Paper and Paperboard Packaging Final-Paperboard Packaging Applications

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Aseptic Packaging-Definition
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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\”
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Development of Aseptic Packaging
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Aseptic packaging was developed in the 1940s in Europe by Dr. Ruben Rausing -Aseptic packaging was approved for use in the US in 1981
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Aseptic Packaging System
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achieves room-temp, shelf-stability fills a sterilized package with sterile food in a sterile environment
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How is food processed in the aseptic packaging system?
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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
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What is used in the aseptic package structure?
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1. polyethylene 2. paperboard 3. polyethylene 4. aluminum foil 5. polyethylene 6. polyethylene
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Aseptic Packaging System
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-aseptic packages are available in a variety of sizes -aseptic packages are made from a continuous roll of material on a specifically designed machine
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Aseptically packaged products, include:
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US–milk, tofu, juices, soy beverages, tomatoes, wines, soups/broths, liquid eggs, teas, whipping cream EUROPE–milk, yogurt drinks, fruit based desserts, savory sauces
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What are the consumer benefits of aseptic packaging?
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-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
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What are the foodservice benefits of aseptic packaging?
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-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
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Three functions of beverage carriers:
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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
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Who supplies beverage carriers in the US?
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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
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CUK
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Coated Unbleached Kraft a special wet-strength designed to perform under humid, damp or iced conditions *primary markets are beer and soft drinks
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beverage carrier: basket carrier
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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
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beverage carrier: wraparound carrier
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most widely used paperboard beverage carrier advantages: -low cost -billboard graphics -efficient packaging operation
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beverage carrier: fully enclosed carrier
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packs up to 24 bottles or 30 cans efficient for multiunit sales billboard graphics for brand recognition
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beverage carrier packaging equipment: basket style equipment
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4 or 6 bottle configurations 180 baskets per minute
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beverage carrier packaging equipment: wrap around machine
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4 or 6 bottle configurations 335 packs per minute
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beverage carrier packaging equipment: fully enclosed machine
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4 to 24 bottle configurations 4 to 30 can configurations 200 packs per minute
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types of beverage carrier packaging equipment
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basket style equipment wrap around machine fully enclosed machine
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Carded Packaging is a general term for:
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1. Blister packaging (plastic sheet is molded) 2. Skin packaging (plastic is formed around package) 3. Clamshell 4. Headers
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What are the considerations for blister packaging?
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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
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What are the components of blister packaging?
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thermoformed blister paperboard card printing inks heat-seal coating
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Blister packaging: Blister
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thermoformed blister made from: PVC Polystyrene PET food grade Static-dissipative plastics other resins as appropriate *thermoforming equipment thermoforms blister, die cuts and strips
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Blister packaging: Paperboard
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Provides structural support for blister packs Typically uses 14 to 30 point board Usually is clay coated for: PRINTING HEAT SEALING
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Blister packaging: Printing Inks
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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
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Blister packaging: Heat Seal Coatings
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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
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Skin Packaging
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uses heated film draped over product and sealed to paperboard card through use of vacuum
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What are the components of skin packaging?
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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
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Assembly of skin packaging
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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
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Clamshell Packaging
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Clamshells are hinged box type containers thermoformed from clear plastics May have snap closure for re-closing and reuse
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What are the components of Clamshell Packaging?
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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
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Assembly of Clamshell Packaging
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Product is placed in open clamshell Printed paperboard card is inserted Clamshell closed and sealed -snap closure -heat seal -impulse seal -sonic seal
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Header Cards
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Header cards are used to display product on hanging display Can be with a bag or holding the product itself
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Header Cards: Paperboard
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Selection of paperboard grade depends on: -weight and size of product -quality of printing expected Headers use -SBS -Recycled
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Assembly of Header Cards
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Header card closures with bags are staples or hot-melt glue Header cards attached to products use staples or wire ties
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Definition of Composite Can
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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
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Utilizing combinations of materials, composite can ensures:
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optimum presentation mechanical strength hermetic seal
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Composite cans offer packaging solutions that are:
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flexible Cost effective for mass consumption and luxury products Applicable for industrial products Vendable products
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History of Composite Cans
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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
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Examples of products packed in composite cans
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concentrate juices powdered beverages refrigerated dough snacks non-food adhesive and sealants pet products
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Composite can designs use various combinations:
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Shape Size Opening/closing systems Barrier materials Paperboard Labels Packing methods
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Gable Top Cartons
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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
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What are the advantages of Gable Top Cartons?
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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
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Gable Top Cartons
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-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
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Ovenable Paperboard Types
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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
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Benefits of Ovenable Paperboard
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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
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What are susceptors?
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metalized area that can create browning or speed up cooking process
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Pressed Paperboard Production
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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
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Why is virgin hardwood used?
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Need to be virgin hardwood when coming in direct contact with food
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Pressed Paperboard Conversion
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-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
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Pressed Paperboard Lidding
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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
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What are the food processors’ convenience for pressed paperboard?
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-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
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What are the consumer conveniences for pressed paperboard?
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-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
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Rigid Paperbox
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Also called \”set-up box\” -Arrives at product packer’s location set-up ready to fill -Manufacturing process begins with: grade selection, cutting, scoring
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Rigid Paperbox: Outer wraps can include-
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printed paper printed aluminum foil printed and embossed paper or foil padded wraps fabrics leather one’s imagination
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The wrapping process of Rigid Paperbox
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-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
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What are the options of rigid paperboy?
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compartments domes hinges interior partitions oval shapes padded cover slanted side shoulder side telescope box three-piece
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Grades of Rigid Paperbox
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Plain chipboard Vat-lined chipboard Book-lined chipboard Solid news Glassine Lined Foil Lined Folding boxboard ***first four grades are major grades used
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Applications of Rigid Paperbox
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Cosmetics computer software confections games jewelry Leather goods Photographic paper Shoes Stationary
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Advantages of Rigid Paperbox
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Product protection Image or icon building Product display Customer reuse and repeat advertising Test market quantities can be made quickly

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