Packaging Technology WILEY-BLACKWELL. Handbook of Paper and Paperboard. Paper and Paperboard Specialist, Fellow of the Packaging Society, London, UK

Transcription

1 Handbook of Paper and Paperboard Packaging Technology Second Edition Edited by Mark J. Kirwan Paper and Paperboard Specialist, Fellow of the Packaging Society, London, UK WILEY-BLACKWELL A John Wiley & Sons, Ltd., Publication

2 Content's Contributors Preface Acknowledgements xv xvii xix 1 Paper and - paperboard raw materials, processing and properties 1 Daven Chamberlain and Mark J. Kirwan 1.1 Introduction - quantities, pack types and uses Choice of raw materials and manufacture of paper and paperboard Introduction to raw materials and processing Sources of fibre Fibre separation from wood (pulping) Whitening (bleaching) Recovered fibre Other raw materials Processing of fibre at the paper mill 12 machine Manufacture on the paper or paperboard Finishing Packaging papers and paperboards Introduction Tissues Greaseproof Glassine Vegetable parchment Label paper Bag papers Sackkraft Impregnated papers Laminating papers Solid bleached board (SBB) Solid unbleached board (SUB) Folding boxboard (FBB) White-lined chipboard (WLC) Packaging requirements Technical requirements of paper and paperboard for packaging Requirements of appearance and performance Appearance properties Performance properties Specifications and quality standards Conversion factors for substance (basis weight) and thickness measurements 48 References

3 vi Contents 2 Environmental and resource management issues 51 Daven Chamberlain and Mark J. Kirwan 2.1 Introduction Sustainable development Forestry Environmental impact of manufacture and use of paper and paperboard Issues giving rise to environmental concern Energy Water Chemicals Transport Manufacturing emissions to air, water and solid waste Used packaging in the environment Introduction Waste minimisation Waste management options Life cycle assessment Carbon footprint Carbon sequestration in forests Carbon stored in forest products Greenhouse gas emissions from forest product manufacturing facilities Greenhouse gas emissions associated with producing fibre Greenhouse gas emissions associated with producing other raw materials/fuels Greenhouse gas emissions associated with purchased electricity, steam and heat, and hot and cold water Transport-related greenhouse gas emissions Emissions associated with product use Emissions associated with product end of life Avoided emissions and offsets Conclusion 84 References 86 3 Paper-based flexible packaging 91 Jonathan Fowle and Mark J. Kirwan 3.1 Introduction Packaging needs which are met by paper-based flexible packaging Printing Provision of a sealing system Provision of barrier properties Manufacture of paper-based flexible packaging Printing and varnishing Coating Lamination 105

4 Contents vii 3.4 Medical packaging Introduction to paper-based medical flexible packaging Sealing systems Typical paper-based medical packaging structures Packaging machinery used with paper-based flexible packaging Paper-based cap liners (wads) and diaphragms Pulpboard disc Induction-sealed disc Tea and coffee packaging Sealing tapes Paper cushioning 121 References 123 Websites Paper labels 125 Michael Fairley 4.1 Introduction Types of labels Glue-applied paper labels Pressure-sensitive labels In-mould labels Plastic shrink-sleeve labels Stretch-sleeve labels Wrap-around film labels Other labelling techniques Label adhesives Adhesive types Label adhesive performance Factors in the selection of labels Nature and function of labels Primary labels Secondary labels Logistics labels Special application or purpose labels Smart, smart-active and smart-intelligent labels Functional labels Recent developments Label printing and production Letterpress printing Flexography Lithography Gravure Screen process Hot-foil blocking/stamping process Variable information printing (VIP), electronically originated Digital printing 155

5 viii Contents 4.7 Print finishing techniques Lacquering Bronzing Embossing Label finishing Introduction Straight cutting Die-cutting Handling and storage Label application, labelling and overprinting Introduction Glue-applied label applicators Self-adhesive label applicators Shrink-sleeve label applicators Stretch-sleeve label applicators In-mould label applicators Modular label applicators Label legislation, regulations and standards Acts of Parliament EC regulations and directives Standards Specifications, quality control and testing Introduction Testing methods for self-adhesive labels Testing methods for wet-glue labels Waste and environmental issues 167 Websites Paper bags 169 Smith Anderson Group Ltd, Fife, UK, and Welton Bibby & Baron Ltd, Radstock, Somerset, UK 5.1 Introduction Paper bags and the environment Types of paper bags and their uses Types of paper bag Flat and satchel Strip window bags Self-opening satchel bags (SOS bags) SOS carrier bags with or without handles Types of paper used Kraft paper - the basic grades Grease-resistant and greaseproof papers Vacuum dust bag papers Paper for medical use and sterilisation bags Wet-strength kraft Recycled kraft Coated papers 176

6 Contents ix Laminations Speciality papers Weights of paper Principles of manufacture Glue-seal bags Heat-seal bags Printing on bag-making machines Additional processes on bag-making machines Additional operations after bag making Performance testing Paper Paper bags Printing methods and inks Printing methods Inks Conclusion Development of the paper bag industry The future 181 Reference 182 Websites Composite cans 183 Catherine Romaine Henderson 6.1 Introduction Composite can (container) Definition Manufacturing methods Historical background Early applications Applications today by market segmentation Designs available Shape Size Consumer preferences Clubstore/institutional Other features Opening/closing systems Materials and methods of construction The liner The paperboard body Labels Nitrogen flushing Printing and labelling options Introduction Flexographic Rotogravure Lithography (litho/offset) printing Labelling options 199

7 x Contents 6.9 Environment and waste management issues Introduction Local recycling considerations Future trends in design and application Introduction Increase barrier performance of paper-bottom canisters Totally repulpable can Non-paper-backed liner Film label Killer paper Glossary of composite can-related terms 201 References 203 Websites Fibre drums 205 Fibrestar Drums Ltd., Cheshire, UK 7.1 Introduction Raw material Production Sidewall Drum base Lid Performance Decoration, stacking and handling Waste management Summary of the advantages of fibre drums Specifications and standards 216 References 216 Websites Multiwall paper sacks 217 Mondi Industrial Bags, Vienna, Austria 8.1 Introduction Sack designs Types of sacks Valve design Sewn closures Sack materials Sack body material Ancillary materials Testing and test methods Sack materials Sack testing Weighing, filling and closing systems Open mouth sacks Valve sacks 241

8 Contenfs xi Sack identification Sack flattening and shaping Baling systems Standards and manufacturing tolerances Standards Manufacturing tolerances Environmental position 250 References 251 Useful contacts 251 Websites Rigid boxes 253 Michael Jukes 9.1 Overview Rigid box styles (design freedom) Markets for rigid boxes Materials Board and paper Adhesives Print Design principles Material preparation Construction Four-drawer box Conclusion 263 References 263 Websites Folding cartons 265 Mark J. Kirwan 10.1 Introduction Paperboard used to make folding cartons Carton design Surface design Structural design Manufacture of folding cartons Printing Cutting and creasing Creasing and folding Embossing Hot-foil stamping Gluing Specialist conversion operations Packaging operation Speed and efficiency Side seam-glued cartons Erection of flat carton blanks 298

9 xii Contents Carton storage Runnability and packaging line efficiency Distribution and storage Point of sale, dispensing, etc Consumer use Conclusion 311 References 311 Suggested further reading 312 Websites Corrugated fibreboard packaging 313 Arnoud Dekker 11.1 Introduction Overview Structure of corrugated fibreboard Types of corrugated fibreboard packaging History of corrugated fibreboard Functions Overview functions Corrugated fibreboard packaging production Packing lines Palletisation and logistic chain Communication Retail-ready Product safety Recycling and sustainability Board properties and test methods Overview of board properties and test methods Box tests Pallet tests Predictions Manufacturing Overview Paper production Corrugated board production Corrugated fibreboard converting Corrugated fibreboard printing Customer packing lines Good manufacturing practice Corrugated fibreboard and sustainability Sustainable sourcing of raw materials Sustainable production Sustainable packaging design Sustainable supply chain 338 References 338 Websites 338 Suggested further reading 339

10 12 Solid board packaging Mark J. Kirwan 12.1 Overview 12.2 Pack design 12.3 Applications Horticultural produce Meat and poultry Fish Beer (glass bottles and cans) Dairy products Footwear Laundry Engineering Export packaging Luxury packaging Slip sheets Partitions (divisions, fitments and pads) Recycling boxes Bag-in-box liquid containers Shelf-ready packaging 12.4 Materials 12.5 Water and water-vapour resistance 12.6 Printing and conversion Printing Cutting and creasing 12.7 Packaging operation 12.8 Waste management 12.9 Good manufacturing practice Reference Websites 13 Paperboard-based liquid packaging Mark J. Kirwan 13.1 Introduction 13.2 Packaging materials Paperboard Barriers and heat-sealing layers 13.3 Printing and converting Reel-to-reel converting for reel-fed form, fill, seal packaging Reel-to-sheet converting for supplying printed carton blanks for packing Sheet-fed for bag-in-box 13.4 Carton designs Gable top Pyramid shape Brick shape

11 xiv Contents Pouch Wedge Multifaceted design Bottle shapes Round cross section Bottom profile for gable top carton Bag-in-box Opening, reclosure and tamper evidence Aseptic processing Post-packaging sterilisation Transit packaging Applications for paperboard-based liquid packaging Environmental issues Resource reduction Life-cycle assessment Recovery and recycling Systems approach 382 References 382 Suggested further reading 383 Websites Moulded pulp packaging 385 Cullen Packaging Ltd, Glasgow, UK 14.1 Introduction Applications Raw materials Production Product drying Printing/decoration Conclusion 392 Website 392 Appendix: Checklist for a packaging development brief 393 Reference 398 Further reading 398 Index 399