the raw materials and manufacture of paper and paperboard, and the basic properties and features on which packaging made from these materials depends for its appearance and performance. The manufacture of 12 of the main types of paper- and paperboard-based packaging is described, together with their end-use applications and the packaging machinery involved. The importance of pack design is stressed, including how these materials offer packaging designers opportunities for imaginative and innovative design solutions.

Authors have been drawn from major manufacturers of paper- and paperboard-based packaging in the UK, the Netherlands, Austria and the USA, and companies over a much wider area have helped with information and illustrations. The editor has wide experience in industry having spent his career in technical roles in the manufacture, printing, conversion and use of paper, paperboard and packaging.

Packaging represents the largest usage of paper and paperboard and therefore both influences and is influenced by the worldwide paper industry. Paper is based mainly on cellulose fibres derived from wood, which in turn is obtained from forestry. The paper industry is a major user of energy and other resources. The industry is therefore in the forefront of current environmental debates. This book discusses these issues and indicates how the industry stands in relation to the current requirement to be environmentally sound and the need to be sustainable in the long term. Other related issues discussed are packaging reduction, life-cycle analysis and assessment, and the options for waste management.

The book is directed at those joining companies which manufacture packaging grades of paper and paperboard, companies involved in the design, printing and production of packaging and companies which manufacture inks, coatings, adhesives and packaging machinery. It will be essential reading for students of packaging technology in the design and use of paper- and paperboard-based packaging as well as those working in the associated media.

The ‘packaging chain’ mainly comprises:

Those responsible for sourcing and manufacturing packaging raw materials.

Printers and manufacturers of packaging, including manufacturers of inks, adhesives, coatings of all kinds and the equipment required for printing and conversion.

Packers of goods, for example within the food industry, including manufacturers of packaging machinery and those involved in distribution.

The retail sector, supermarkets, high street shops, etc., together with the service sector, hospitals, catering, education, etc.

The packaging chain creates a large number of supplier/customer interfaces, both between and within companies, which require knowledge and understanding. The papermaker needs to understand the requirements of printing, conversion and use. Equally, those involved in printing conversion and use need to understand the technology and logistics of papermaking together with the packaging needs of their customers and society. Whatever your position within the packaging chain, it is important to be knowledgeable about the technologies both upstream and downstream from your position.

Packaging technologists play a pivotal role in defining packaging needs and cooperating with other specialists to meet those needs in cost-effective and environmentally sound ways. They work with suppliers to keep abreast of innovations in the manufacture of materials and innovations in printing, conversion and use. They need to be aware of trends in distribution, retailing, point-of-sale/dispensing, consumer use, disposal options and all the societal and environmental issues relevant to packaging in general.

Acknowledgements

My thanks go to the contributing authors and their companies. It is not easy these days to find time for such additional work, and their contributions are much appreciated.

The text has been greatly enhanced by the diagrams kindly provided by a large number of organisations and by the advice and information that I have received from many individuals in packaging companies and organisations involved in the paper, paperboard, packaging and allied industries.

In particular, I would like to acknowledge the help that I have received from the following:

The Confederation of European Paper Industries (CEPI), Pira International (now Smithers Pira), The Packaging Society (IOM3, Institute of Materials, Minerals & Mining), Pro Carton, British Carton Association (BPIF Cartons), Swedish Forest Industries Federation, PITA, Confederation of Paper Industries, Sonoco, Fibrestar Drums, London Fancy Box, INCPEN, Iggesund Paperboard, M-Real (now Metsä Board Corporation), Stora Enso, Bobst SA, AMCOR Flexibles, Billerud Beetham (manufacturer of medical packaging paper, formerly Henry Cooke), Bill Inman (former Technical Manager at Henry Cooke), Alexir Packaging (folding cartons), Smurfit Kappa Packaging (for corrugated fibreboard and solid board), Smurfit Kappa Lokfast, Tetra Pak, Elopak, SIG Combibloc, Rapak, Lamican, HayssenSandiacre Europe Ltd (for Rose Forgrove), Marden Edwards, Robert Bosch GmbH, Rovema Packaging Machines, IMA (tea packaging machinery), Easypack Ltd, DieInfo, Bernal, Atlas, Michael Pfaff (re. rotary cutting and creasing), Diana Twede (School of Packaging, Michigan State University), Neil Robson (re. packaging issues in relation to the developing world), Mondi Industrial Bags, Cullen Packaging, National Starch and Chemical (adhesives), Sun Chemical (inks), Smith Anderson Group, Welton, Bibby & Baron, Interflex Group (wax/paper flexible packaging) and John Wiley & Sons.

This book would not have been attempted without the experience gained in my packaging career, for which I thank former colleagues at Reed Medway Sacks, Bowater Packaging (carton, paper bag and flexible packaging manufacture), Cadbury Schweppes (foods ­packaging), Glaxo (ethical and proprietary pharmaceuticals packaging), Thames Group (paperboard manufacture) and, in particular, Iggesund Paperboard, who encouraged me to become involved in technical writing.

In helping me to complete this second edition, I acknowledge the consistent help I have received from Richard Coles (Open University and Greenwich University), who involved me in lecturing on packaging technology at B.Sc. and Institute of Packaging Diploma level at West Herts College, Watford, UK, and Daven Chamberlain, Editor of Paper Technology, whom I have also known for many years and who has a wide technical background in the paper industry.

I am indebted to Professor Frank Paine, who stimulated my interest in producing this book in the first place, for his cheerful support and encouragement over many years. I first met Frank as a colleague in Bowater in the 1960s. He has 60 years of international experience in packaging technology research and practice and substantial experience in authorship and editing.

I would like to dedicate this book to the memory of my former colleague, Richard Slade (Findus and Cadbury Schweppes), who involved me in packaging development from the 1960s onwards, and to that of Dennis Hine, who led, lectured and wrote about much of the investigative work on carton performance and packaging machine/packaging materials interactions at Pira International over many years.

Mark J. Kirwan

1  Paper and paperboard – raw materials, processing and properties

Daven Chamberlain1 and Mark J. Kirwan2

1Paper Technology, Bury, Lancashire, UK2Paper and Paperboard Specialist, Fellow of the Packaging Society, London, UK

1.1 Introduction – quantities, pack types and uses

Paper and paperboard are manufactured worldwide. The world output for the years quoted is shown in Table 1.1. The trend has been upward for many years; indeed, worldwide production has more than doubled in just three decades. Both materials are produced in all regions of the world. The proportions produced per region in 2010 are shown in Table 1.2.

Paper and paperboard have many applications. These include newsprint, books, tissues, stationery, photography, money, stamps, general printing, etc. The remainder comprises packaging and many industrial applications, such as plasterboard base and printed ­impregnated papers for furniture. In 2010, paper and paperboard produced for packaging applications accounted for 51% of total paper and paperboard production (BIR, 2011).

A single set of figures for world production of paper and paperboard hides a very ­significant change that has taken place in the last decade. A large amount of investment has poured into Asia, resulting in the creation of many new mills with large and fast machines. Consequently, the proportion of world production originating from Asia has increased by 10% since 2003; Europe and North America have been the casualties, and both regions have experienced significant numbers of mill closures during this period.

As a result of the widespread uses of paper and paperboard, the apparent consumption of paper and paperboard per capita can be used as an economic barometer, i.e. indication, of the standard of economic life. The apparent consumption per capita in the various regions of the world in 2010 is shown in Table 1.3.

The manufacture of paper and paperboard is therefore of worldwide significance and that significance is increasing. A large proportion of paper and paperboard is used for packaging purposes. About 30% of the total output is used for corrugated and solid fibreboard, and the overall packaging usage is significant. Amongst the membership of CEPI (Confederation of European Paper Industries), 43% of all paper and paperboard output during 2011 was used in packaging, (CEPI, 2011).

Not only is paper and paperboard packaging a significant part of the total paper and paperboard market, it also provides a significant proportion of world packaging ­consumption. Up to 40% of all packaging is based on paper and paperboard, making it the largest ­packaging material used, by weight. Paper and paperboard packaging is found wherever goods are produced, distributed, marketed and used.

Table 1.1 World production of paper and paperboard

Source: BIR (2010).

Year

Total tonnage (million tonnes)

1980

171

1990

238

2000

324

2005

367

2006

382

2007

394

2008

391

2009

371

2010

394

Table 1.2 World production % of paper and paperboard by region for 2010

Source: BIR (2010).

Region

% of world production

Europe

27.1

Latin America

5.2

North America

22.5

Africa

1.1

Asia

43.1

Australasia

1.0

Table 1.3 Apparent per capita consumption of all types of paper and paperboard in 2010

Source: BIR (2010).

Location

Apparent consumption (kg)

North America

234.8

Europe

142.0

Australasia

135.0

Latin America

45.5

Asia

40.0

Africa

7.8

Many of the features of paper and paperboard used for packaging, such as raw material sourcing, principles of manufacture, environmental and waste management issues, are ­identical to those applying to all the main types of paper and paperboard. It is therefore important to view the packaging applications of paper and paperboard within the context of the worldwide paper and paperboard industry.

According to Robert Opie (2002), paper was used for wrapping reams of printing paper by a papermaker around 1550; the earliest printed paper labels were used to identify bales of cloth in the sixteenth century; printed paper labels for medicines were in use by 1700 and paper labels for bottles of wine exist from the mid-1700s. One of the earliest references to the use of paper for packaging is in a patent taken out by Charles Hildeyerd on 16 February 1665 for ‘The way and art of making blew paper used by sugar-bakers and others’ (Hills, 1988). For an extensive summary of packaging from the 1400s using paper bags, labels, wrappers and cartons, see Davis (1967).

The use of paper and paperboard packaging accelerated during the latter part of the ­nineteenth century to meet the developing needs of manufacturing industry. The ­manufacture of paper had progressed from a laborious manual operation, one sheet at a time, to ­continuous high-speed production with wood pulp replacing rags as the main raw material. There were also developments in the techniques for printing and converting these materials into ­packaging containers and components and in mechanising the packaging operation.

Today, examples of the use of paper and paperboard packaging are found in many places, such as supermarkets, traditional street markets, shops and departmental stores, as well as for mail order, fast food, dispensing machines, pharmacies, and in hospital, catering, ­military, educational, sport and leisure situations. For example, uses can be found for the packaging of: