Packaging & Labelling Brian Russell Graham Penkett

Exam expectations Paper/card are the compulsory materials so always expect questions in exam to relate to this topic

Packaging - The Good Old Days Brian Russell Nicola Deacon

Early Packaging There has always been some kind of packaging. When Stone Age man killed a wild animal and carried it home to share with his family, he probably wrapped the meat in a skin or leaves to protect it from insects, the sun or the rain.

Spices used to disguise the horrid taste/smell Food often went ‘off’ because it could not be kept for long Early Packaging

1500 BC Glass-blowing developed 1795 Napoleon offered a prize for anyone who could preserve food – won by a chef who used glass bottles/corks tin ‘canisters’ of food were carried into battle (Crimean War) Food in ‘cans’ becomes popular Early Packaging

Were they really ‘Good’ Old Days? Food stored in sacks/drums

In some parts of the World… Food is still displayed like this

Discuss the way the Food is – Protected and preserved Advertised Displayed Weighed and Measured Priced What Foods are available? Shopping in Great-Grandmother’s day (80 years ago)

Massive changes have happened during the past 50 years – since scenes like this:- Food poisoning? Insects/Flies? Hygiene?

Wasted Food In U.K. - very little Food is wasted (2-3%) In developing countries about 30% - 50% is wasted. (e.g. goes rotten; is damaged) Can you think WHY?

Interesting Facts In the U.K. alone over £10 billion was spent by manufacturers on Packaging. Every £1 spent on packaging protects at least £9 worth of food and goods. A Coca-cola canning line is able to fill 2,000 cans a minute.

Interesting Facts Packaging of emergency dressings and fluids (such as saline and plasma) saves lives.

Interesting Facts Packaging stops goods going to waste but ends up as waste itself. About 8 million tonnes each year – the same as the amount of old carpets thrown away each year. This figure has been constant for the past 20 years – because thinner materials and new technologies.

Reducing Packaging

Interesting Facts Over 60% of all packaging is for Food Pizzas made in Britain are specially packaged for sale in Italy and Spain.

Some products break easily, go rotten, dry out, lose flavour, go soggy etc.

Write a list of the different kinds of special protection these products need

Look at the pictures again – how do you know what is in the pack? How is this done?

Why package? Protect Inform Contain Transport Preserve Display I PICT PD

Protect Inform Contain Transport Preserve Display

Protect Inform Contain Transport Preserve Display

Protect Inform Contain Transport Preserve Display

Protect Inform Contain Transport Preserve Display

Protect Inform Contain Transport Preserve Display

Protect Inform Contain Transport Preserve Display

How would you solve the following 4 problems?

Purpose of packaging is to: Protect Inform Contain Transport Preserve Display I PICT PD

Food packaging Typical themes: Materials (food grade) Composite materials Spillage Security Hygiene Insulation Legal requirements How are they made?

Card materials Who invented the first carton? 100 years ago a printer (in New York) who made paper bags produced a carton from strong paper and board. He also developed the creasing/cutting of the board. (Die cutting) Kellogg Corporation were the first big users.

Card nets Flat shapes which fold into 3D forms Often food related in exam Glue tabs Locking tabs Position of images Position of text

Cutting card nets Die-cutting (creasing done with rounded blade) I Cut – Die Cut

Card materials Typical card materials used: Duplex board - bleached liner therefore cheaper for general packaging Solid white board – bleached wood pulp, used for more expensive packaging Foil lined board – keep heat and moisture in Corrugated card (transit packaging) – cheap, rigid, good insulator, recyclable…

Typical order of work: Finishing – print, varnish, emboss… Wastage/separation – die-cut/crease Forming - folding Assembling – glue, inserts… Commercial manufacturing

Commercial Manufacturing Typical litho presses set up for 4 process colours, a spot colour and varnish in one continuous cycle Typical folding machine for small cartons

Commercial Manufacturing Typical rotogravure printing presses set up for 4 process colours, metallic spot colours and varnish in one continuous cycle Typical flexographic press used for printing plastic film

Printing card Typically offset lithographic or gravure process used 4 process colours – yellow, magenta, cyan, black Varnishing, foil blocking, embossing are common

Offset lithography Flat aluminium plates (specially treated) Photographically exposed then wrapped around roller Exposed parts attract water Non exposed parts allow ink to stick Print onto plain roller to reverse image Transfers to card or other materials

Gravure Printing Used for very large print runs Uses engraved plates Ink is held in recesses known as cells Paper is pressed onto plate and ink is lifted from cells

Rotogravure Presses Cylinders are placed in line with a heater between each one to dry the ink

Flexographic printing Uses a printing plate made of rubber, plastic, or some other flexible material. Ink is applied to a raised image on the plate, which transfers the image to the printing

Printing terms Process colours – yellow, magenta and cyan make full range of colours, black adds definition (and text) Spot colours – mixed to exact colour Web offset – printed onto a roll (e.g. newspapers) Plate – has the image on, wraps around a cylinder Offset cylinder (or blanket cylinder) – reverses image Impression cylinder – presses paper onto plate Varnish – adds shine (or could apply a matt finish) to print, sometimes in isolated areas Substrate – material to be printed e.g. paper

Other Types of Carded Packaging 2 Main Types Blister Packaging Skin Packaging

Blister Packaging

A ‘blister’ is formed in a piece of plastic film (usually PVC or PET). Often the blister is the shape of a specific mould – longer product runs are required to be able to justify blister packaging. ‘Stock’ blisters can be bought (various sizes) Blister is ‘heat sealed’ to the card. The card has a heat seal coating.

Blister Packaging Key Points Uses film (PVC/PET) and paperboard. Ideal for small retail items. Excellent for Point-of-Sale Display Provide good visible stock security

Skin Packaging

The product is placed on a type of paper/board which allows air to pass through it. The board also has a heat seal coating. Plastic film is heated then stretched over the product and air is sucked out. (like a vacuum former) The plastic film sticks to the heat seal coating on the card.

Carded Packaging List – in your pack of worksheets Products that you are likely to find in a blister or skin packaging.

Metals 2 Main Metals Steel Aluminium 15 thousand million cans are bought every year Most homes use about 14 cans every week.

Metals What are the advantages of using cans? Canned food keeps well. Convenient because food has already been cooked. No need to add preservatives – cooking & canning preserves No food is wasted. Drinks cans are easy to open/easy to chill

Glass What are the advantages of using Glass? Can see contents clearly. Opened and sealed easily. Does not affect taste of food. Glass is impermeable. Can be re-used/re-cycled. Raw materials to make glass are cheap

Other packaging materials Common materials: Expanded polystyrene – insulated cups and trays, protection in transit High impact polystyrene – vacuum formed trays Low density polythene – carrier bags, film, bottles PET – pop bottles, blister packs Aluminium – foil containers, drinks cans Tin-plated mild steel - cans

Design issues Sometimes asked to design in exam: Graphic images – logos, ideograms, symbols… Text – to create impact, position on nets Nets – accuracy, scale, tabs… Input images onto computer – scan, digital camera, drawing package, clipart… Explain use of ICT Communication skills – colour, tone, line etc

Packaging information Key information found on packaging includes: Product name Description/contents Manufacturer’s details Technical information Safety information Consumer Protection Storage/maintenance information Environmental information Barcode Design protection

Food Labelling If manufacturers make claims like this the actual amounts must be printed in the ingredients list. Ingredients are listed in order of weight, including additives so they can be compared with similar products or so we can avoid ingredients we do not wish to eat. Additives must be listed and explain their job. The manufacturer can use the name of the additive or the "E" number if it has one agreed by the European Union. Instructions for safe storage Date mark must appear on the product Nutritional information now appears on many food products Name and address of manufacturer, packer or retailer so contact can be made. The "e" means that the average quantity must be accurate but the weight of each pack might vary slightly.

Product Maintenance Care labels Servicing information

Product storage/handling Advice, warnings, instructions

Consumer Protection BSI Kite Marks Tested against specific standards shown with reference number adjacent Conformité Europeenne Meets minimum requirements from EU directive to be allowed to be put on sale

Environmental Issues Recycling symbol Specific Material Information Disposal of Waste Equipment Green dot

Design Protection Copyright Registered Design (often used with trade marks) Trade Mark Patents

You are a Toy manufacturer which makes a toy zoo, chatter telephone and a ‘take-apart’ racing car. Suggest methods of packaging for one of them. Illustrate your answer with drawings and explanations such as the kind of packaging you would recommend and any special problems or possibilities that you can think of.