The document discusses the history and evolution of packaging from early natural materials to modern developed materials like plastics and metals. It provides details on the functions of packaging including physical protection, barrier protection, containment, convenience, and security. The document also discusses considerations for package design such as requirements, regulations, sustainability, and relationship to the product and logistics. Key factors in packaging machinery selection and common machinery types are outlined. Advantages and challenges of returnable packaging versus expendable packaging are compared.

2.  The first packages used the natural materials available at the time: Baskets of reeds,
wineskins ,Bota bags, wooden boxes, pottery vases, ceramic amphorae,
wooden barrels, woven bags, etc. Processed materials were used to form packages as
they were developed: for example, early glass and bronze vessels. The study of old
packages is an important aspect of archaeology.
 The earliest recorded use of paper for packaging dates back to 1035, when
a Persian traveler visiting markets in Cairo noted that vegetables, spices and hardware
were wrapped in paper for the customers after they were sold.
 Iron and tin plated steel were used to make cans in the early 19th
century. Paperboard cartons and corrugated fiberboard boxes were first introduced in
the late 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. In-plant recycling has long been
common for production of packaging materials. Post-consumer recycling of aluminum
and paper based products has been economical for many years: since the 1980s, post-
consumer recycling has increased due to curbside recycling, consumer awareness,
and regulatory pressure.

3.  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 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, sterile and safe for the intended shelf life is a primary
function.
 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 granular
materials need containment.
 A single-serving shampoo packet
 Security – Packaging can play an important role in reducing the security risks of
shipment. Packages can be made with
 Convenience – Packages can have features that add convenience in distribution,
handling, stacking, display, sale, opening, reclosing, use, dispensing, and reuse.

5.  Package design and development are often thought of as an integral part of
the new product development process. Alternatively, development of a package (or
component) can be a separate process, but must be linked closely with the product
to be packaged. Package design starts with the identification of all the
requirements: structural design, marketing, shelf life, quality assurance, logistics,
legal, regulatory, graphic design, end-use, environmental, etc.
 An example of how package design is affected by other factors is the relationship
to logistics . When the distribution system includes individual shipments by a small
parcel carrier, the sortation , handling, and mixed stacking make severe demands
on the strength and protective ability of the transport package.. A package
designed for one mode of shipment may not be suited for another.

6. sustainable packaging:
Package development involves considerations for sustainability,
environmental responsibility, and
applicable environmental and recycling regulations. It may involve a life
cycle assessment[16][17] which considers the material and energy inputs and
outputs to the package, the packaged product (contents), the packaging
process, the logistics system, waste management, etc. It is necessary to know
the relevant regulatory requirements for point of manufacture, sale, and use.
The traditional “three R’s” of reduce, reuse, and recycle are part of a waste
hierarchy which may be considered in product and package development.
Waste hierarchy

7. A choice of packaging machinery includes: technical capabilities, labor
requirements, worker safety, maintainability, serviceability ,reliability, ability to
integrate into the packaging line, capital cost , floor space , flexibility (change-
over, materials, etc.), energy usage, quality of outgoing packages, qualifications
(for food, pharmaceuticals, etc.), throughput, efficiency, productivity ,ergonomics
, return on investment, etc.
Packaging machinery can be:
 purchased as standard, off-the-shelf
 purchased custom-made or custom-tailored to specific operations
 manufactured or modified by in-house engineers and maintenance staff.

8.  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, powered, 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.
 Weighing Machines: Check weigher, multihead weigher
 Wrapping machines: Stretch wrapping, Shrink wrap, Banding

9. Bakery goods shrink wrapped by High speed conveyor with
shrink film, heat sealer and heat bar code scanner for sorting
tunnel on roller conveyer transport packages.
Robotics used to palletize
Automatic stretch wrapping bread Equipment for
machine thermoforming packages at
NASA

10. General saving advantages of returnable packaging;
Reduces total cost
• Improves product protection
• Improves workers safety
• Improves housekeeping
• Improves space utilization
• Improves environmental impact
Reduces cost
•Export packaging is typically used once and then thrown away. The cost of this package is added into
the product unit cost. Returnable packaging eliminates this recurring cost. If your packaging will
remain constant for a long period, returnable containers and dunnage are frequently lower in annual
cost than expendables.
• The Initial investment will be much higher, however. Over a period of time, the cost of a returnable
container system is typically much less than that of expendable one-way packaging.
• improves product protection
•Returnable containers are constructed to support heavy loads and to provide excellent resistance to
impact, resulting in better protection of the product carried inside.
• A well-designed returnable package can often provide more handling and storage protection then an
expendable packaging.
• mproves workers safety
•Returnable containers and pallets provide handles and smooth grasping areas for ease of use
and reduce worker injuries.
• A returnable can often be fitted with material-handling features, like handles, that would not be
economically feasible with an expendable container.
• Improves housekeeping
•Returnable packaging eliminates dirt, dust, and the trash clean-up associated with expendable
packaging.
• Improves space utilization

11. An example;
1 returnable with a lifetime of 100 turns replaces 100 expendable containers.
Weight for the expendable; 25 kg
Weight for the returnable; 40 kg
T otal packaging material weight saving would be;
100 x 25 – 1 x 40 =2,460 Kg !!!
Important note : The principal driving force since the 1980s has been pressure from environmental sources .

12. General disadvantages of returnable packaging;
• Large capital expense or high Initial Investment
• Increased transportation expense, mainly for the returns
• Cost for tracking and accounting and sometimes cleaning
• Storage space for empties
•Large capital expense
Initial cost is probably the largest deterrent to the wide use of returnables. Savings over time have to be
significant to justify the capital expense. On the other hand, by the experience we have had, Pay-Off-
time for the Investments are normally <1 year, which means the Investment is quickly covered.
•Increased transportation expense
Returnables have to be returned and the return trip is usually not free. The cost must be factored in. Our
experience shows that the return cost is normally dominating over other costs. The degree of
“collapsibility” or “nestability” of containers and dunnage is of key importance and increases with
shipping distance.
•Cost for tracking and accounting
Because returnable packaging is relatively expensive, it´s important that they don´t get lost in the return
system. A loss rate of 10% losses per trip will give the result of complete system loss in just 10 cycles (10%
loss x 10 cycles results in 100% loss). On top of this cleaning might sometimes be an issue.
• Storage space for empties
It typically takes more space to store empty returnable packaging than to store expendable packaging
due to strength and design.