Chapter 1

Introduction to Food
Packaging

Food Packaging Technology

CFB 30203

OBJECTIVES

To introduce the students the history of

packaging development, definitions and
the general function of packaging.

CHAPTER OUTLINES
1.1
1.2
1.3
1.4
1.5
1.6

HISTORICAL
DEFINITIONS
FUNCTIONS OF PACKAGING
PACKAGE ENVIRONMENTS
DESIGN SUCCESSFUL PACAKGING
PACKAGING MATERIALS SELECTIONS AND
MACHINERY CONSIDERATIONS

LEARNING OUTCOMES
At the end of the course students should be able to :

DEFINE PACKAGING
DISCUSS FUNCTIONS OF PACKAGING
EXPLAIN THE KEY FACTORS IN DESIGNING
SUCCESSFUL PACKAGING
EXPLAIN PACKAGING MATERIALS SELECTION
AND MACHINERY CONSIDERATIONS

1.1 Historical
The last 200 years have seen the pack evolve
from being a container for the product to
becoming an important element of total product
design
For example, the extension from packing tomato
ketchup in glass bottles to squeezable coextruded multi-layer plastic bottles with oxygen
barrier material for long shelf life.

CONT. 1.1 Historical

CONT. 1.1 Historical

Military requirements have helped to accelerate

or precipitate some key packaging
developments.
These include the invention of food canning in
Napoleonic France and the increased use of
paper-based containers in marketing various
products, including soft cheeses and malted
milk, due to the shortage of tinplate for steel
cans during the First World War

CONT. 1.1 Historical

CONT. 1.1 Historical

The quantum growth in demand for pre-packaged foods

and food service packaging since the Second World War
has dramatically diversified the range of materials and
packs used.
These have all been made possible by developments in
food science and technology, packaging materials and
machine technology.
An overview of some developments in packaging during
the past 200 years is given below.

CONT. 1.1 Historical

18001850s. In 1809 in France, Nicolas Appert produced the means of

thermally preserving food in hermetically sealed glass jars.

In 1810, Peter Durand designed the soldered tinplate canister and

commercialised the use of heat preserved food containers. In
England, handmade cans of patent preserved meats were produced
for the Admiralty (Davis, 1967). In 1852, Francis Wolle of
Pennsylvania, USA, developed the paper bag-making machine
(Davis, 1967).

CONT. 1.1 Historical

1870s. In 1871, Albert L. Jones in the USA patented (no. 122,023) the
use of corrugated materials for packaging. In 1874, Oliver Long
patented (no. 9,948) the use of lined corrugated materials (Maltenfort,
1988). In 1879, Robert Gair of New York produced the first machinemade folding carton (Davis, 1967).
1880s. In 1884, Quaker Oats packaged the first cereal in a folding box
(Hine, 1995).
1890s. In 1892, William Painter in Baltimore, USA, patented the
Crown cap for glass bottles (Opie, 1989). In 1899, Michael J. Owens of
Ohio conceived the idea of fully automatic bottle making. By 1903,
Owens had commercialized the industrial process for the Owens
Bottle Machine Company (Davis, 1967).

CONT. 1.1 Historical

1900s. In 1906, paraffin wax coated paper milk containers were being
sold by G.W. Maxwell in San Francisco and Los Angeles
(Robertson,2002).
1980s. Co-extruded plastics incorporating oxygen barrier plastic
materials for squeezable sauce bottles, and retort able plastic
containers for ambient foods that could be microwave heated. PETcoated dual-ovenable paperboard for ready meals. The widget for
canned draught beers was commercialized there are now many
types of widget available to form a foamy head in canned and glass
bottled beers. In 1988, Japans longest surviving brand of beer,
Sapporo, launched the contoured can for its lager beer with a ringpull that removed the entire lid to transform the pack into a handy
drinking vessel.

CONT. 1.1 Historical

1990s. Digital printing of graphics on carton sleeves and labels for

food packaging was introduced in the UK; shrink-sleeve plastic
labels for glass bottles were rapidly adopted by the drinks industry;
shaped can technology became more widely adopted in the USA and
Europe as drinks companies sought ways of better differentiating
their brands.
2000 . ?

1.2 Definitions
There are many ways of defining packaging
reflecting different emphases.
i.

A means of ensuring safe delivery to the ultimate

consumer in sound condition at optimum cost.

ii. A coordinated system of preparing goods for

transport, distribution, storage, retailing and end-use.
iii. A techno-commercial function aimed at optimizing
the costs of delivery while maximizing sales (and
hence profits).

1.3 Functions of packaging

Containment: depends on the products physical form
and nature. For example, a hygroscopic free-flowing
powder or a viscous and acidic tomato concentrate
ii. Protection: prevention of mechanical damage due to the
hazards of distribution
iii. Preservation: prevention or inhibition of chemical
changes, biochemical changes and microbiological
spoilage
iv. Information about the product: legal
requirements,
product ingredients, use etc.
v. Convenience: for the pack handlers and user(s)
throughout the packaging chain
i.

Cont. 1.3 Functions of packaging

vi. Presentation: material type, shape, size, colour,

merchandising display units etc.
vii. Economy: for example, efficiency in distribution,
production and storage
viii.Environmental responsibility: in manufacture, use,
reuse, or recycling and final disposal.
ix. Brand communication: e.g. pack persona by the use of
typography,symbols, illustrations, advertising and
colour, thereby creating visual impact
x. Promotion (Selling): free extra product, new product,
money off etc.

Cont. 1.3 Functions of packaging

Food spoilage
HUMIDITY

BIOLOGICAL

TEMPERATURE

PHYSICAL

LIGHT

PROTEIN
FLAVOUR

PROTECTION

FAT

FOOD

MOISTURE
PHYSICAL
PROPERTIES

CARBOHYDRATE
VITAMIN
COLOUR

CONVENIENCE
CONTAINMENT

MACHINE
ABILITY
COMMUNICATION

CADANGAN STRUKTUR
1.4 Package Environments
PROGRAM (Rujuk lampiran 1)

environment
society
economy

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1.4 What is Package environments

The packaging has to perform its function in three different
environments. Failure to consider all 3 environments
during package developments will results :

i.
ii.
iii.
iv.

Poorly designed packages

Increased costs
Consumer complaints
Rejection of the product by consumer

1.4.1 Climatic environment

Is the environment that can cause damage to the
product as a result of gases, water and water
vapour, light (particularly UV), dust, pressure and
the effects of heat or cold.
The appropriate application of technology will
help prevent or delay such deleterious effects
during processing, distribution and storage

1.4.2 Physical environment

Is the environment in which physical damage can be caused to the
product during warehouse storage and distribution that may involve
one or more modes of transportation (road, rail, sea or air) and a
variety of handling operations (pallet movement, case opening, order
picking etc.).
These movements subject packs to a range of mechanical hazards
such as impacts, vibrations, compression, piercing, puncturing etc.
In general, the more break-bulk stages there are, the greater is the
opportunity for manual handling and the greater is the risk of product
damage due to drops.
In the retail environment, the ideal is a through-distribution
merchandising unit for example, the roll cage for cartons of fresh
pasteurised milk.

1.4.3 Biological environment

is the environment in which the package
interacts with pests such as rodents, birds,
mites and insects and microbes.
For pests, an understanding of their survival
needs, sensory perceptions, strength,
capabilities and limitations is required.
For microbes, an understanding of microbiology
and methods of preservation is necessary

1.5 Designing successful packaging

Keys to successful packaging design

Product needs

Environmental
performance

Market needs
and wants

Packaging materials,
machinery and
production processes

KEYS

Distribution
needs and
wants
Consumer needs
and wants

1.5.1 Product needs

The product and its package should be considered together i.e. the
total product concept.

A thorough understanding of a products characteristics, the

intrinsic mechanism(s) by which it can deteriorate, its fragility in
distribution and possible interactions with packaging materials i.e.
compatibility is essential to the design and development of
appropriate packaging.

These characteristics concern the physical, chemical, biochemical

and microbiological nature of the product .
The greater the value of the product, the higher is the likely
investment in packaging to limit product damage or spoilage i.e.
there is an optimum level of packaging

1.5.2 Distribution needs and wants of

packaging
A thorough understanding of the distribution system is fundamental
for designing cost-effective packaging that provides the appropriate
degree of protection to the product and is acceptable to the user(s).

Distribution may be defined as the journey of the pack from the point
of filling to the point of end use.

In some instances, this definition may be extended to include

packaging reuse, waste recovery and disposal. The three distribution
environments are climatic, physical and biological (Robertson, 1990).

1.5.3 Packaging materials, machinery and

production processes
Changes may be due to the need for improved product quality,
productivity, logistics service, environmental performance and
profitability
May effect the consumer acceptance

involves selection of the most appropriate materials, machinery and

production processes for safe, environmentally sound and cost
effective performance of the packaging system.

1.5.4 Consumer needs and wants of packaging

The overall implications of social and economic trends relating to
nutrition, diet and health can be summarised concisely as quality,
information, convenience, variety, product availability, health, safety
and the environment.
Consequently, the food processing and packaging systems
employed need to be continuously fine-tuned to meet the balance of
consumer needs in particular product areas
E.g refer text book

1.5.5 Multiple food retail market needs and

wants
Important for packaging suppliers to be fully aware of market
demand and respond quickly to changes
Packaging for fast-moving consumer goods (f.m.c.g.) has been
referred to as part of the food retail marketing mix and thus closely
affects all the other marketing variables i.e. product, price,
promotion, and place

Table 1.17
Packaging characteristics valued in multiple retail
logistics and distribution include:

Pallet type, size and security; pack

stability, handling, opening features, bar
code scan, ease of read, minimum pack
damage, hygiene etc.

Storage, inventory, transport, store

labour costs etc.

Product availability, reliability and

responsiveness, e.g. efficient consumer
response (ECR), just-in-time (JIT) delivery;
and modular packaging systems for
efficient distribution, retail shelf space
utilisation and ease of merchandising
operations

Meets the retailers guidelines for

acceptable transit packaging

Minimise overall distribution cost

Facilitates logistics service requirements

to be met

Returnable packaging systems

Waste minimisation, e.g. plastic tray

systems for fruit, vegetables, meat and
baked products

Shelf life extension

For example, perishable product

availability, reduced spoilage, expansion
of chilled product range, stock
rationalisation and reduced inventory
costs

1.5.6 Environmental performance of

packaging
For over a decade, packaging and packaging waste have been the
focus of attention from politicians as a result of pressure from the
public, media and environmental pressure groups

Table 1.18
Environmental performance of packaging
Resource efficiency in pack
manufacture

Energy, water, materials, source

reduction and product redesign

Waste minimization in
production and distribution

Energy, water, materials,

pollutants

Waste recovery

Reuse, recycle, composting,

incineration with energy
recovery; collection and sorting
systems

Waste disposal

Landfill, incineration: pollutants;

biodegradation, photodegradation

Continued 1.5.6 Environmental performance of packaging

For many years, the packaging sectors of the food industry

have made significant efforts, for both commercial and
environmental reasons, to reduce the amount of packaging
and its environmental impact through light-weighting and
packaging redesign.
Examples of light-weighting are given below:

Food cans 50% lighter than 50 years ago

Yoghurt pots 60% lighter than 30 years ago
PET bottles for carbonated drinks 33% lighter than
almost 30 years ago
Drinks cartons 16% lighter than 10 years ago

Continued 1.5.6 Environmental performance of packaging

Strategies for sustainable packaging

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Continued 1.5.6 Environmental performance of packaging

Packaging that is functional, cost effective and meets

sustainability principles or design criteria.
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Example of Packaging innovation

In the future, cooking eggs will be as easy as pulling the package. Gogol Mogol is an ambitious project from
KIAN, we know that boil eggs can be very time consuming, so how bout a new way of cooking, storing and of
course, packing eggs?
The package design enables store owners to sold these eggs by arranging them in vertical position and also
these eggs wont occupy much space in your bag. Each individual package for an egg is made from recycled
cardboard with several layers. Under the first cardboard layer is the second catalyst. Then there is
a membrane, separating catalyst from some smart material (smart material is the third layer). When you are
pulling out membrane (by stretching a tag), chemical reaction between a catalyst and a smart material begins,
and the egg begins to heat up. So, in a few minutes, when you open the cover of the egg package, you have a
boiled egg easy breakfast with Gogol Mogol.

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1.6 Packaging materials selection and

machinery
Packaging is constantly changing with the introduction of
new materials, technology and processes.

Most packaging operations in food manufacturing

businesses are automatic or semi-automatic operations.
Such operations require packaging materials that can run
effectively and efficiently on machinery.

Table 1.10
Key properties of glass

1.
2.
3.
4.
5.
6.
7.
8.

Inert with respect to foods

Transparent to light and may be coloured
Impermeable to gases and vapours
Rigid
Can be easily returned and reused
Brittle and breakable
Needs a separate closure
Widely in use for both single and multi-trip
packaging

Table 1.11
Key properties of tinplate and aluminium

1. Rigid material with a high density for steel and a

low density for aluminium
2. Good tensile strength
3. An excellent barrier to light, liquids and foods
4. Needs closures, seams and crimps to form packs
5. Used in many packaging applications: food and
beverage cans, aerosols, tubes, trays and drums
6. Can react with product causing dissolution of the
metal

Table 1.12
Key properties of paper and paperboard

1. Low-density materials
2. Poor barriers to light without coatings or
laminations
3. Poor barriers to liquids, gases and vapours unless
they are coated, laminated or wrapped
4. Good stiffness
5. Can be grease resistant
6. Absorbent to liquids and moisture vapour
7. Can be creased, folded and glued
8. Tear easily
9. Not brittle, but not so high in tensile as metal
10. Excellent substrates for inexpensive printing

Table 1.13
Key properties of plastics

1. Wide range of barrier properties

2. Permeable to gases and vapours to varying
degrees
3. Low density materials with a wide range of
physical and optical properties
4. Usually have low stiffness
5. Tensile and tear strengths are variable
6. Can be transparent
7. Functional over a wide range of temperatures
depending on the type of plastic
8. Flexible and, in certain cases, can be creased

Continued 1.6 Packaging materials selection and machinery

Packaging needs to be of the specified

dimensions, type and format within specified
tolerances.
The properties of the material will need to take
account of the requirements of the packing and
food processing operations.
They will, therefore, need to have the required
properties such as tensile strength and stiffness,
appropriate for each container and type of
material.

Continued 1.6 Packaging materials selection and machinery

Packaging should focus on resource-efficiency

and not just waste and recycling

minimising energy and raw material use

minimising the impact on the waste
stream
not causing environmental damage.

REFERENCES

Robertson, G.L Food Packaging Principle s and Practice, Marcel Dekker Inc.
(2004)
C. Richards, Food Packaging Technology, Blackwell Publisher. (2009)
Raija Ahvenainen , Novel food packaging techniques, (2003)
S. Rangana, Canning and Aseptic Packaging, Tata McGraw Hill,( 2000).
Soroka, W. Fundamentals of Packaging Technology. 3rd Edition. Institute of
Packaging Professionals, Naperville, IL. (2002).
Brody and Marsh, Wiley Encyclopedia of Packaging Technology, 2nd Edition,
John Wiley & Sons, Inc. New York, NY. (1997).

Thank you

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