PACKAGING TECHNOLOGY

INDEX

S. No. Topic

01 Definition

02 Types Of Packaging

03 Importance of Packaging

04 Packaging History

05 Work Flow

06 Standard Operating Procedure

07 Sampling Plan (Mil.Std 105e)

08 Acceptable Quality Limit (AQL)

09 Art work Development

10 Properties of Packaging Films

11 Definitions

12 Extrusion Coating

13 Wrapper Process

14 Issue in Wrappers

15 Kraft paper

16 Properties Of Paper

17 Cartons Process and its issue

18 Box Process and its issue

19 Test of packaging materials

20 Packaging Equipment’s

21 Anatomy of Barcode

22 Packaging Symbols

23 Wrapping Machine

24 Packaging Film (Single & Laminated) Properties

Packaging:

Definition Packaging is the technology of enclosing or protecting products for distribution, storage, sell, and use. Packaging also refers to the process of designing, evaluating, and producing packages. Packaging can be described as a coordinated system of preparing goods for transport, warehousing, logistics, sale, and end use. Packaging contains, protects, preserves, transports, informs, and sells. In many countries it is fully integrated into government, business, and institutional, industrial, and personal use. Types of Packaging

Primary packaging is the material that first envelops the product and holds it. This usually is the smallest unit of distribution or use and is the package which is in direct contact with the contents.

The wrapper which is directly contact with the product.

Wrapper include in primary.

Secondary packaging is outside the primary packaging, and may be used to prevent pilferage or to group primary packages together.

Boxes etc.

Tertiary or transit packaging is used for bulk handling, warehouse storage and transport shipping. The most common form is a palletized unit load that packs tightly into containers.

Cartons, Jars etc.

TYPES

Aseptic

processing Primary

Liquid whole eggs or dairy

products

Trays Primary Portion of fish or meat

Bags Primary Potato chips, apples, rice

Boxes Secondary

Corrugated box of primary

packages: box of cereal cartons,

frozen pizzas

Cans Primary Can of tomato soup

Cartons, coated

paper Primary

Carton of eggs, milk or juice

cartons

Flexible

packaging Primary Bagged salad

Pallets Tertiary

A series of boxes on a single pallet

used to transport from the

manufacturing plant to a

distribution center

Wrappers Tertiary Used to wrap the boxes on the

pallet for transport

Important Functions of Packaging

Physical protection – The objects enclosed in the package may require protection from, among other things, mechanical shock, vibration, electrostatic discharge, compression, temperature, etc.

Barrier protection – A barrier to oxygen, water vapor, dust, etc., is often required. Permeation is a critical factor in design. Some packages contain desiccants or oxygen absorbers to help extend shelf life. Modified atmospheres or controlled atmospheres are also maintained in some food packages. Keeping the contents clean, fresh, sterile and safe for the duration of the intended shelf life is a primary function. A barrier is also implemented in cases where segregation of two materials prior to end use is required, as in the case of special paints, glues, medical fluids, etc. At the consumer end, the packaging barrier is broken or measured amounts of material are removed for mixing and subsequent end use.

Containment or agglomeration – Small objects are typically grouped together in one package for reasons of storage and selling efficiency. For example, a single box of 1000 pencils requires less physical handling than 1000 single pencils. Liquids, powders, and granular materials need containment.

Information transmission – Packages and labels communicate how to use,

transport, recycle, or dispose of the package or product. With pharmaceuticals, food, medical, and chemical products, some types of information are required by government legislation. Some packages and labels also are used for track and trace purposes. Most items include their serial and lot numbers on the packaging, and in the case of food

products, medicine, and some chemicals the packaging often contains an expiry/best-before date, usually in a shorthand form. Packages may indicate their construction material with a symbol.

Marketing – Packaging and labels can be used by marketers to encourage potential buyers to purchase a product. Package graphic design and physical design have been important and constantly evolving phenomena for several decades. Marketing communications and graphic design are applied to the surface of the package and often to the point of sale display. Most packaging is designed to reflect the brand's message and identity.

Security – Packaging can play an important role in reducing the security risks of shipment. Packages can be made with improved tamper resistance to deter manipulation and they can also have tamper-evident features indicating that tampering has taken place. Packages can be engineered to help reduce the risks of package pilferage or the theft and resale of products: Some package constructions are more resistant to pilferage than other types, and some have pilfer-indicating seals. Counterfeit consumer goods, unauthorized sales (diversion), material substitution and tampering can all be minimized or prevented with such anti-counterfeiting technologies. Packages may include authentication seals and use security printing to help indicate that the package and contents are not counterfeit. Packages also can include anti-theft devices such as dye-packs, RFID tags, or electronic article surveillance tags that can be activated or detected by devices at exit points and require specialized tools to deactivate. Using packaging in this way is a means of retail loss prevention.

Convenience – Packages can have features that add convenience in distribution, handling, stacking, display, sale, opening, reclosing, using, dispensing, reusing, recycling, and ease of disposal

Portion control – Single serving or single dosage packaging has a precise amount of contents to control usage. Bulk commodities (such as salt) can be divided into packages that are a more suitable size for individual households. It also aids the control of inventory: selling sealed one-liter bottles of milk, rather than having people bring their own bottles to fill themselves.

PACKAGING HISTORY:

The Evolution of Packaging:

Product packaging plays several important functions which enable commerce and trade. The functions of modern day packaging go beyond containing, protecting and preserving products. It also includes functions to communicate, promote and transact products. Packaging provides several visceral cues designed to affect consumer’s perception of the product and influence their behavior. These functions are considered normal today, but it took over 150 years for product packaging to evolve into a carefully designed artifact that integrates multiple functions of commerce into a thin film wrapped around products. Growing competition and continuous technological innovations have shaped the evolution of packaging since 1860s. As we researched key technology and material innovations during this vast period, it became evident that these developments revolved closely around cultural phenomenon and consumer behaviors prevalent around given time periods. So we sectioned our analysis across 6 time periods and mapped the technological developments against cultural developments. This approach provided unique lenses to look at the history of packaging and revealed very interesting perspectives on where things stand today and how we can design better for the future of packaging.

Early Age Packaging Materials

The conclusive summary of historic development of packaging above

suggests a lot of patterns across several decades. Lets dive deep into

each of those time periods to have a better understanding of these

patterns. It is interesting to see how the innovations, while trying to

meet consumer needs, periodically shaped consumer behaviors too.

As a result of the Industrial Revolution, there were significant

innovations in improving manufacturing processes and materials.

Most materials used for storing products included wood crates,

barrels, cloth, glass — were primarily rigid and expensive. But

manufacturers of high value goods saw packaging as a reflection of

the quality of their products, and hence there was a palpable interest

in finding new and cheaper ways to make a trade more appealing.

1. Glass

In 1200 B.C. glass was pressed into molds to make cups and bowls. The techniques to blow glass continued to evolve and split molding was developed in 17th century allowing for irregular shapes. Since 19th century, glass is primarily used to package medicines, spirits, liquids,

In 1830s, tin boxes were used for selling cookies, chocolates, and tobacco products. Soon after, first soft metal tubes were produced in 1841 to be used for artist paints and they gained instant popularity.

3. Paper

In 1690, first paper mill in the U.S. was built near Philadelphia. At that time paper was hand-made out of parchment and rags, both of which were expensive and limited in supply.

In 1796, Lithography was invented Alois Senfelder in Munich. This enabled printing of black-and-white illustrations on printed labels. One-color lithographed or letterpress labels were widely used on glass bottles, metal boxes and early paperboard boxes. Color printing or chromolithography was invented in 1837 and became popular soon after manufacturers realized its potential.

First paper making cylinder machine was installed in 1817 by Thomas Gilpin in Delaware used to make paperboards and other forms of paper used in packaging. This gave birth to ‘flexible packaging’. Mechanization made paper plentiful but cost limited its use until paper could be made commercially from wooden pulp in 1850s. The invention of paper bag making machine in by Francis Wolle in 1852 further pushed use of paper in packaging.

1860s, 1870s, 1880s: The Era of Dual Use Packaging

The second wave of Industrial Revolution began during this time and

with major developments in railroads, trade suddenly flourished.

Materials and processes during this time were still expensive and

laborious. During this time packaging was primarily seen as a way of

storage, and reserved for only high value goods like jewelry, gift items,

shoes, and premium foods. As the materials were indispensable, they

were structurally designed to serve a function after product use. Thus,

dual use packaging was a solution to command high price and assure

ingenuity of the manufacturing quality.

More innovations during this period:

1866 — First printed metal boxes were made for Dr. Lyon’s tooth powder. Metal tear-strip was also invented during this time. Further innovations in sealing the packaging to preserve goods, continued during this period.

1867 — Process for deriving cellulose fiber from wood pulp was developed. Wood being cheap and plentiful, this fiber source rapidly replaced cloth fibers as the primary source of paper fiber. Today, virtually all paper has wood pulp as the source of cellulose fiber.

1870 — First registered U.S. trademark was awarded to the Eagle-Arwill Chemical Paint Company, thus establishing a goodwill between manufacturer and the consumer.

1879 — Robert Gair accidently invented paperboard cartons when a

metal rule normally used to crease bags shifted in position and cut the

and other high value goods.

2. Metals

In 1200 A.D. the process of tin plating was invented in Bohemia. Tin was the first metal that economically allowed use of metals in packaging, soon it was used to make tin cans and tin foils. In early 1800s Nicholas Appert, found that food sealed in tin containers and sterilized by boiling could be preserved for long periods. Over a period of time, this established metal packaging as a food grade packaging material.

bags. Gair concluded that cutting and creasing paperboard in one

operation would have advantages; the first automatically made carton,

now referred to as “semi-flexible packaging,” was created. Such folding

cartons or “tubular cartons” dominate the dried, processed food

market.

Packaging Shape as an Identity — Coca-Cola

In early 1900s, Coca Cola found that a straight-sided bottle wasn't distinctive enough and that Coca-Cola was becoming easily confused with ‘copycat’ brands. Glass manufacturers were approached to come up with a unique bottle design for Coca-Cola. The Root Glass Company of Terre Haute, Indiana, designed with the famous contour shape, which won enthusiastic approval from Coca-Cola in 1915 and was introduced in 1916. The new bottle design instantly became an integral part of the brand identity and is today one of the most recognized icons in the world — even in the dark.

More innovations during this period:

1890 — Michael Owens invented first automatic rotary bottle-making machine. Suddenly, glass containers of all shapes and sizes became economically attractive for consumer products, and from the early 1900s until the late 1960s glass containers dominated the market for liquid products.

1894 — Thompson and Norris produced the first double-faced corrugated boxes that prevented material from stretching during transportation. Corrugated boxes played an essential role in developing mass distribution throughout the 20th century.

1920s, 1930s, 1940s: The Era of “Silent Salesman”

In the early part of the 19th century, retailers played an important role

in making a trade happen. Food items were sold in loose, and needed

wrapping and weighing. This meant that consumer had to wait while

their orders were made up. But the rise of cheap and clean packaging

solutions had solved this problem to a large extent and retailer’s role in

facilitating a trade started to marginalize. This allowed for huge retail

chains to come in where products were displayed on the shelf, and

consumer themselves had to make a purchase choice. The big chains

had a price advantage, and were slowly gaining momentum.

But immediately after The Great Depression, supermarkets became a

dominant force and marked a major shift in the consumer behavior.

Manufacturers once again turned to product packaging to be the silent

salesman — differentiating from competition and affecting a sale.

Increasing Visual Appeal — Flexography

Most packaging till this period leaned on distinct typographic treatments to create a visual identity. Due to limitations of letterpress printing, product packaging could only be embraced with illustrative painted imagery to define the contents, it was not truly an interpretation or an honest impression of the product contents. It was after the invention of aniline printing technology in late 1920s that packaging materials afforded visual information with a higher degree of accuracy, reproducing impressions of actuality realistically. The aniline printing used aniline dye on rubber blocks and the technique allowed printing on any kind of substrate including corrugated boards, milk cartons, paper bags, folding cartons and metallic films. This technique later on came to be known as

Flexography, and is now the default for package printing.

More innovations during this period:

1920s — Nutritional value of canned foods gradually approached that of the fresh product. For consumers, the choice between fresh or canned food increasingly became a question of taste, preference, and convenience.

1924 — DuPont bought licensed exclusive rights to make and sell Cellophane in U.S. The cellophane sheet was a clear, transparent protective layer wrapped over primary packaging, to prevent product from moisture and extend its shelf life.

1931—Aluminum foil was packaged in appropriate sizes and thicknesses, in both rolls and sheets a decade after first aluminium foil laminated carton was produced. It started being used as an institutional wrap primarily for use by hotel, restaurant, and hospital kitchens.

1930s and 1940s — The years preceding World War II, amidst a climate of escalating industry consolidation, were also a time of tremendous innovations for synthetics like vinyl, ethylene, and acrylic. U.S. government massively invested in building industrial infrastructure for this new sector. And these innovations lead to discovery of PVC, Nylon, Teflon, Polystyrene, Polyethylene, each of which transformed several industries and heralded the rise of Plastic Age in years to follow.

1950s, 1960s, 1970s: Convenience As The Motivation

Post World War II, U.S. experienced massive economic growth over next three

decades as its gross national product grew more than nine times the value of

$100 billion in 1940. During the time, even the poorest Americans were affluent

compared to world standards. As a result of this, everyone was able to afford

most luxuries available at the time. This lead to an exuberant growth in

consumerism, and everyone wanting to have a modern and convenient lifestyle.

Most development of the moldable metals and plastics, happened much earlier

than this period, but its exploits were primarily limited to military use. But after

WWII, the consumer market exploded with the continuous innovations in

aluminium and plastics. Owing to mega efforts of giants like DuPont, Dow

Chemicals, and the likes — shinier, sturdier, cleaner, more flexible, and modern

looking materials were available at cheaper price compared to traditional

materials. This provided impetus to re-invent existing packaging solutions and

plastics and metal cans took over majority of consumer packaging, while paper

was limited in use and glass reserved for high value products only.

Explosion of the Toxins — Plastics

DuPont and Dow Chemical’s heralded the rapid rise of plastics as they were used for textiles, tires, toys, paints, electronics, and as packaging material, affecting all aspects of life. Alan Pendry captured the versatility of plastics in his award winning short film The Shape of Plastics, in 1962. While the widespread use of plastics made a lot of economic sense, its environmental effects were soon apparent. In absence of regulations, it was difficult to keep a check on manufacturers. U.S. government passed National Environmental Protection Act in 1970 and form EPA as an authority to tackle environmental issues and form necessary regulations.

More innovations during this period:

1950 — Polyethylene was invented to be used as cable shielding material, but soon it outgrew its original use and was used to make products such as food and garbage bags, packaging films, and milk containers. In less than a decade, the demand for PE grew from 5 million pounds to 1.2 billion pounds at the end of 1960.

1960 — Reynolds and Alcoa made all-aluminium cans out of one piece of metal. This solved the problem of weights of cans, now only a lid needed to be attached. This provided impetus for invention of rip-off closure and the pop-top lids on aluminium cans.

1977 — Polyethylene Terephthalate (PETE) invented as material for beverage packaging is today one of the most commonly used plastics.

Packaging machines may be of the following general types:

Accumulating and collating machines

Blister packs, skin packs and vacuum packaging machines

Bottle caps equipment, over-capping, lidding, closing, seaming and sealing machines

Box, case and tray forming, packing, unpacking, closing and sealing machines

Cartoning machines

Cleaning, sterilizing, cooling and drying machines

Coding, printing, marking, stamping, and imprinting machines

Converting machines

Conveyor belts, accumulating and related machines

Feeding, orienting, placing and related machines

Filling machines: handling dry, powdered, solid, liquid, gas, or viscous products

Inspecting: visual, sound, metal detecting, etc.

Label dispenser

Orienting, unscrambling machines

Package filling and closing machines

Palletizing, depalletizing, unit load assembly

Product identification: labeling, marking, etc.

Sealing machines: heat sealer

Slitting machines

Weighing machines: check weigher, multihead weigher Wrapping machines: stretch wrapping, shrink wrap, banding Form, fill and seal machines.

STANDARD OPERATING PROCEDURE OF PACKAGING

SAMPLING, TESTING, CLEARANCE:

Receiving Intimation for inspection and sampling:

Store provides daily receiving of in-coming materials of

24hours receiving in the early first half on next working

day through e-mail.

In case of urgent material requirement, concerned

departments intimate to QA for urgent sampling and

further material status.

In case of late receiving, concerned department

intimates QA earlier in working hours.

Procedure for Sampling and Inspection:

Materials are inspected as per daily receiving and

samples are drawn of each item as per approved

sample plan, refer SOP “Sampling Plan & AQL of

Packaging Materials”.

In case of any deviation / unusual observation QA

Inspector / Officer / Executive reports to immediate

Head(s) and concerned departments immediately.

Procedure for Testing and analysis:

All in-coming materials are tested as per work instructions.

Assure that COA (certificate of analysis) must be submitted by supplier with every incoming delivery.

Material analysis report of testing parameters is filled against standard specifications and QA status with comments to be updated on ERP in respective organization and Status stickers to be pasted on items within 2 working days.

In case of any deviation observed QA shall report all testing / analysis results against standard specifications of each material to immediate Head(s) and concerned departments.

In case of HOLD /REJECTED material QA shall intimate all concerns through e-mail / other communication means and paste Yellow and Red stickers respectively on Hold/ Rejected lots.

In case of Rejection of any material QA issue a Rejection Certificate refer SOP “Rejection Approval Criteria “duly signed by QA Officer / Executive / AM / Sr. Manager for Dispose off , return back to supplier or sale out as per management decision for the subject material.

In case of HOLD, additional sampling, retesting and machine / line trial will be conducted by QA and sometimes R&D personnel as well (if required).

As per further results of re-sampling / machine trial, decision is made for the utilization or rejection of the subject HOLD material.

In case of conditional acceptance of any material either penalty or warning is given to the supplier against deviation / problem observed during sampling / inspection /testing /machine trial as per policy.

SAMPLING PLAN (MILITARY STANDARD 105e) USED IN INDUSTRY FOR SAMPLING OF

MATERIALS:

General Requirements:

Sample Size Unit:

In general lot size no’s shall be considering of main packing/supply unit like: For Packaging

materials packing units are Reels, Cartons, and Bundles of boxes etc.

4.2.2 Packaging Materials:

For Wrappers, Poly-hi shrink, Bopp, PVC, Aluminum foil at least 1 meter pcs

/reel.

Boxes, Jars, Tins, Sticker, Poly bags. Caps Seal are taken in form of No’s/Pcs.

Cartons are in form of Pcs/No’s.

Glue is 100 ml.

Hot melt wax is 100 gm.

Procedure:

Packaging materials sampling is carried out as per sampling Plan reference

Annexure II.

Packaging testing is then performed with reference to related material

standard & specifications respectively.

The material are then accepted when comply with specification & standards

else rejected.

Rejection due to variation in physical attributes are subjected to follow AQL’s

reference Annexure – III, IV &V for RM/PM defect categorization and rejection

level with respect to lot size.

At In process stage the Semi Finished Products at Hilal 1 & 2 are tested for

Micro analysis as per Sampling plan.

Switching Rule of Inspection:

Start the sampling from normal level with respect to sampling plan. Sampling as per sample size should be in such a way that the whole lot

presence must be covered by dividing the sample size to whole lot randomly. In case of following conditions the sampling level can be switched to Reduced

inspection from normal. Production steady 10 consecutive lots accepted Approved by responsible authority

Similarly when below conditions observed the reduced inspection shall be

switch to normal inspection level. Lot rejected Irregular production Lot meets neither accept nor reject criteria. Other conditions warrant return to normal inspection.

The normal inspection shall also switch to tightened inspection when experience 2 out of 5 consecutive lots rejected.

Similarly in case of 5 consecutive lots accepted the tightened inspection can be switched to normal level and in case of 3 lots rejected on tightened inspection the supplier will be consider for black list.

Definitions

Term/word/statement Meaning/Description

AQL It is defined as the maximum number of defects per unit of

product that for the purpose of sampling inspection can be

considered satisfactory/acceptable. The Acceptable Quality

Limit, commonly referred to as AQL, is a method widely used

to measure a production order sample to find whether or

not the entire product order has met the specifications.

Defects classification Are divided into 3 Critical, Major & Minor as below.

Critical A defect that can compromise product safety, purity, or

identity that may be harmful to the consumer.

Major A defect that jeopardizes the integrity or function of the

package.

Minor A defect that does not affect product safety, purity, or

identity, or package integrity of functions

Reference Used:

S.

No

Description

1. Military Standard Sampling procedure and tables for inspection by attributes Mil

–STD-105E 10th May 1989. (Single Sampling Plan)

FLOW CHART OF SAMPLING PLAN:

Start

Reduced Normal Tightened

Production Steady 10 Consecutive Lots

accepted Approved by responsible

authority

2 out of 5 consecutive lots rejected

Lot rejected Irregular production Lot meets neither accept

nor reject criteria Other conditions warrant

return to normal inspection

5 consecutive lots accepted

Lot size Code letter

Sample size

GENERAL INSPECTION LEVEL

1(REDUCED) 2(NORMAL) 3(TIGHTENED)

2 to 8 A 2 2 2 3

9 to 15 B 3 2 3 5

16 to 25 C 5 3 5 8

26 to 50 D 8 5 8 13

51 to 90 E 13 5 13 20

91 to 150 F 20 8 20 32

151 to 280 G 32 13 32 50

281 to 500 H 50 20 50 80

501 to 1200 J 80 32 80 125

1201 to 3200

K 125 50 125 200

3201 to 10000

L 200 80 200 315

10001 to 35000

M 315 125 315 500

35001 to 150000

N 500 200 500 800

150001 to 500000

P 800 315 800 1250

500001 to 10,00,000

Q 1250 500 1250 2000

10,00,000 over

R 2000 800 2000 2000

After tightened

inspection, if three

consecutive lots

rejected, the

AQL (Acceptable Quality Limit): (FOR BOXES)

AQL (Acceptable Quality Limit): (FOR WRAPPERS):

AQL (Acceptable Quality Limit): (FOR CARTONS):

Class 0 (0%) Class 1 (Critical) = 0.15% Class 2 (Major) = 1.5% Class 3 (Minor) = 4.0%

Wrong Artwork

Wrong Text & Barcode

Wrong/right grain of board

Wrong Printing color

Dimension difference

Low Box Board Strength

Grammage Variation

Improper Creasing

High Moisture

Flaps size deviation

Improper side and clutch pasting

Inappropriate clutch lock

Weak Perforation

Un related things (physical hazards)

Mis-Registration

Quantity variation in cases

Embossing (if in artwork)

Flaps lock cut problem

Box Binding

Wrong orientation of flap

Scratches

Stickiness

Class 0 (0%) Class 1 (Critical) = 0.15% Class 2 (Major) = 1.5% Class 3 (Minor) = 4.0%

Wrong Artwork

Wrong Structure

Wrong Winding Direction

Variation in Inner Core

Diameter

De-lamination (Weak peel

strength)

Dimension difference

Reel Slitting size deviation

Misprinting

Colour variation

Photo cell mark missing

Liquid contamination

Variation in Reel outer

diameter

Excessive joints (More than 2)

Static Charge

Stickness

Mis- registration

Grammage (low/high)

Thickness (low/high)

Undesirable smell

Damaged edges

Damaged Core

Wrinkles

Uneven winding

Loose / Tight winding

Packing

Outer Core diameter

Class 0 (0%) Class 1 (Critical) = 0.15% Class 2 (Major) = 1.5% Class 3 (Minor) = 4.0%

Wrong Artwork

Wrong Text & Barcode

Wrong Printing Colour

Wrong panel printing

Water absorbing outer liner

No. of plies deviation

Short dimensions

Low box Compression

Strength

Tearing of outer paper

Improper Creasing

High Moisture

Flaps size deviation

Improper side pasting

Grammage deviation

Un related things (physical

hazards)

Liner separation (Lesser

binding)

Misprinting

Quantity variation in bundles

Tearing of inner paper

Two side pasting,

Sharp edges

Carton binding

AQL INSPECTION (FOR CRITICAL) 0.15%

Lot size Code letter

Sample size for reduced

maximum rejects

allowed for

reduced

Sample size for Normal

maximum rejects

allowed for

normal

Sample size for

Tightened

maximum rejects

allowed for

tightened

2 to 8 A 2 0 2 0 2 0

9 to 15 B 2 0 3 0 3 0

16 to 25 C 2 0 5 0 5 0

26 to 50 D 3 0 8 0 8 0

51 to 90 E 5 0 13 0 13 0

91 to 150 F 8 0 20 0 20 0

151 to 280

G 13 0 32 0 32 0

281 to 500

H 20 0 50 0 50 0

501 to 1200

J 32 0 80 0 80 0

1201 to 3200

K 50 0 125 0 125 0

3201 to 10000

L 80 1 200 1 200 1

10001 to 35000

M 125 1 315 1 315 1

35001 to 150000

N 200 2 500 2 500 1

150001 to

500000 P 315 3 800 3 800 2

500001 to

10,00,000 Q 500 4 1250 5 1250 3

10,00,000 over

R 800 5 2000 7 2000 5

AQL INSPECTION (FOR MAJOR) 2.5%

lot size Code

letter

Sample

size for

reduced

maximum

rejects

allowed

for

reduced

Sample

size for

Normal

maximum

rejects

allowed

for

normal

Sample

size for

Tightened

maximum

rejects

allowed

for

tightened

2 to 8 A 2 0

2 0

3 0

9 to 15 B 2 0

3 0

5 0

16 to 25 C 2 1

5 0

8 0

26 to 50 D 3 1

8 0

13 0

51 to 90 E 5 2

13 1

20 1

91 to 150 F 8 3

20 1

32 1

151 to

280 G 13

4 32

2 50

1

281 to

500 H 20

5 50

3 80

2

501 to

1200 J 32

7 80

5 125

3

1201 to

3200 K 50

9 125

7 200

5

3201 to

10000 L 80 12 200 10 315 8

10001 to

35000 M 125 - 315 14 500 12

35001 to

150000 N 200 - 500 21 800 18

150001

to

500000

P 315 - 800 21 1250 18

500001

to

10,00,000

Q 500 - 1250 21 2000 18

10,00,000

over R 800 - 1250 21 2000 18

AQL INSPECTION (FOR MINOR) 4%

lot size Code

letter

Sample

size for

reduced

maximum

rejects

allowed

for

reduced

Sample

size for

Normal

maximum

rejects

allowed

for

normal

Sample

size for

Tightened

maximum

rejects

allowed

for

tightened

2 to 8 A 2 0 2 0 3 0

9 to 15 B 2 1 3 0 5 0

16 to 25 C 2 1 5 0 8 0

26 to 50 D 3 2 8 1 13 1

51 to 90 E 5 3 13 1 20 1

91 to 150 F 8 4 20 2 32 1

151 to

280 G 13 5 32 3 50 2

281 to

500 H 20 7 50 5 80 3

501 to

1200 J 32 9 80 7 125 5

1201 to

3200 K 50 12 125 10 200 8

3201 to

10000 L 80 - 200 14 315 12

10001 to

35000 M 125 - 315 21 500 18

35001 to

150000 N 200 - 500 21 800 18

150001

to

500000

P 315 - 800 21 1250 18

500001

to

10,00,000

Q 500 - 1250 21 2000 18

10,00,000

over R 800 - 1250 21 2000 18

ART WORK DEVELOPMENT PROCEDURE

Design Input/Idea Raised

Evaluation

( advantges costing & marketing

point of view)

Sent to R&D for text/information

verification

Review by QA

Uploading the artworks on server.

Provide Artwork & CD to Vendor for

Epson making.

Epson Approval

Feedback & Approval Not Physable Rejected

OK

Artwork Development by Creative

Design Approval by

Marketing & DirectorNot OK

Correction

OK

Verify & sign Epson by Marketing,

Creative, Export, R&D & QA

respectively Correction requried

Submission of Epson by vendor

Cylinder Making & Print Proof

sample submission by vendorPrint Proof Approval

Preparation of Shade

Card and submission

OK

Not OK resubmit by vendor

PROPERTIES OF PACKAGING FILMS:

S.NO. STRUCTURE MICRON BURNING TEST

1 BOPP 20 SLIGHLTY BLACK SMOKE , DRIPPING

LIKE WAX,

2 MOPP 18, 20 SLIGHLTY BLACK SMOKE , DRIPPING

LIKE WAX,

3 MCPP 25 BLACK SMOKE, BREAK AND THAN

DROP, SHRINK AFTER BURNING

4 WCPP 25 BLACK SMOKE, BREAK AND THAN

DROP, SHRINK AFTER BURNING

5 PET 12

HEAVY BLACK SMOKE, BREAK AND

THAN DROP, NO DRIPPING, SHRINK

AFTER BURNING, RAPIDLY BURNING,

SPARK DURING BURNING

6 PVC 170

HEAVY BLACK SMOKE,SLOW BURNING,

SLIGHLTY SPARK DURING BURNING,

BLACK SHAPED AFTER BURNING, NO

BREAKAGE OBSERVED

7 ALU.FOIL 7, 20 SLIGHTLY WHITE SMOKE, NO DRIPPING

& SHRINKAGE, WHITE AFTER BURN

8 LDPE 55, 60 SLIGHLTY WHITE SMOKE , DRIPPING

LIKE WAX, SLOW BURNING

S.NO. STRUCTURE MICRON DENSITY VISUAL TEST TEAR TEST

1 BOPP 20 0.9 CRYSTAL CLEAR EASY TO

TEAR

2 MOPP 18, 20 0.9 SILVER EASY TO

TEAR

3 MCPP 25 … SILVER STRETCH BEFORE

TEAR

4 WCPP 25 … WHITE MILKY STRETCH BEFORE

TEAR

5 PET 12 1.38 CRYSTAL CLEAR EASY TO

TEAR

6 PVC 170 1.28 CRYSTAL CLEAR SLIGHTLY

RESIST

7 ALU.FOIL 7, 20 2.71 SILVER EASY TO

TEAR

8 LDPE 55, 60 0.92 HAZYNESS/CLOUDNESS STRETCH BEFORE

TEAR

PROPERTIES

S.NO. FILMS W.V.T.R

1 PVDC 0.05

2 HDPE 0.3

3 P.P 0.4

4 LDPE 1.2

5 PET 1.3

6 PVC 4

7 NYLON 24

8 E.V.O.H ABSORB WATER

PROPERTIES

S.NO. FILMS O.T.R

1 ETHYLENE VINYL ALCOHOL 0.02

2 PVDC 0.2

3 NYLON 3

4 PET 5

5 HDPE 110

6 P.P 150

7 LDPE 480

NEW PACKAGING FILMS

BIAXIALLY ORIENTED POLYAMIDE:

POLYAMIDE PROPERTIES DIS ADVANTAGE

MOSTLY USED IN CURED

MEAT AND CHEESE PRODUCT

WITH OPE+P.E

SUPERNYL AND SANTONYL

MAINLY LAMINATED WITH

P.E, PET, CPP.

DENSITY 1.13

GOOD HEAT RESISTANCE ,

MELTING POINT 220 •C

HIGH TENSILY STRENGTH

RESISTANCE TO FAT AND OIL

BARRIER PROPERTIES OF GASES IS

GOOD IN DRY CONDITIONS BUT

NOT GOOD IN HIGH HUMIDITY

GOOD PRINTIBILITY

THICKNESS RANGE 10 TO 30

MICRON

WATER

TRANSMISSI

ON RATE IS

HIGH.

EVOH PROPERTIES DISADVANTAGE

EVOH RESINS ARE

HYDROLYSED CO POLYMER

OF ETHYLENE AND VINYL

ACETATE

EVOH ARE USUALLY

EMBEDDED IN POLY OLIFIN

LAYER WITH A GOOD WATER

BARRIER

P.E+EVOH+P.E AND

P.A+EVOH+P.E MOSTLY USED

IN READY MEALS, BAKERY

PRODUCTS, PASTA

HIGH MECHANICAL STRENGTH

ELASTICITY

SURFACE HARDNESS

LOW HAZINESS

HIGH RESISTANCE TO OIL

EXCELLENT BARRIER TO

ODOURS

GOOD GAS BARRIER PROPERTY

IN DRY CONDITIONS

UNDER INFLUENCES

OF HIGH HUMIDITY

GAS BARRIER

PROPERTIES

DETERIORATE

BAREX PROPERTIES

MOSTLY USED IN BEVERAGE BOTTLE

LAMINATES WITH PAPER/ALU/BAREX WE CAN USED IN SPICES AND LEMON JUICES

GOOD CLARITY HIGH IMPACT

STRENGTH RESISTANCE TO OIL

AND FATS

PVDC PROPERTIES DIS ADVANTAGES

Another name is

Saran

Vinylidene chloride is

co polymerized with

vinyl chloride

Slightly yellowish cast

in heavy section

Density (1.68)

Good gas (oxygen)

permeability

Good water vapor

barrier 0.1

gm/meter/24hr

Good odor barrier

Soft and transparent

films

Difficult to handle on

printing

Must be stored in a

cool placed otherwise

shrinkage can cause

HDPE (PROPERTIES) DIS ADVANTAGES

Good tensile strength

Good chemical resistance

Films is colorless

Prevent from mechanical

damage

High tear resistance

High moisture barrier

Tensile strength 4.45 MPa

Heat sealing

Heavier than LDPE

Bad UV light resistance

ALUMINUM FOIL PROPERTIES DIS ADVANTAGE

The first use of foil in the

United States was in 1913 for

wrapping Life Savers, candy

bars, and gum.

The first aluminum foil rolling

plant, "Dr. Lauber, Neher &

Cie." was opened in

Emmishofen, Switzerland.

In 1911, Bern-based Tobler

began wrapping its chocolate

bars in aluminum foil,

including the unique

triangular chocolate bar,

Toblerone.

Annual production of

aluminum foil was

approximately 800,000 tones

(880,000 tons) in Europe and

600,000 tones (660,000 tons)

in the USA in 2003.

Approximately 75% of

aluminum foil is used for

packaging of foods,

cosmetics, and chemical

products, and 25% used for

industrial applications.

Sodium silicate solutions is

used for bonding with paper

It is usually printed by

flexography and gravure is

sometime used.

Aluminum foils thicker than

25 µm are impermeable to

oxygen and water.

As aluminum foil acts as a

complete barrier to light

and oxygen (which cause

fats to oxidize or become

rancid), odors and flavors,

moisture, and bacteria, it is

used extensively in food

and pharmaceutical

packaging.

7mic foil has water vapor

transmission rate is about

0.2 gm per meter square

per 24hr at 38©

Chemical and greases

resistance is good

It is unaffected by sun light

and temp about 550 ºf.

Density = 2.7

High cost

METALLIZED FILM PROPERTIES

Vaporizing molten metal and

depositing it onto a cold polymer web.

the process take place in a vacuum

chamber

Two most common substrates are PET

and OPP

Good moisture barrier

Good gas barrier

Prevent from light

Cheaper than aluminum

Thickness of the deposited layer is

about 30nm

Glossy metal appearance

1. BOPP PROPERTIES DIS ADVANTAGE

When polypropylene film is

extruded and stretched in both the

machine direction and across

machine direction it is called

biaxial oriented polypropylene.

Biaxial-Oriented Polypropylene

(BOPP) films have become a

popular, high growth film on the

world market because of a unique

combination of properties such as

better shrinkage, stiffness,

transparency, seal ability, twist

retention and barrier.

high melting point (169

•c)

low density (0.9)

low cost

high tear resistance

toughness

clarity

Good moisture barrier

Micron (BOPP,MOPP)=

18,20

MCPP = 25

Sealing temp = 176.6 ©

Low aroma barrier

Degraded by UV

Attacked by chlorinated

solvents and aromatics.

Must be stored in a cool

placed otherwise

shrinkage can cause

PET PROPERTIES DIS ADVANTAGES

(C10H8O4)n

It was a British discovery

It is still the most well-

known name used for

polyester film.

The PET bottle was

patented in 1973 by

Nathaniel Wyeth.

PET in its natural state is a

colorless, semi-crystalline

resin.

In its un oriented states is

usually combined with

other films

When it is used alone , it

should always be the

oriented

Good Gas barrier

Good barrier to alcohol

It is strong and impact-

resistant.

Melting point 205 •c.

1.37 density

High transparency

Good print ability

Sealing temp = 135 ©

MICRON = 12

Not good moisture barrier

Low aroma barrier

Noisy films

Not good tear strength

P.E PROPERTIES DIS

ADVANTAGES

Discovered in

England in the

early 1930

Straight chain of

hydrocarbons

Two main types

: LDPE and HDPE

Printing by

gravure and

flexography

Soft and

flexible

Good moisture

barrier

Low cost

Good chemical

resistance

MICRON = 65

Sealing temp =

135

Density = 0.93

Slightly haziness

Difficult to get

adhesive on it ,

because its

surface is non

polar

Chemical resistance

Ability of a material to retain utility and appearance following contact with chemical agents. Chemical resistance implies that there is no significant chemical activity between the contacting materials.

Co-extrusion (COEX)

Simultaneous extrusion of two or more different thermoplastic resins into a

sandwich-like film with clearly distinguishable individual layers.

Corona treatment

A treatment to alter the surface of plastics and other materials to make them more receptive to printing inks.

Degradation

A change or break-down in a material's chemical structure.

De-lamination

Separation or splitting of laminate layers caused by lack of or inadequate

EXON PROPERTIES

Vacuum deposited aluminum

Transparent multilayer poly propylene

core

Broad sealing range

Good moisture barrier

Good light barrier

Good gas barrier

Easy to convert

Metal appearance

Flavor and aroma barrier

15 micron

13.7 grammage

73.3 yield

Optical density 2.3

Water transmission rate = 0.3

gm/meter square/24hr

PVC PROPERTIES DIS ADVANTAGES

It was first discovered by

Henri Victor

Vinyl is made by

chlorination of ethylene

to produce vinyl chloride,

which is then

polymerized with a

benzyl per oxide to

produce PVC

When it is oriented it is

the most popular shrink

films

Two types : plasticized

and un plasticized

Good toughness

Resistance to oil

Machine ability is good

Good gas barrier

Good moisture barrier

Sealing temp = 107.2

Micron = 170

Density = 1.40

Sunlight can have a degrading

effect

Vapors from heat sealing can

be harmful if inhaled

LDPE PROPERTIES DIS ADVANTAGES

Density 0.91 to 0.93

Molecular weight

distribution is narrower

Good tensile strength

Good tear strength as

compare to HDPE

Good moisture barrier but

not good as HDPE

Good chemical resistance

Good seals

High melting point

Poor gas barrier as compare

to HDPE

DEFINITIONS:

Aluminum foil

A thin gauge (.285-1.0 mil) aluminum foil laminated to plastic films to provide oxygen, aroma and water vapor barrier properties.

Barrier

In packaging, this term is most commonly used to describe the ability of a material to stop or retard the passage of atmospheric gases, water vapor, and volatile flavor and aroma ingredients. A barrier material is one that is designed to prevent, to a specified degree, the penetrations of water, oils, water vapor, or certain gases, as desired. Barrier materials may serve to exclude or retain such elements without or within a package.

Biaxial orientation

Orientation of plastic films in both machine and cross machine (transverse) directions by stretching. Biaxial stretched films are generally well balanced in both directions and much stronger in terms of tear strength.

Cast film

Plastic film produced from synthetic resins (such as polyethylene) by the cast process. In this process, the molten resin is extruded through a slot die onto an internally cooled chill roll.

adhesion, or by mechanical disruption such as peeling or shearing forces.

Directionality

The tendency for certain materials to have properties imparted by the flow direction through a machine.

Ethylene-vinyl acetate (EVA)

A polar copolymer of ethylene and vinyl acetate, retaining some of the properties of polyethylene but with increased flexibility, elongation, and impact resistance. EVA is frequently specified as the extrusion coating on polypropylene, aluminum foil and poly (ethylene terephthalate), to provide good heat-seals at high converting rates, or as the adhesion layer in some laminates.

Ethylene-vinyl alcohol (EVOH)

Can be regarded as a copolymer of polyethylene in which varying amounts of the -OH functional group have been incorporated. A typical packaging EVOH is about 20 to 35% ethylene. EVOH is one of the best polymeric oxygen barriers available to packagers. However, its susceptible to water requires that for most applications it be laminated or co-extruded into a protective sandwich with materials that will keep the EVOH layer away from water.

Extrusion

The process of forming a thermoplastic film, container, or profile by forcing the polymer melts through a shaped orifice.

Extrusion coating

A process where a film of molten polymeric material is extruded onto the surface of a substrate material and cooled to form a continuous coating.

Extrusion lamination

A laminating process in which individual layers of multi-layer packaging materials are laminated to each other by extruding a thin layer of molten synthetic resin (such as polyethylene) between the layers.

Film

Generally used to describe a thin plastic material usually not more than 75 micrometers (0.003 inch) thick.

Flexible packaging

A package or container made of flexible or easily yielding materials that, when filled and closed, can be readily changed in shape. A term normally applied to bags, pouches, or wraps made of materials ranging in thickness from 13 to 75 micrometers (0.0b0á to 0.003 inch) such as paper, plastic film, foil, or combinations of these.

Flexographic printing

A method of printing using flexible rubber or photopolymer printing plates in which the image to be printed stands out in relief. Fluid ink metered by an engraved roll is applied to the raised portions of the printing plate and then transferred to the substrate.

Gas transmission rate (GTR)

The quantity of a given gas passing through a unit area of the parallel surfaces of a film, sheet, or laminate in a given time under the test conditions. Test conditions may vary and must always be stated.

Gauge

Thickness. In North America, film thickness, measured in mils, is usually given in gauges. A 100 gauge shrink film is one mil, or 1/1000 of an inch, thick. In Europe, the film thickness metric is the micron. A quick equivalency equation is: 1 mil = 25.4 microns.

Gravure printing

Gravure is abbreviated from the term rotogravure. During gravure printing an image is etched on the surface of a metal cylinder and chrome plated for hardness. The ink fills the cells and is transferred onto the printing substrate.

Gusset

The fold in the side or bottom of the pouch, allowing it to expand when contents are inserted

HDPE

High density, (0.95-0.965) polyethylene. Have much higher stiffness, higher temperature resistance and much better water vapor barrier properties than LDPE, but it is considerably hazier.

Heat-seal coating

An adhesive coating applied to a packaging material that is capable of being activated by heat and pressure to form a bond.

Heat-seal layer

A heat sealable innermost layer in plastic packaging films and laminates. Can be either adhesive laminated or extrusion coated onto a non-sealable film (or foil).

High barrier

Describes a material or package that has very low gas permeability characteristics; that is, it offers a great deal of resistance to the passage of a gas through its volume.

Laminate

(A) noun a product made by bonding together two or more layers of material. (b) Verb To unite layers of material to produce a multilayer material.

Laminated film

An adhered combination of two or more films or sheets made to improve overall characteristics. Also multilayer film.

Light resistance

The ability of material to withstand exposure to light (usually sunlight or the ultraviolet part of the light spectrum) without change of color or loss of physical and/or chemical properties.

LLDPE

Linear low density polyethylene. Tougher than LDPE and has better heat-seal strength, but has higher haze.

Mach inability

The ability of a film to run on packaging equipment.

Machine direction (MD)

The direction that film moves through the packaging equipment.

MDPE

Medium density, (0.934-0.95) polyethylene. Have higher stiffness, higher melting point and better water vapor barrier properties.

Metalize

Applying a thin coating of metal to a nonmetallic surface by chemical deposition or by exposing the surface to vaporized metal in a vacuum chamber.

MET-OPP

Metalized OPP film. It has all the good properties of OPP film, plus much improved oxygen and water vapor barrier properties, (but not as good as MET-PET).

MET-PET

Metalized PET film. It has all the good properties of PET film, plus much improved oxygen and water vapor barrier properties. However, it is not transparent. See also VMPET.

Moisture vapor transmission rate (MVTR)

A depreciated term, usually measured at 100% relative humidity, expressed in grams/100 square inches/24 hours, (or grams/square meter/24 Hrs.) See WVTR.

Nylon

Polyamide resins, with very high melting points, excellent clarity and stiffness. Two types are used for films - nylon-6 and nylon-66. The latter has much higher melt temperature, thus better temperature resistance, but the former is easier to process, and it is cheaper. Both have good oxygen and aroma barrier properties, but they are poor barriers to water vapor.

Polyethylene film (PE)

Made in high density, low density, linear low density and metallocene variations. By far the largest volume packaging film family.

Poly (ethylene terephthalate) film (PET)

Polyester, (Polyethylene Terephtalate). Tough, temperature resistant polymer. Biaxial oriented PET film is used in laminates for packaging, where it provides strength, stiffness and temperature resistance. It is usually combined with other films for heat seal ability and improved barrier properties.

Tear resistance

The ability of a film to resist the propagation of a tear.

Tensile strength

The amount of pull a film can withstand without tearing apart or stretching.

Thermoforming

A method of forming plastics where a plastic sheet is heated to a point where it is soft and formable.

Transverse direction (TD)

The direction perpendicular to the machine direction.

Vapor barrier

A layer of material through which water vapor will pass only slowly, or not at all.

Water vapor transmission rate (WVTR)

A measure of the rate of water vapor transmission through a material. Usually measured at 100% relative humidity, expressed in grams/100 square inches/24 hours, (or grams/square meter/24 Hrs.) See MVTR.

OPP

Oriented PP (polypropylene) film. A stiff, high clarity film, but not heat sealable. Usually combined with other films, (such as LDPE) for heatsealability. Can be coated with PVDC (polyvinylidene chloride), or metalized for much improved barrier properties.

Optics

The visual properties of a film, such as clarity, gloss, haze, opacity, etc.

Orientation

The process of mechanically stretching plastic film or parts in order to produce a straightening and alignment of the molecules in the stretch direction. If done in one direction, the material is said to be uniaxial or monoaxially oriented. if done in two directions, the film is biaxial oriented.

(OTR)

Oxygen transmission rate. Varies considerably with humidity, therefore it needs to be specified. Standard conditions of testing are 0, 60 or 100% relative humidity. Units are cc./100 square inches/24 hours, (or cc/square meter/24 Hrs.) (cc = cubic centimeters)

Polypropylene film (PP)

Unoriented film is soft and clear but brittle at low temperatures. This property as well as stiffness, strength and clarity is improved by orientation.

PVDC

Polyolefin

Family name for the polymers (plastics) derived by ethylene and propylene, such as polyethylene (PE) and polypropylene (PP)

Polyvinylidene chloride. A very good oxygen and water vapor barrier, but not extricable,

therefore it is found primarily as a coating to improve barrier properties of other plastic films,

(such as OPP and PET) for packaging. PVDC coated and ’saran‘coated are the same.

EXTRUSION COATING PROCESS:

Extrusion coating is the coating of a molten web of synthetic resin onto a substrate material. It is a versatile coating technique used for the economic application of

various plastics, notably polyethylene, onto paperboard, corrugated fiberboard, paper, aluminum foils, cellulose, Non-woven’s, or plastic films.

Process

Coating

The actual process of extrusion coating involves extruding resin from a slot die at temperatures up to 320°C directly onto the moving web which may then passed through a nip consisting of a rubber covered pressure roller and a chrome plated cooling roll. The latter cools the molten film back into the solid state and also imparts the desired finish to the plastic surface. The web is normally run much faster than the speed at which the resin is extruded from the die, creating a coating thickness which is in proportion to the speed ratio and the slot gap.

Laminating

Extrusion laminating is a similar process except that the extruded hot molten resin acts as the bonding medium to a second web of material.

Co-extrusion

Co-extrusion is, again, a similar process but with two, or more, extruders coupled to a single die head in which the individually extruded melts are brought together and finally extruded as a multi-layer film.

PRINTED WRAPPERS PROCESS FLOW>>>>

Class 0 (Critical) (Major) (Minor)

Wrong Artwork

Wrong Structure

Wrong Winding

Direction

Variation in Inner

Core Diameter

De-lamination

(Weak peel

strength)

Dimension

difference

Reel Slitting size

deviation

Misprinting

Color variation

Photo cell mark

missing

Liquid

contamination

Variation in Reel

outer diameter

Excessive joints

(More than 2)

Static Charge

Stickiness

Mis- registration

Grammage

(low/high)

Thickness

(low/high)

Undesirable smell

Damaged edges

Damaged Core

Wrinkles

Uneven winding

Loose / Tight

winding

Packing

Outer Core

diameter

Raw Material (Films)

Receiving

Printing

Lamination

Curing

Slitting/Cutting

Packing

Dispatch

KRAFT PAPER:

Kraft paper or kraft is paper or paperboard (cardboard) produced from chemical pulp produced in the kraft process.

Sack Kraft Paper, or just sack paper is a porous kraft paper with high elasticity and high tear resistance, designed for packaging products with high demands for strength and durability.

Pulp produced by the kraft process is stronger than that made by other pulping processes; acidic sulfite processes degrade cellulose more, leading to weaker fibers, and mechanical pulping processes leave most of the lignin with the fibers, whereas kraft pulping removes most of the lignin present originally in the wood. Low lignin is important to the resulting strength of the paper, as the hydrophobic nature of lignin interferes with the formation of the hydrogen bonds between cellulose (and hemicellulose) in the fibers.

Kraft pulp is darker than other wood pulps, but it can be bleached to make very white pulp. Fully bleached kraft pulp is used to make high quality paper where strength, whiteness and resistance to yellowing are important.

Manufacture

Wood pulp for sack paper is made from softwood by the kraft process. The long fibers provides the paper its strength and wet strength chemicals are added to even further improve the strength. Both white and brown grades are made. Sack paper is then produced on a paper machine from the wood pulp. The paper is microcrepped to give porosity and elasticity. Micro-crepping is done by drying with loose draws allowing it to shrink. This causes the paper to elongate 4% in the machine direction and 10% in the cross direction without breaking. Machine direction elongation can be further improved by pressing between very elastic cylinders causing more microcrepping. The paper may be coated with polyethylene (PE) to ensure an effective barrier against moisture, grease and bacteria. A paper sack can be made of several layers of sack paper depending on the toughness needed.

Kraft paper is produced on paper machines with moderate machine speeds. The raw material is normally softwood pulp from the kraft process.

Maintaining a high effective sulfur ratio or sulfidity is important for the highest possible strength using the kraft process.

The kraft process can use a wider range of fiber sources than most other pulping processes. All types of wood, including very resinous types like southern pine, and non-wood species like bamboo and kenaf can be used in the kraft process.

Qualities

Normal kraft paper is strong and relatively coarse. It has high tensile strength. The grammage is normally from 40–135 g/m2.

Sack kraft paper, or just sack paper is a porous kraft paper with high elasticity and high tear resistance, designed for packaging products with high demands for strength and durability.

Absorbent kraft paper is made with controlled absorbency, i.e., a high degree of porosity. It is made of clean low kappa hardwood kraft and has to have a good uniformity and formation.

Spinning kraft paper is an especially strong type of kraft paper with relatively low grammage (40 g/m2). This paper requires the best possible machine direction strength and cross machine elongation. This is done by high fiber orientation on the papermachine.

Hunting cartridge paper is a kraft paper used in shotgun shells. This paper needs a high tensile strength in the machine direction, which is the axial direction of the cartridges. In the cross direction, the cartridge is supported by the gun-pipe, but a sufficient elongation is needed. The body of the cartridge is wound of a kraft paper of 80–120 g/m2, which is further covered by an outer sheet of 60–80 g/m2 with colour and printing.

Candy wrapping paper or twisting paper are thin 30–40 g/m2 kraft papers and is mostly flexo or offset printed. These papers requires a good strength, with highly oriented fibers. Twisting paper is mostly opaque and often supercalendered.

Applications

Kraft paper (plastic hazard free) is used paper sacks for cement, food, chemicals, consumer goods,flour bags etc.

Kraft papers are used in paper grocery bags, multiwall sacks, envelopes and other packaging.

Kraft paper is an inexpensive material for lining particle boards.

Properties of Paper

Basis Weight (GSM)

Brightness, Whiteness and Color

Bulk Dimensional Stability

Folding Endurance (Double Folds)

Formation Gloss

Machine and Cross Direction

Moisture

Opacity Porosity

Sizing / Cobb

Smoothness

Stiffness Stretch (Elongation)

Tearing Resistance

Temperature and Humidity: Conditioning of Paper

Thickness Wax Pick No. (Surface Strength)

Wire side and Felt side

Basis Weight (GSM) The weight or substance per unit area is obviously fundamental in paper and paper board products. The Basis weight of paper is the weight per unit area. This can be expressed as the weight in grams per square meter (GSM or g/M2), pounds per 1000 sq. ft. or weight in kgs or pounds per ream (500 sheets) of a specific size. REAM WEIGHT is a common term to signify the weight of a lot or batch of paper. Control of basis weight is important as all other properties are affected. Variations in moisture content in paper affect the grammage. Brightness, Whiteness and Colour Brightness is defined as the percentage reflectance of blue light only at a wavelength of 457 nm. Whiteness refers to the extent that paper diffusely reflects light of all wave lengths throughout the visible spectrum. Whiteness is an appearance term. Colour is an aesthetic value. Colour may appear different when viewed under a different light source. Brightness is an arbitrarily defined, but carefully standardized, blue reflectance that is used throughout the pulp and paper industry for the control of mill processes and in certain types of research and development programs. Brightness is not whiteness. However, the brightness values of the pulps and pigments going into the paper provide an excellent measure of the maximum whiteness that can be achieved with proper tinting. The colour of paper, like of other materials, depends in a complicated way on the characteristics of the observer and a number of physical factors such as the spectral energy distribution of the illuminant, the geometry of illuminating and viewing, the nature and extent of the surround and the optical characteristics of the paper itself. Bulk Bulk is a term used to indicate volume or thickness in relation to weight. It is the reciprocal of density (weight per unit volume). It is calculated from caliper and basis weight. Sheet bulk relates to all other sheet properties. Decrease the bulk or in other words increase the density, and the sheet gets smoother, glossier, less opaque, darker, lower in strength etc.

Dimensional Stability

An important consequence of the absorption and de-absorption of

moisture by paper is the change in dimension that usually

accompanies changes in moisture content. Such changes in dimension

may seriously affect register in printing processes and interfere with

the use of such items as tabulating cards. Uneven dimensional

changes cause undesirable cockling and curling. Dimensional changes

in paper originate in the swelling and contraction of the individual

fibres. It has been observed that cellulosic fibers swell in diameter

from 15 to 20% in passing from the dry condition to the fibre

saturation point. It is impossible to be precise about the degree of this

swelling because paper-making fibres differ considerably in this

property, and because the irregular cross-section of fibres creates

difficulty in defining diameter. Change that occurs in the dimensions

of paper with variation in the moisture content is an important

consideration in the use of paper. All papers expand with increased

moisture content and contract with decreased moisture content, but

the rate and extent of changes vary with different papers.

Folding Endurance (Double Folds)

Folding endurance is the paper's capability of withstanding multiple

folds before it breaks. It is defined as the number of double folds that

a strip of 15 mm wide and 100 mm length can withstand under a

specified load before it breaks. It is important for printing grades

where the paper is subjected to multiple folds like in books, maps, or

pamphlets. Fold test is also important for carton, box boards,

ammonia print paper, and cover paper etc. Folding endurance is a

requirement in Bond, Ledger, Currency, Map, Blue Print and Record

Papers.

Formation

Formation is an indicator of how the fibres and fillers are distributed

in the sheet. Formation plays an important role as most of the paper

properties depend on it. Paper that is poorly formed will have weak,

thin spots and thick spots. These will affect properties like caliper,

opacity, strength etc. Paper formation also affects the coating

capabilities and printing characteristics of the paper.

Gloss It is the specularly and diffusely reflected light component measurement against a known standard. Gloss is important for printing such things as magazine advertisements. The level of gloss desired is very dependent on the end use of the paper. Gloss and smoothness are different properties and are not dependent on each other. Machine and Cross Direction Paper has a definite grain direction due to greater orientation of fibres in the direction of travel of the paper machine. This grain direction is known as machine direction. The cross direction is the direction of paper at right angles to the machine direction. Some of the properties vary with the MD and CD and hence the values are reported in both the directions. While sheeting the paper, machine and cross direction are to be kept in mind and the sheet cutting to be done to suit the end use requirements. Examples: 1. all printing papers are to be cut in long grain (The biggest dimension in the grain direction). 2. Book papers fold better and the book stays open better if the sheets are out so that the machine direction runs up and down the pages. 3. Wrap around labels for metal cans and bottles are to be cut with the machine direction vertical to obtain greater flexibility about the can. Long grain and Short grain: The sheet is in long grain if the larger dimension is parallel to grain (MD) direction. The sheet is said to be in short grain if the larger dimension is parallel to cross direction (CD). Moisture Most physical properties of paper undergo change as a result of variations in moisture content. Water has the effect of plasticizing the cellulose fibre and of relaxing and weakening the inter fibre bonding. The electrical resistance and the dielectric constant of paper both vary with moisture content. The absorption and reflectance of certain bands of infrared and microwave radiation by paper are affected by its moisture content. The amount of water present in a sheet of paper is usually expressed as a percent. The amount of water plays an important role in calendaring, printing and converting process. Moisture control is also significant to the economic aspect of paper making. Poor moisture control can adversely affect many paper properties.

Opacity

Opacity is the measure of how much light is kept away from passing

through a sheet. A perfectly opaque paper is the one that is

absolutely impervious to the passage of all visible light. It is the ratio

of diffused reflectance and the reflectance of single sheet backed by a

black body. Opacity is important in Printing Papers, Book Papers, etc.

Porosity Because paper is composed of a randomly felted layer of fibre, it follows that the structure has a varying degree of porosity. Thus, the ability of fluids, both liquid and gaseous, to penetrate the structure of paper becomes a property that is both highly significant to the use of paper. Paper is a highly porous material and contains as such as 70% air. Porosity is a highly critical factor in Printing Papers Laminating Paper, Filter Paper, and Cigarette Paper. Bag Paper, Ant tarnish Paper and Label Paper. Porosity is the measurement of the total connecting air voids, both vertical and horizontal, that exists in a sheet. Porosity of sheet is an indication of absorptive or the ability of the sheets to accept ink or water. Porosity can also be a factor in a vacuum feeding operation on a printing press.

Sizing / Cobb

Because paper is composed of a randomly felted layer of fibre, it's

structure has a varying degree of porosity. Thus, the ability of fluids,

both liquid and gaseous, to penetrate the structure of paper becomes

a property that is both highly significant to the use of paper. The need

to limit the spreading of ink resulted in "sizing" the paper with

gelatinous vegetable materials which had the effect of sealing or

filling the surface pores. Later, the term "sizing" was applied to the

treatment of paper stock prior to the formation of the sheet, with

water-repellent materials such as rosin or wax. Resistance towards

the penetration of aqueous solution / water is measured by Sizing or

Cobb values.

Smoothness

Smoothness is concerned with the surface contour of paper. It is the

flatness of the surface under testing conditions which considers

roughness, liveliness, and compressibility. In most of the uses of

paper, the character of the surface is of great importance. It is

common to say that paper has a "smooth" or a "rough" texture. The

terms "finish" and "pattern" are frequently used in describing the

contour or appearance of paper surfaces. Smoothness in important

for writing, where it affects the ease of travel of the pen over the

paper surface. Finish is important in bag paper as it is related to the

tendency of the bag to slide when stacked. Smoothness of the paper

will often determine whether or not it can be successfully printed.

Smoothness also gives eye appeal as a rough paper is unattractive.

Stiffness

Stiffness is the measure of force required to bend a paper through a

specified angle. Stiffness is an important property for box boards,

corrugating medium and to certain extent for printing papers also. A

limpy and flimsy paper can cause feeding and delivery problems in

larger sheet presses. A sheet that is too stiff will cause problems in

copier machines where it must traverse over, under, and around feed

rollers. Bond papers also require certain stiffness to be flat in

typewriters etc.

Stretch (Elongation)

Stretch is the amount of distortion which paper undergoes under

tensile stress. Stretch elongation is usually expressed, as percent

stretch to rupture. Stretch can be related to the paper's ability to

conform and maintain conformance to a particular contour, e.g.

Copier paper, multicolor offset printing papers, liquids packing

cartons base papers etc. It is an important property in sack Kraft

papers which are used for cement bags etc. Stretch is higher in cross

direction than machine direction.

Tearing Resistance

Tearing resistance indicates the behavior of paper in various end use

situations; such as evaluating web run ability, controlling the quality

of newsprint and characterizing the toughness of packaging papers

where the ability to absorb shocks is essential. fibre length and

interfibre bonding are both important factors in tearing strength. The

fact that longer fibres improve tear strength is well recognized. The

explanation is straight forward; longer fibres tend to distribute the

stress over a greater area, over more fibres and more bonds, while

short fibres allow the stress to be concentrated in a smaller area.

Temperature and Humidity: Conditioning of Paper

conditioning of paper is also of importance in many printing and

converting operations. In addition to the effect of moisture content

on physical properties, it also determines the buildup of static of the

paper sheet subjected to pressure and to friction. The tendency for

paper to develop static becomes greater with increasing dryness.

Cellulosic fibres are hygroscopic i.e. they are capable of absorbing

water from the surrounding atmosphere. The amount of absorbed

water depends on the humidity and the temperature of the air in

contact with the paper. Hence, changes in temperature and humidity,

even slight changes, can often affect the test results. So, it is

necessary to maintain standard conditions of humidity and

temperature for conditioning.

Thickness

Thickness or Caliper of paper is measured with a micrometer as the

perpendicular distance between two circular, plane, parallel surfaces

under a pressure of 1 kg./ CM2. Caliper is a critical measurement of

uniformity. Variations in caliper can affect several basic properties

including strength, optical and roll quality. Thickness is important in

filling cards, printing papers, condenser paper, saturating papers etc.

Wax Pick No. (Surface Strength) This indicates the surface strength of the paper. This test is important for all uncoated printing papers.

Wire side and Felt side Also referred as wire side and top side. The side which is in contact with the paper machine wire during paper manufacture is called the wire side. The other side is top side. Certain properties differ between wire and felt side and it is customary to measure these properties on both the sides. In case of paper to be printed on one side only, best results are obtained by printing on felt side. Postage stamps are printed on wire side and then gummed on felt side, where the smoothness is helpful for attaining an even application.

CARTON PROCESS FLOW>>>>

Class 0 (Critical) (Major) (Minor)

Wrong Artwork

Wrong Text & Barcode

Wrong Printing Color

Wrong panel printing

Water absorbing

outer liner

No. of plies deviation

Short dimensions

Low box

Compression

Strength

Tearing of outer

paper

Improper Creasing

High Moisture

Flaps size deviation

Improper side pasting

Grammage deviation

Un related things

(physical hazards)

Liner separation

(Lesser binding)

Misprinting

Quantity

variation in

bundles

Tearing of inner paper

Two side pasting,

Sharp edges

Carton binding

BOX PROCESS FLOW>>>>

Class 0 (Critical) (Major) (Minor)

Wrong Artwork

Wrong Text & Barcode

Wrong/right grain of

board

Wrong Printing color

Dimension

Difference

Low Box Board

Strength

Grammage Variation

Improper Creasing

High Moisture

Flaps size deviation

Improper side and clutch

pasting

Inappropriate clutch lock

Weak Perforation

Un related things

(physical hazards)

Mis-Registration

Quantity variation in

cases

Embossing (if in artwork)

Flaps lock cut problem

Box Binding

Wrong orientation of flap

Scratches

Stickiness

Receiving of Sheets

Printing

Film Lamination

Die cutting

Breakage o f Boxes

Grinding, Gluing, Pasting

Packing

Test for Packaging items:

Test for Boxes:

Grammage Dimension Moisture Tearing strength Stiffness test Colour test Creasing test Weight of box Bursting strength Thickness Box compression test

Test for Cartons:

Grammage Dimension Moisture Tear test Bursting test Puncture test Edge crush test Thickness Fluting check Carton compression test

Test for Wrapper:

Grammage Wax (if paper) Dimension Tear test Co friction test Tensile test Peel off Heat seal test Sealing strength test

Water Vapor Permeability Analyzer

Application To test the water vapor transmission rate (WVTR) of packaging materials, such as plastic film, composite film, coextrusion film, aluminum-plated film, aluminum foil, infusion bag, sheets, paper, paper board, solar battery panel, cellophane, ceramics and porcelain, and various containers such as bag, pouch, bottle, can, bowl, box, widely used in the industries of food, pharmaceuticals, personal care, household, electronics and so on.

Working Principle Electrolytic detection sensor method. Fix the test sample in the middle of test chamber to separate the chamber into upper room and lower room. When humid gas flows in upper room and dry gas in lower room, the water molecules in upper room penetrate through the sample into the dry gas, and electrolytic sensor system detect and analyze the water content and calculate the water vapor transmission rate. Features 1. Temperature control: International advanced electromagnetic technology, program controlled, and no need of external accessories. Precision: 0.1℃. 2. Humidity control: Dual gas flow method, with broad range, high precision and stable flow. 3. Standard gas calibration and standard film calibration. 4. Auto judgment and auto stop. 5. Leakage protection; over range protection; auto save data when power is cut off; incorrect operation warning. 6. Wholly automatic, software easy to use. Curves of transmission rate, water vapor density, humidity and temperature, auto record and continuous display. Can easily monitor interaction of parameters and the whole testing process. 7. Highly modularized. Setting, testing, baseline, calibration, report etc are independent. Powerful data analysis. Easy to operate. 8. Built-in computer, can work without external computer. 9. Support quick test, applicable to evaluation test. 10. Two chambers can work independently at the same time for two different samples. 11. Software upgrade, data backup and fault diagnosis through USB port. Specifications Test range 0.001~100 g/(m2•24h) Test precision 0.001 g/(m2•24h) (film and sheet) Temperature range 15~45℃(5~55℃ optional) Temperature precision ±0.1℃

Humidity range 0﹪RH, 30~90%RH, 100%RH Number of samples 1~2 pieces Test area 50.24cm2 Sample size Φ100mm Sample thickness ≤ 2mm Carrier gas 99.999% N2 (user provide) Carrier gas pressure ≥ 0.1Mpa

Instrument size 610mm x 550mm x 400mm

Oxygen Permeability Analyzer Application To test the oxygen transmission rate (OTR) of packaging materials, such as plastic film, composite film, coextrusion film, aluminum-plated film, aluminum foil, infusion bag, sheets, paper, paper board, solar battery panel, cellophane, ceramics and porcelain, and various containers such as bag, pouch, bottle, can, bowl, box, widely used in the industries of food, pharmaceuticals, personal care, household, electronics and so on. Working Principle Coulometric sensor method. Fix the test sample in the middle of test chamber to separate the chamber into upper room and lower room. When oxygen flows in upper room and nitrogen in lower room, the oxygen molecules penetrate through the sample into the lower room, and coulometry sensor system detect and analyze the oxygen content and calculate the oxygen transmission rate. To test container, oxygen is outside and nitrogen is inside of the container. Features 1. Adopts international advanced electromagnetic temperature control technology can control temperature rising and lowering without any external accessory. 2. The humidity control adopt double air humidity control method, humidity control area is large and with high accuracy. 3. Has two calibration methods: standard gas calibration and standard film calibration. 4. Has the functions of double cavity pressure control and automatic pressure balance. 5. Can judge and stop automatically. 6. Has leakage auto protection function. 7. The software operation is easy, all testing program is automatic. It records and continuously displays the curves of the permeation rate, oxygen concentration, humidity and temperature. It can monitor the mutual influence between the parameters. 8. Has good ability of data analysis, easy to operate Specifications Test range 0.02 ~ 16500 cm3/(m2•24h) (max possibility: 260000 cm3/(m2•24h)) Temperature range 15°C~45°C (5°C~50°C optional) Temperature accuracy ±0.1°C Gas supply pressure 0.1~0.2MPa Environment temperature 23°C Sample size Φ100mm Test area 50.24cm2 Sample thickness ≤ 2mm Number of samples 2 pieces Carrier gas port 1/8 inch Instrument size 630mm x 560mm x 350mm Power supply AC 220V 50Hz

Instructions

1 Study the bar code. The first digit indicates the type of product.

2 Digits 2 through 6 are the manufacturer's identification number, which is chosen by the Uniform Code Council.

3 The manufacturer creates digits 7-11 to differentiate its products from other manufacturer's products.

4 The last digit is the check digit, which corrects erroneously keyed bar codes. To check the validity of the hand-keyed bar code, cashiers use a multiplication algorithm to get a sum equal to the check digit.

HOW TO READ BARCODE WITH THE HELP OF LINES

DIGIT CODE

0 3211

1 2221

2 2122

3 1411

4 1132

5 1231

6 1114

7 1312

8 1213

9 3112

• Note that bar codes are made up of both white

and black lines. The white spaces in between

the black lines are part of the code.

• Understand that there are four different

thicknesses to the lines. Henceforth, the

skinniest line will be referred to as "1," the

medium-sized line as "2," the next largest line as

"3." and the thickest is "4."

• If we consider 0 digit and we make their code

with the help of line so first we read from the

left side. The white thick line is equal to 3

numbers as we discuss above. Than we read

black which is equal to 2 and than white and

black which is equal to 1 digit. The code will be

3211.

• We read whole barcode by the help of above

method.

ANOTHER WAY TO READ BARCODE

DIGIT CODE

0 0001101

1 1100110

2 1101100

3 0111101

4 1011100

5 1001110

6 0101111

7 1000100

8 1001000

9 1110100

• Note that bar codes are made up of both

white and black lines. The white spaces in

between the black lines are part of the code.

• Note that black skinniest line is equal to 1 and

also white skinniest line is equal to 0. If three

black lines attached together so we read as

111 and just like this we read other lines.

SYMBOLS MEANING SYMBOLS MEANING

Do not use hand hooks

Handle with care

This way up

Do not roll

Keep away from sunlight

Content should be stored at 10 to 20 •c

Keep away from water

If you are not happy with the quality of the

product than call on customers service

numbers

Centre of gravity

Suitable for vegetarian

Do not clamp as indicated

Symbol suggest that customers should aware

that the product could contain wheat, gluten

and nut

Recyclable

Used dustbin

90 perc recyclable so used recycle bin

Do not stand on carton

Clamp as indicated