Lesson 1

HISTORY OF PACKAGE DEVELOPMENT

1.1 Introduction and History of Package Development

1.1.1 Changes in packaging to meet society’s needs

 Packaging is not a recent phenomenon.

 Packaging is an activity closely associated with the evolution of society and,

can be traced back to human beginnings.

 The nature, degree, and amount of packaging at any stage of a society’s growth
reflect the needs, cultural patterns, material availability and technology of that
society.

 A study of changing roles of packaging and forms over the centuries is a study
of the growth of civilization.

 Social changes are inevitably reflected in the way we package, deliver and
consume goods.

1.1.2 The origins of packaging

1. We don’t know what the first package was, but we can certainly speculate.

2. Primitive humans: nomadic hunter / gatherers lived off the land. Social groupings
restricted to family units.

3. They would have been subject to the geographical migrations of animals and the
seasonal availability of plant food.

4. Primitive people needed containment and carrying devices and out of this need
came the First “package” which might be

a) A wrap of leaves

b) An animal skin

c) The shell of a nut or gourd

d) A naturally hollow piece of wood

  Early packaging materials were Fabricated sacks, baskets and bags, made from
materials of plant or animal origin; wood boxes replaced hollow logs; a clay
bowl, the fire-dried clay pots (pottery and ceramic trade).

 The discovery of glass: About 1500 B.C., the earliest hollow glass objects
appeared in Mesopotamia and Egypt.

 In China, Ts’ai Lun is credited with making the first true paper from the inner
bark of mulberry trees. The name “paper” given to the Chinese invention made
of matted plant fibers.

 Paperboard cartons and corrugated fiberboard boxes were first introduced in the
late 19th century.

 In 768, the oldest existing printed objects (Japanese Buddhist charms); in 868,
the oldest existing book (the Diamond Sutra) printed, found in Turkistan.

 Iron and tin plated steel were used to make cans in the early 19th century.

 Packaging advancements in the early 20th century included Bakelite closures

on bottles, transparent cellophane overwraps and panels on cartons, increased
processing efficiency and improved food safety.

 As additional materials such as aluminum and several types of plastic were

developed, they were incorporated into packages to improve performance and
functionality.

1.1.3 The industrial revolution and modern food packaging

The Industrial Revolution started in England in about 1700 and spread rapidly. It is
the change that transformed people with peasant occupations and local markets into an
industrial society with world-wide connections. This new type of society made great
use of machinery and manufactured goods on a large scale for general consumption.

1.2 Definitions of Packaging

Packaging is described / defined in various ways:

 Packaging is best described as a coordinated system of preparing goods for

transport, distribution, storage, retailing, and use of the goods.
 Packaging is a complex, dynamic, scientific, artistic, and controversial business
function.

 Packaging is science, art and technology of enclosing or protecting products for

distribution, storage, sale, and use. Packaging also refers to the process of
design, evaluation and production of packages.

 Packaging is an act of providing outer covering to an object or an act of putting

the product in container or enclosing the object.

 Packaging is a technique of using appropriate forms of container and

components so as to protect, carry, identify and merchandize the content.

 Packaging may be defined as the protection of materials of all/any kind by

means of container so designed as to prevent damage to the contents by outside
influences.

 Packaging is a means of ensuring safe delivery of the product to the ultimate

consumer in sound condition at minimum cost.

 Packaging is a techno-economic function aimed at minimizing costs of delivery

while maximizing sales (and hence profits).

 Dictionary meaning: To package i.e. to put (a commodity) into protective

wrapper or container for shipment / transport or storage.

 Package means a covering wrapper or container which attracts the eye of the
customer and at the same time protects the merchandize.

 Packaging is descried as a complex, dynamic, scientific, artistic and

controversial segment of business. It is certainly dynamic and constantly
changing. New materials need new methods, a new methods demand new
machinery, new machinery results in better quality and better quality opens up
new markets which require changes in packaging. The cycle is repeating.

 Packaging is an all-embracing term and covers the operation of cleaning, giving

protective coating, weighing and filling, closing, labeling, surface designing,
printing, cartooning and bracing, containerizing, marketing and may also
include material handling.

 Packaging is defined as “the enclosure of products, items, or packages in a

wrapped pouch, bag, box, cup, tray, can, tube, bottle, or other container to
 perform the following functions: containment; protection or preservation;
communication; and utility or performance.” If the device or container
performs one or more of these functions, it is considered a package. This
definition implies that packaging serves more than one function; i.e., it is
multifunctional.

Packaging functions range from technical ones to marketing oriented ones as shown in
the following Table 1.1

Table 1.1 Functions of packaging

Technical Functions Marketing Functions

contain measure communicate promote
protect dispense display sell
preserve store inform motivate

Technical packaging professionals need science and engineering skills, while

marketing professionals need artistic and motivational understanding.

1.3 Changing Needs and New Roles

 All historical changes have had an impact on the way products are bought,
consumed and packaged.

 Packaging is important to food supply because food is organic in nature (an

animal or plant source) and one characteristic of such organic matter is that it
has a limited natural biological life.

 Most food is geographically and seasonally specific.

 In a world without packaging, we would need to live at the point of harvest to

enjoy these products, and our enjoyment of them would be restricted to the
natural biological life span of each.

 It is by proper storage, packaging and transport techniques that we are able to

deliver fresh potatoes and Apples, throughout the year and throughout the
world.
  We are free of the natural cycles of feast and famine that are typical of societies
dependent on natural regional food-producing cycles.

 Central processing and pre-packaged food has the advantage that it allows
value recovery from what would normally be wasted and the By-products of
the processed-food industry form the basis of other sub-industries.

 The economical manufacture of durable goods also depends on sound

packaging. A product’s cost is directly related to production volume,
distribution and packaging.

 Humankind’s global progress is such that virtually every stage in the

development of society, packaging is present somewhere in the world today.

1.3.1 The United Nations and packaging

a. The less-developed countries do not have adequate land to raise enough food.

b. Food goes beyond its natural biological life, spoils, is lost, is infested with insects
or eaten by rodents, gets wet in the rain, leaks away or goes uneaten for numerous
reasons, and is lost all of which can be prevented by sound packaging principles.

c. No industry can recover secondary value from food by-products and a poor
economy can not afford wastages.

d. Packaging is perceived to be a weapon against world hunger.

1.4 Status of Packaging in India

1.4.1 Indian packaging industry

 Early 1950’s showed slow pace but 1980-85 onwards greater change was
witnessed.

 The market volume of the Indian packaging industry amounts to about Rs.
77,570 crore and has constantly grown by approximately 15 percent year per
year.

 It is expected that the pace of growth will accelerate to between 20-25 percent
per year.
 The highest demand for packaging and the associated equipment come from the
food processing industry at 50 percent and from the pharmaceutical industry at
25 percent.

 The Indian packaging industry contributes nearly 2 per cent to the country’s
overall GDP.

 Food and beverages which will apply mainly packaging are using some 60-65
per cent of all packaging materials.

 Rapid urbanization increased spending power of large growing middle class,

growing number of working women, changing life style/standard of living,
liberalization and organized retail sector are the catalysts to the growth of
packaging.

 According to the ‘India Food Report 2008’ published by Research and Markets.
The Indian food market is estimated to total about Rs. 8,82,350 crore.

 Food retail turnover is expected to grow from the current Rs 3,39,365 crore
mark to 7,27,212 crore by 2025.

 There are about 600-700 packaging machinery manufacturers, 95 percent of

which are in the small and medium sector located all over India.

 Indian packaging machinery imports are around Rs 606 crore (20-25 percent)
while the Indian packaging machinery exports are rapidly growing.

 Germany and Italy are the largest suppliers of packaging machinery to India but
focus is now shifting to Taiwan and China.

 Indian companies are now placing increasing emphasis on attractive and

hygienic packaging. This promises enormous potential for the future.

 Today consumer is showing greater awareness towards food packaging for

assurance on quality, quantity and hygiene of foods.

 Potential benefits offered by unit packaging in retailing are also well realized.

 Self service groceries, super markets (especially in urban sector) increased the
demand for retail packs.
  Changes in purchasing power, family sizes, frequency of shopping, inflation,
changed food habits lead to changes in packaging material and pack sizes.

 Every sector of user industry has become package conscious and the need for
scientific, functional and aesthetic packaging is being realized.

 Nationwide marketing becoming common trend for processed foods.

 Expanding electronic media unprecedented audience reach (Paper, radio, TV)

widen market of packaged food.

 Thus dramatic change is observed bringing overall revolution in packaging

concept, style and forms.

 New concepts like aseptic packaging, system packaging, thermoforming, in-

pack sterilization of foods have taken industrial footing in Indian market.

1.4.2 The modern packaging industry

[Link] The broad industry divisions

 “Converters”: to take various raw materials and convert them into useful
packaging materials or physical packages (cans, bottles, wraps). To this point,
packaging becomes a materials application science. The company forming the
physical package will also print or decorate the package.

 Package “users”: the firms that package products are also regarded as part of
the packaging industry and are divided into a number of categories and each of
these can be further subdivided.

 The “supplier”: manufacturers of machines for the user sector and the suppliers
of ancillary services, such as marketing, consumer testing and graphic design,
are also important sectors of the packaging industry.

[Link] Professional packaging associations

 IoPP: Institute of Packaging Professionals, Illinois, USA

 PAC: Packaging Association of Canada, Toronto

 PMMI: Packaging Machinery Manufacturers Institute, Reston, VA, USA

 FPA: Flexible Packaging Association, Linthicum, MD, USA

  WPO: World Packaging Organization, Stockholm, Sweden

[Link] Other organizations having a major impact on packaging activities

 ISO: International Organization for Standards, Geneva, Switzerland

 ASTM: American Society for Testing and Materials, Pennsylvania, USA

 TAPPI: Technical Association of the Pulp and Paper Industry, Norcross, GA,
USA

 ISTA : International Safe Transit Association, Michigan, USA

 FSSAI: Food Safety and Standards Authority of India, New Delhi

Fig. 1.1 The packaging industry can be divided into those that use packaging for
their products and those that supply to these users
 Lesson 2
IMPORTANCE OF PACKAGING

2.1 Introduction

This lesson deals with basic functions of packaging and importance of packaging in
food industry.

2.2 Functions of Packaging

The functions of a package are “to preserve the quality and freshness of food, to add
appeal to the food to attract consumers, and to facilitate its storage and distribution.”
The basic functions required of a package can be grouped under five major categories.

2.2.1 To contain the product

The primary function of any package is to contain the food and facilitate handling,
storage, and distribution all the way from the manufacturer to the ultimate user or
even the time the rest portion is utilized by the consumer. However, there are usually
various levels of packaging. A primary package is one that comes into direct contact
with the contained product, e.g., metal cans, glass jars, and plastic pouches. By law, a
primary package must not yield any substance that may be injurious to the health of
the consumer. Further development to facilitate handling is to bundle a series of
primary packages together, and this lead to the concept of secondary packages.
Examples of secondary package is corrugated box in which tins of apple juice are
packed. As methods of handling and transportation have become more sophisticated,
these secondary packages are often palletized and secured by strapping with metal or,
more commonly, by shrink- or stretch-wrapped film to give yet another level of
packaging,i.e tertiary packaging. In turn, these pallet loads may be packed into large
metal containers, i.e., quaternary packaging for transportation over long distances by
air, land, or sea. The secondary, tertiary and quaternary packaging are also known as
packing. The following are considered in this regard

• Adequate size and shape (biscuit package, tubs for detergent)

• Proper constructional features. No leakage, spillage, diffusion, i.e. loss prevention.

• Package: Must contain the commodity in natural form (biscuits packed in Pillow
pack, prevent damage)

• No subsequent damage after packaging during handling transportation and storage.

• Thus package must be strong enough to contain the commodity as it is.

• Optimum compatibility (nontoxic, non soluble with product… No physical,
chemical or biochemical changes/alteration… i.e. inert to the product.)

• Containment or agglomeration - Small objects are typically grouped together in one

package for reasons of efficiency. For example, a single box of 1000 pencils requires
less physical handling than 1000 single pencils. liquids, powders, and granules need
containment.

2.2.2 To protect the product

One of the most important function of any container is to protect the product
contained against any form of loss, damage, deterioration, spoilage, or contamination
that might be encountered throughout the distribution chain. Packaging can prevent
physical damage, e.g., bruising caused by vibrational shocks during transportation or
stacking in a warehouse. Proper packaging will also prevent material loss, e.g.,
potatoes from a weak sack or juice from a leaky can. Packaging can also protect
products against moisture loss or gain, dust, and light, especially UV light, which
causes deterioration of some light-sensitive products. It can also protect the package
contents against temperature fluctuations in the transit of chilled and frozen foods.
Packaging can also be used to control the availability of oxygen to fruits and
vegetables and to protect against loss of flavor or fragrance and help products retain
their nutritional value. Proper packaging may also protect the product against
microbial spoilage by bacteria, yeasts, and molds. It can also protect against
microbiological spoilage of stored products due to rodents and insects.

Packaging protects the product against damages which may be due to different
hazards viz. (a) Mechanical, (b) Environmental (c) Microbial and Biochemical hazard.
(d) Social Hazards.

Table 2.1 Hazard, damage and protection of packaging materials

Sr. Storage Hazard Damage Protection

No
I Handling and Drop, shunting, Breakage, loss Cushioning,
transportatio shocks, of shape, blocking.
n vibrations, dusting, seepage
stack load,
 compression
etc.
II Storage Stack load, Crushing, Adequate
compression, distortion compression
sticking, strength of package.
Attack by
resistance and
rodents and spillage,
repulsiveness to
insects contamination,
insects
spoilage
III Environment Biological or Contamination Toughness of
during otherwise packaging material
storage (to resist
transportatio penetration).
n and High/low Physical, Efficiency of closure
distribution humidity chemical and providing.
moisture/water. biological
Water vapour barrier
deterioration
properties. Package
due to loss/gain
desiccant etc.
of moisture
O2 Oxidative O2 Barrier
rancidity
Vacuum– O2

N2/CO2 flushing

packaging in
impermeable
package
 Light Vitamin Use of opaque or
Destruction, colour like Yellow,
U.V. rays
Off flavour red, brown, etc. for
development, packaging material.
Oxidative
rancidity,
Bleaching of
pigments
Storage Temperature Change of state, Heat insulation

Increase of Use of poor

moisture ingress conductor

Increased rate of Use of reflective

deterioration insulation
Time Gradual and Early/immediate
slow changes marketing (FIFO)
occur and
Proper schedule of
staling and other
dispatching order
deteriorative
providing
changes occur

Heat insulation

Use of Barrier
material

Barrier protection - A barrier from 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, and
safe for the intended shelf life is a primary function of the package.

2.2.3 Medium of communication

An important function of any food package is to identify the product and its origin; to
inform the consumer how to use the contents; to provide any other information needed
or required; and very importantly, to attract the user and encourage purchase of the
product. Package design has been an important and constantly evolving phenomenon
for many years. Marketing communications and graphic design are applied to the
surface of the package and in many cases the point of sale/display. The information a
package can convey to the consumer may include the following

• Product manufacturing and best buy dates

• Proper storage conditions

• Cooking instructions

• Size and number of servings or portions per pack

• Nutritional information per serving

• Manufacturer’s name and address

• Cost

• Suggested recipes

• Country of origin

• Information transmission - Packages and labels communicate how to use, transport

recycle, or dispose of the package or product.

2.2.4 Means of minimizing costs

An important factor often overlooked is that packaging actually reduces costs for the
consumer. Packaging reduces food costs by reducing the cost of processing. Foods
can be processed where they are grown, waste is treated at the processing plant, and
shipping weights are reduced, thereby lowering the cost of transportation. The
handling of packages in quantity is important for the economics of bulk storage,
warehousing, transport, and distribution. Proper packaging facilitates efficient and
mechanized handling, distribution, and marketing of products, thus reducing the high
labour costs that would have to be absorbed into the price of the product. Thus,
packaging not merely contains the product, but it is a process of bringing goods from
the production point to the point of use in a most beneficial manner. This involves all
aspects of handling, storage, preservation, distribution, advertising, sales promotion,
display dispensity, preparation and various other facts of industry.

2.2.5 Means of selling product

The packaging and labels can be used by marketers to encourage potential buyers to
purchase the product. Packaging is often referred to as the “silent salesman.”
Robertson (1992) concisely summarized the multifunctions of packaging when he
stated that “a package must protect what it sells and sell what it protects.” Packages
can have features which add convenience in distribution, handling, display, sale,
opening, reclosing, use, and reuse. According to Jelen (1985), primary packages
should have the following characteristics to facilitate the sale of products:

• Sanitary

• Non toxic

• Transparent

• Lightweight

• Tamper evident

• Easy to pick up and handle

• Easy to fit into cupboards, shelves, refrigerators, etc.

• Easy to open and dispense from

• Easy to reclose

• Returnable, recyclable, or reusable

• Safe and presents no hazards in the way of broken glass or sharp jagged metal edges

• Display the product

•Glamorize: Create an illusion of something very precious, by decoration, embossing

techniques and exotic closures, but it should not deceive the people.
The desirable polyfunctional properties of packaging materials are summarized in
Table 2.2.

Table 2.2 Functional requirements of packaging materials

No Functional Property Specific Factors

.
1 Gas permeability O2, CO2, N2, H2O vapor
2 Protection against Light, odor, microorganisms, moisture
environmental factors
3 Mechanical properties Weight, elasticity, heat-sealability,
mechanical sealability, strength
(tensile, tear, impact, bursting)
4 Reactivity with food Grease, acid, water, color
5 Marketing-related Attractiveness, printability, cost
properties
6 Convenience Disposability, repeated use,
resealability, secondary use
7 Aroma Aroma compound barrier property
(Source: Jelen, P. 1985. Food packaging technology. In Introduction to Food
Processing, Reston Publishing, Reston, VA, pp. 249–266.)
2.3 Other Functions of a Package

1. Dispensing: Consumers: Product not used all at once, remove a portion…without

destroying/damaging the remaining product/container.

2. Preserve: Remaining product in container-Protection and preserve it for

extended/desired period.

3. Measuring / Portion control: Single serving or single dosage package 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.

4. Security- Packaging can play an important role in reducing the security risks of
transport. Packages can be made with improved tamper resistance to deter tampering
and also can have tamper-evident features to help indicate tampering. Packages can be
engineered to help reduce the risks of package pilferage: Some package constructions
are more resistant to pilferage and some have pilfer indicating seals. Packages may
include authentication seals 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 loss prevention.

2.4 Packaging Types

2.4.1 Terms used

• Package: It cuts contact between material and outside influences. Package material
comes in direct contact with the product (Packaging).

• Pack: Secondary container. Packing material never comes in contact with product.

• Packing: Number of containers/packages put together in big container is called

pack…Process of packing.

Packaging may be looked at as several different types. For example a transport

package or distribution package is the package form used to ship, store, and handle the
product or inner packages. Some identify a consumer package as one which is
directed toward a consumer or household. It is sometimes convenient to categorize
packages by layer or function: "primary", secondary", etc.

* 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 (viz. butter in parchment paper).

* Secondary packaging is outside the primary packaging – perhaps used to group

primary packages together (viz. paper board pack containing butter wrapped in veg.
parchment paper).

* Tertiary 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 (viz. Boxes containing 20-25 or 50 butter packs are put together).

These broad categories can be somewhat arbitrary. For example, depending on the
use, a shrink wrap can be primary packaging when applied directly to the product,
secondary packaging when combining smaller packages, and tertiary packaging on
some distribution packs.

Table 2.3 Differences between packaging and packing

Reasons for selecting a particular style/type of packaging are vast and varied,
numerous and changing. Product and packaging are becoming so interdependent that
one cannot separate/consider one without another. Greatest part of food is spent in
some form of package.

2.5 Requirements for Producing Successful Package

Four sets of facts are necessary to be known for producing a successful package:

2.5.1 Facts about the product

• The nature of the product, the material from which it is made and the manner in
which it can deteriorate.

• Its size and shape.

• Its weight and density: eg., Powder – Bulk Density … size of tins

• Its weakness-which parts will break, move about, become bent or scratch or abrase
the box easily.

• Its strengths: which part will withstand loads or pressures and which might be
suitable for loading the product in the pack.

• The effect of moisture and temperature changes on the product and whether it will
absorb moisture or corrode.

• Compatibility: whether the product is likely to be affected by any of the possible

packaging materials, which items can be packed together, with protection if necessary
and which items must not be packed together under any circumstances.
• How far stripping down may be carried out to reduce the package size to a minimum
such that the customer can handle them.(Generally for merchandize foods like kitchen
machine, blender etc.)

2.5.2 Facts about the transport hazards

• The type of transport-road, rail, sea or air.

• The degree of control over the transport. Is it private or public transport?

• The form of transport- bulk, freight container, Unitized load, postal, passenger train,
etc.

• The mechanical conditions and duration of storage (manufacturer State Distributor

District Distributor … Taluka / City Retailer. The longer the journey or handling more
strength is required in packaging & packing materials leading to higher cost).

• The nature and intensity of mechanical and climatic hazards in transport, storage,
retailing and use. Packaging / packing material has to withstand wide range of
temperatures and relative humidity

• Whether handling aids are available for loading and off-loading at all points between
maker and user. (Viz. Lifts, Trolleys, Slip conveyers etc.)

• The importance of minimum volume in relation to transport costs. Over packaging

must be prevented.

[Link] Hazards may be

• Mechanical: Impact (vertical, horizontal), stationary package impacted by another,

vibration, compression, Racking or deformation, piercing, puncturing, tearing etc.

• Climatic hazard: (High / low temperature / pressure) light, liquid/water (fresh /

polluted), dust, and water vapour, R.H.

• Biological: (Microorganisms, fungi, moulds, bacteria, beetles, moths, flies, ants,

termites, mites, rodents (rats and mice), birds.

[Link] Contamination by other goods

• By materials of adjacent packs

• By leaking contents of adjacent packs

• Radioactivity.

Packaging is considered as 5th P of Management

• Protection

• Preservation

• Presentation

• Promotion

• Packaging

• Portability

• Pollution Free