Paper and Paperboard Packaging Final-Paperboard Packaging Applications
Unlock all answers in this set
Unlock answersquestion
Aseptic Packaging-Definition
answer
A food processing technology that functions as a system incorporating a paperboard based package -Also known as the \"drink box\", \"juice box\" or \"brick-pack\"
question
Development of Aseptic Packaging
answer
Aseptic packaging was developed in the 1940s in Europe by Dr. Ruben Rausing -Aseptic packaging was approved for use in the US in 1981
question
Aseptic Packaging System
answer
achieves room-temp, shelf-stability fills a sterilized package with sterile food in a sterile environment
question
How is food processed in the aseptic packaging system?
answer
Foods are processed using Ultra High Temps (UHT)--Rapidly heats food (3 to 15 seconds at 195 to 285 degrees F or 90.5 to 140.5 degrees C) AND rapidly cools food -Process places least amount of thermal stress on product
question
What is used in the aseptic package structure?
answer
1. polyethylene 2. paperboard 3. polyethylene 4. aluminum foil 5. polyethylene 6. polyethylene
question
Aseptic Packaging System
answer
-aseptic packages are available in a variety of sizes -aseptic packages are made from a continuous roll of material on a specifically designed machine
question
Aseptically packaged products, include:
answer
US--milk, tofu, juices, soy beverages, tomatoes, wines, soups/broths, liquid eggs, teas, whipping cream EUROPE--milk, yogurt drinks, fruit based desserts, savory sauces
question
What are the consumer benefits of aseptic packaging?
answer
-shelf stable product that can be kept for long periods of time without refrigeration -perceived to offer and maintain product safety -process maintains nutritional value (UNLIKE RETORT) -brick shape is easy to handle -paperboard construction is shatter proof -offers tamper evident features
question
What are the foodservice benefits of aseptic packaging?
answer
-shelf stable product that can be kept for long periods of time without refrigeration -light weight carton -space efficient block shape for storage -easy open, easy pour -recloseable -eliminates can opener and sharp metal edges -easily crushed to minimize space in garbage containers
question
Three functions of beverage carriers:
answer
unitize multiple single units provide product protection in transit provide a marketing billboard to attract customers **can be used for other humid or wet applications **both graphic packaging international and MedWestvaco offer beverage carrier wrapping equipment **beverage carriers used with metal cans, glass and plastic bottles and composite cans as well as plastic tubs and bowls
question
Who supplies beverage carriers in the US?
answer
In the US, there are two companies supplying beverage carriers, both produce Coated Unbleached Kraft (CUK): -Graphic Packaging International (supplies solid unbleached sulfate-SUS) -MeadWestvaco (supplies Coated Natural Kraft-CNK) **Although often used interchangeably with CUK, SUS and CNK are registered trade names
question
CUK
answer
Coated Unbleached Kraft a special wet-strength designed to perform under humid, damp or iced conditions *primary markets are beer and soft drinks
question
beverage carrier: basket carrier
answer
holds 4, 6, or 8 individual bottles separated by paperboard carriers arrive flat; can be shipped to: -bottler who fills bottles and places in carrier -bottle maker who ships bottles in carrier. Bottler takes bottles out of carrier, fills and reuses carrier
question
beverage carrier: wraparound carrier
answer
most widely used paperboard beverage carrier advantages: -low cost -billboard graphics -efficient packaging operation
question
beverage carrier: fully enclosed carrier
answer
packs up to 24 bottles or 30 cans efficient for multiunit sales billboard graphics for brand recognition
question
beverage carrier packaging equipment: basket style equipment
answer
4 or 6 bottle configurations 180 baskets per minute
question
beverage carrier packaging equipment: wrap around machine
answer
4 or 6 bottle configurations 335 packs per minute
question
beverage carrier packaging equipment: fully enclosed machine
answer
4 to 24 bottle configurations 4 to 30 can configurations 200 packs per minute
question
types of beverage carrier packaging equipment
answer
basket style equipment wrap around machine fully enclosed machine
question
Carded Packaging is a general term for:
answer
1. Blister packaging (plastic sheet is molded) 2. Skin packaging (plastic is formed around package) 3. Clamshell 4. Headers
question
What are the considerations for blister packaging?
answer
weight of package (if too heavy, could bust out) shape and size of product sharp or pointed edges of product impact resistance required compatibility with product heat seal capability facts affecting assembly
question
What are the components of blister packaging?
answer
thermoformed blister paperboard card printing inks heat-seal coating
question
Blister packaging: Blister
answer
thermoformed blister made from: PVC Polystyrene PET food grade Static-dissipative plastics other resins as appropriate *thermoforming equipment thermoforms blister, die cuts and strips
question
Blister packaging: Paperboard
answer
Provides structural support for blister packs Typically uses 14 to 30 point board Usually is clay coated for: PRINTING HEAT SEALING
question
Blister packaging: Printing Inks
answer
Printing inks provide graphic appeal to catch the consumer's eye Factors to consider, include ability to: bond with paperboard and heat-seal coating withstand heat-seal temp resist abrasion resist fading when exposed to retail lighting resist cracking when card is bent compatible with packaged product
question
Blister packaging: Heat Seal Coatings
answer
Heat-seal coating is critical to package integrity Coating must function with plastic used in blister Applied by: -roll coater -Last station on printing press -spray
question
Skin Packaging
answer
uses heated film draped over product and sealed to paperboard card through use of vacuum
question
What are the components of skin packaging?
answer
Plastic film- LDPE - least expensive PVC - clear Surlyn - clear and thin Paperboard card requirements- High porosity for vacuum Uncoated May need perforations Printing inks and Heat-seal coating requirements- Must be resistant to temps of film Must be compatible with all components and product
question
Assembly of skin packaging
answer
product positioned on printed paperboard card film is held in frame and heated frame and film move down over product film is draped over product and lays on paperboard card vacuum is applied to pull film around product and bond to heat-seal coated paperboard
question
Clamshell Packaging
answer
Clamshells are hinged box type containers thermoformed from clear plastics May have snap closure for re-closing and reuse
question
What are the components of Clamshell Packaging?
answer
PLASTIC SHEET: selection criteria -weight of product -shape and size of product -sharp or pointed product edges -impact resistance required -compatibility with product -compatibility with heat-seal -factors affecting assembly PAPERBOARD CARD AND INKS -card is not attached to clamshell -no need for heat-seal coating -inks must be compatible with product
question
Assembly of Clamshell Packaging
answer
Product is placed in open clamshell Printed paperboard card is inserted Clamshell closed and sealed -snap closure -heat seal -impulse seal -sonic seal
question
Header Cards
answer
Header cards are used to display product on hanging display Can be with a bag or holding the product itself
question
Header Cards: Paperboard
answer
Selection of paperboard grade depends on: -weight and size of product -quality of printing expected Headers use -SBS -Recycled
question
Assembly of Header Cards
answer
Header card closures with bags are staples or hot-melt glue Header cards attached to products use staples or wire ties
question
Definition of Composite Can
answer
A composite can is a convolute wound, spiral wound, linear draw or single wrap rigid body involving several layers of materials, including paper, foil and plastics in various combinations, with one of both end closures permanently affixed
question
Utilizing combinations of materials, composite can ensures:
answer
optimum presentation mechanical strength hermetic seal
question
Composite cans offer packaging solutions that are:
answer
flexible Cost effective for mass consumption and luxury products Applicable for industrial products Vendable products
question
History of Composite Cans
answer
1950s-refrigerated dough 1960s-citrus concentrate in 6 and 12 oz composite cans 1960s-1980-quarts of motor oil 1970-Proctor and Gamble introduces Pringles
question
Examples of products packed in composite cans
answer
concentrate juices powdered beverages refrigerated dough snacks non-food adhesive and sealants pet products
question
Composite can designs use various combinations:
answer
Shape Size Opening/closing systems Barrier materials Paperboard Labels Packing methods
question
Gable Top Cartons
answer
Gable top is one of the oldest closures of paperboard (original patents issues in 1915) Today, gable top cartons are extrusion coated with a wide range of polymers to meet a variety of product protection needs *Aluminum foil, metalized film or holograms can be laminated to gable top cartons for barrier and decoration
question
What are the advantages of Gable Top Cartons?
answer
easy open/easy close design different pour spouts available product protection easy to transport-maximizes cube provides billboard to show case product liquid and flowable dry product applications consumer friendly single component package
question
Gable Top Cartons
answer
-a variety of fitments for easy opening, pouring and reclosing can be attached to gable top cartons -windows can be added to show product for retail display or level of contents for consumer convenience -gable top cartons can be made in a variety of sizes for brand family identification
question
Ovenable Paperboard Types
answer
Two types of oven able paperboard: -tapered carton with attached lid -pressed and formed containers *both can withstand cooking temps of 400 F for up to 60 minutes *both will perform through 8 freeze/thaw cycles during distribution and in the home
question
Benefits of Ovenable Paperboard
answer
Ability to print single color to process graphics Transmission of microwave energy Susceptors added for browning Used in schools and prisons--no lethal weapons Compatible with a variety of products Rigid enough for family style entrees Can be made into compartment trays Custom shapes with up to 2.25 inch depth **Many standard and custom shapes available
question
What are susceptors?
answer
metalized area that can create browning or speed up cooking process
question
Pressed Paperboard Production
answer
paperboard manufactured to FDA regulations Kraft process uses virgin hardwood and softwood bleached fibers All ingredients comply with applicable CFR Biological tests conducted continually Extrusion coated with PET
question
Why is virgin hardwood used?
answer
Need to be virgin hardwood when coming in direct contact with food
question
Pressed Paperboard Conversion
answer
-PET coated paperboard shipped to converters -Paperboard rewetted up to 11% moisture (DIPS and SPRAYS) -Wetted paperboard rewound and allowed to equilibrate for 2 to 3 days -Paperboard is printed with water based flex inks -Printed Paperboard cut into blanks -Pressed in heated male/female dies--similar to thermoforming
question
Pressed Paperboard Lidding
answer
Pressed paperboard trays are compatible with several lidding systems -Clear or printed reelable Mylar film from DuPont -Paperboard lid with heat activated peelable adhesive -Clear plastic (OPS) domes for product display
question
What are the food processors' convenience for pressed paperboard?
answer
-ingredients placed directly into printed pressed paperboard trays -Food in trays goes from food prep to cooking ovens to retail to consumer, eliminating: --labor for depanning and repacking --cost of washing basking or cooking pans --non-stick coating eliminating labor and cost of applying release agents -Susceptors permit baked products to brown evenly
question
What are the consumer conveniences for pressed paperboard?
answer
-no cooking pots or pans to use or clean -printed paperboard is aesthetically pleasing when served on the table -printed pattern can be compatible with dish ware -leftovers, can be returned to refrigerator and reheated -disposal in trash is easy and convenient, no washing
question
Rigid Paperbox
answer
Also called \"set-up box\" -Arrives at product packer's location set-up ready to fill -Manufacturing process begins with: grade selection, cutting, scoring
question
Rigid Paperbox: Outer wraps can include-
answer
printed paper printed aluminum foil printed and embossed paper or foil padded wraps fabrics leather one's imagination
question
The wrapping process of Rigid Paperbox
answer
-hot melt glue applied to wrap -stayed box placed on wrap -plunger pushes box onto wrap forcing wrapper around box -plunger mechanism also folds edges of wrap to inside of box
question
What are the options of rigid paperboy?
answer
compartments domes hinges interior partitions oval shapes padded cover slanted side shoulder side telescope box three-piece
question
Grades of Rigid Paperbox
answer
Plain chipboard Vat-lined chipboard Book-lined chipboard Solid news Glassine Lined Foil Lined Folding boxboard ***first four grades are major grades used
question
Applications of Rigid Paperbox
answer
Cosmetics computer software confections games jewelry Leather goods Photographic paper Shoes Stationary
question
Advantages of Rigid Paperbox
answer
Product protection Image or icon building Product display Customer reuse and repeat advertising Test market quantities can be made quickly
