Semester 1 - IoPP

1 Fundamentals of Packaging Technology Seminar Course Outline Semester 1. Day One Course Introduction Course Overview 1-3 Market Research Course Logistics Why perform market studies Market study tools 1-1 Perspective on Packaging Broad based studies Demographic Workshop: Part One Focused studies A definition of packaging Updating persona through market The historical evolution of packaging research and packaging materials The industrial revolution and packaging 1-4 Graphic Design Growth of modern packaging roles Demographic Workshop: Part Two The modern packaging industry Technical and communication roles compared 1-2 Package Development The importance of demographic and Process psychographic information Management of the packaging function The modern retail environment The package as the purchase motivator Project Scope and objectives Fundamental messages: Cords of The package development process familiarity and points of difference The package design brief Equity and brand names Specifications Emotional aspects of color Basics of graphic design: balance, unity, direction, typography and illustrations Day Two 1-5 Introduction to Printing 1-6 Printing Methods and Printing Methods Preparing the artwork, prepress proofing Flexographic and Related Relief Printing Processes Package printing methods and printing presses Nature and production of the printing plate Line art, color selection and Pantone Matching System Configuration of the printing station Halftone art, screens and screen sizes Advantages and limitations of flexography Process art, moire patterns Offset letterpress (dry offset) and Color bleeds, trap, special colors applications Fundamentals of Packaging Technology Seminar Course Outline Semester 1.

2 Day Two, Cont. Lithography Gravure Nature and production of the printing Nature and production of the printing plate plate Configuration of the printing station Configuration of the printing station Advantages and limitations of lithogra- Advantages and limitations of gravure phy Principal packaging applications of Principal packaging applications of gravure lithography Special Decorating Techniques Screen, heat transfer, hot stamp and pad printing, reflective metallics and surface gloss Day Three 1-7 Color Perception 1-9 Labels and Labeling Physics of color The functions of a label The human perception of color Types of labels Additive and subtractive color synthetics Label forms Ink as a modifier of light Label materials The four process printing colors Affixing labels Standard color viewing conditions The visual comparison of colors 1-8 Electronic Product Coding EPC advantages through the supply chain EAN/UPC symbologies UPC structure RFID tags RFID readers RFID advantages For details and registration: RFID limitations Fundamentals of Packaging Technology Seminar Course Outline Semester 2.

3 Day One Please bring a calculator 2-1 Paper and Paperboard Dimensioning, grain direction Fiber sources and fiber quality Die-boards and paperboard cutting and Furnish make-ups creasing Fourdrinier and cylinder-type paper Folding carton manufacture machines Set-up boxes, designs, applications and Machine direction and cross direction limitations Coatings, calendaring and other treat- 2-3 Corrugated Fiberboard ments Containerboard grades and standard Paper characterization flute sizes Paper and paperboard grades and General applications of standard flutes applications Mullen Test and edge crush tests (ECT). 2-2 Folding Cartons Using McKee formula to estimate box General paperboard construction classes compression strength General design considerations Carrier rules and regulations Tube-style folding cartons: basic designs Corrugated board manufacture and variations Single, double and triple wall boards Tray-style cartons: basic designs and Microflute and wave flute comparisons variations Day Two Please bring a calculator 2-4 Corrugated Boxes General industry tolerances Regular slotted container (RSC) produc- Wax and other treatments tion and styles Die cut container production and style 2-5 Box Compression examples Strength Workshop Bliss box styles Standard compression strength measure- Decorating by direct printing (post ment printing) Difference between compression Preprint, litho labeling and litho strength and stacking strength laminating options Impact of humidity, time, pallet pattern Scoring allowances and overhang Dimensioning corrugated containers and pads Using Fibre Box Association stacking strength factors Fundamentals of Packaging Technology Seminar Course Outline Semester 2.

4 Day Two, Cont. Calculating required compression Vibration sources, relative movement strength damage Determining required ECT values to Resonance, stack resonance, load meet required stack strength skewing Stacking HDPE bottles Unit loads and unit load efficiency Tracking and acting on distribution losses 2-6 Distribution Environment Industry guidelines and practices Package transport and distribution hazards Pallet issues A systems approach to distribution pack- Recommended minimum and aging maximum container dimensions Sources of shock inputs and effects Recommended load stability Good shipping practices Day Three 2-7 Protective Packaging 2-8 Pre-Shipment Testing Understanding G factors Purpose Damage boundary curves ISTA test procedures Cushioning against shock ASTM D4 169 test procedures Selecting cushioning materials Planning a pre-shipment test Using dynamic cushioning tables Spring-mass relationships and isolating 2-9 Industrial Packaging inputs 2-10 Wood Packages For details and registration: Fundamentals of Packaging Technology Seminar Course Outline Semester 3.

5 Day One 3-1 Introduction to Polymers 3-3 Packaging Polymers Structure of HDPE, LDPE, LLDPE and 3-2 Polymer Chemistry mPE. Polymers, plastics and polymerization Polyethylene density and property trends Polymer classifications Structure and general properties Terminology and abbreviation of polypropylene, poly(vinyl) and poly(vinylidene chloride), polystyrene, Copolymers and properties poly(vinyl alcohol), poly(vinyl acetate). A review of basic chemical concepts and ethylene-vinyl acetate, polyamide, Polarity, solubility, permeability and poly(ethylene terephthalate), other lesser barrier used polymers Coefficient of friction and adhesion Thermosets and thermoplastics compared; thermoset applications Glass transition and melt temperatures Thermal history and crystallinity 3-4 Property Comparisons Oriented plastics and shrink plastics General properties of packaging polymers Hydrocarbons and polyethylene Factors affecting barrier properties Oxygen and moisture vapor barrier comparisons Classes of polymer additives Day Two 3-5 Extrusion molding Basic form-fill-seal machines Plasticating extruders High barrier constructions Cast and blown plastic film and sheet Wet bond, dry bond, and extrusion Co-extruded and oriented plastic films laminating Video presentation.

6 Analytical and Specifying plies, caliper, and roll Physical Testing orientation Example laminate constructions 3-6 Flexible Packaging 3-7 Thermoforming Aluminum foil properties and applications Extruded profiles and typical packaging Vacuum metallizing process applications Metallized paper and film applications Common thermoforming methods and materials Structural, barrier, sealing and aesthetic properties Thermoform packaging applications Fundamentals of Packaging Technology Seminar Course Outline Semester 3. Day Two, Cont. 3-8 injection molding The injection molding process injection molds, tooling costs Sprues, runners, gates and undercuts Part characteristics and packaging applications Day Three 3-9 Blow molding 3-11 Closures The extrusion blow molding process Closure selection criteria Parisons and parison programming Container finish standards and thread The injection blow molding process styles injection stretch blow molding Closure dimension designations Extrusion and injection blow molding Closure liner functions and types compared Common plastic closure designs General bottle design considerations Metal continuous thread, lug, roll-on, press-on and crown closures 3-10 Bottle Design Criteria Child-resistant and tamper-evident General design elements designs Decorating options Special bottle designs Environmental stress cracking For details and registration: Fundamentals of Packaging Technology Seminar Course Outline Semester 4.

7 Day One 4-1 Environmental Issues Measuring sustainable packaging . Defining packaging's role in the solid Wal-Mart's sustainable scorecard waste issue No single sustainable solution . Proportion of packaging in the waste Creating sustainable packaging strate- stream gies, yet implementing them one step at The four R's hierarchy: reduce, reuse, a time. recycle and recover Environmental concerns and the con- 4-2 Adhesives sumer Mechanical and specific theories of The packaging professional's role in the adhesion environmental issue Surface tension and dyne level Adhesive viscosity Starch, dextrin, and casein adhesives 4-1A Sustainable Packaging and their applications The concept of cradle-to-cradle product Emulsion adhesives: advantages, appli- design cations, green strength The need to push packaging system Hot melt adhesives: advantages, and boundaries applications Central definitions of sustainable pack- Elastomeric and cold seal adhesives: aging advantages and applications Design strategies that implement the Good manufacturing practices definitions Trouble shooting adhesive problems Day Two 4-3 Metal Containers 4-4 Aerosols Can-making metals Component parts and operation Welded, adhesive, bonded and Aerosol propellants and formulations mechanical clinch three-piece cans Other pressurized dispensing systems Shallow draw, draw and redraw, draw Aerosol container legal requirements and iron two-piece cans Impact extruded cans and collapsible 4-5 Glass Packaging tubes Raw materials for soda glass and special Protective coatings and decorations glasses Sizing conventions The glass furnace and glass manufacture Fundamentals of Packaging Technology Seminar Course Outline Semester 4.

8 Please bring a calculator Day Two, Cont. Blow-and-blow and press-and-blow bottle production 4-9 Production Line Workshop Surface coatings and annealing Basic design layout and assignment of Decorating options machine speeds Video presentation: Efficiency and output, calculating Glass Bottle Manufacture production line efficiency Purpose and placement of buffers 4-6 Special Designs 4-10 Laws and Regulations Statutes versus regulations Role of the Federal agencies Day Three Fair Packaging and Labeling Act Food, Drug and Cosmetic Act Federal Insecticide, Fungicide and 4-7 Packaging Machinery Rodenticide Act Package design and machine-ability Hazardous Materials Transportation Act The packaging machine industry Miscellaneous acts impacting Stock machines and custom machines packaging Intermittent and rotary machine 4-11 Packaging Software configurations Standards Applications Use in Fast changeovers Packaging 4-8 Filling Systems Special Packaging Applications Product categories and filler selection Graphics Design Fill-to-level liquid filling systems Structural Design Fill-to-volume liquid filling systems Specifications Flask fillers Spatial Efficiency Auger fillers Performance Design Gravimetric filling Test and Measurement Support Statistical combining methods or filling For details and registration.