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In this lecture
Plastic packaging
Assoc. Prof. Pham Van Hung
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Introduction
z Plastics are: “organic macromolecular
compounds obtained by polymerisation,
polycondensation, polyaddition or any
similar process from molecules with a
lower molecular weight or by chemical
alteration of natural macromolecular
compounds”.
z Introduction
z Advantages and disavantages
z Classification of plastic packages
z Plastic materials
z Manufacture of plastic packaging
z Environmental problem
Introduction
z The first plastics were appeared in the
first haft of the 20th century.
z Polyethylene, the most widely used
today was invented in 1933
today, 1933.
z About 50% of Europe’s food is packed in
plastic packaging.
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Classification Classification

z Plastics can be classified into two types z Thermoplastics:

z Thermoplastic z is a material which becomes soft when
heated and hard when cooled.
z Thermoplastic materials can be cooled
and heated several times.
z Thermosetting z They can be recycled.
z Thermoplastic can be moulded into any
shape.

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Classification Advantages

z Thermosettings z flowable and mouldable under certain

conditions, to make sheets, shapes and
z can be moulded once by heat and pressure. structures
z They cannot be resoftened, as reheating z generally chemically inert, though not
causes the
th material
t i l tto d
degrade
d => nott used
d to
t necessarily impermeable
any great extent for food packaging. z cost effective in meeting market needs
z Its polymer chains are joined together by z lightweight
cross-links, so they cannot slide past each z provide choices in respect of transparency,
other easily. colour, heat sealing, heat resistance and
barrier.

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Disadvantages Use of plastics in food packaging

z can lose shape, crush under weight or break
and split easily during transportation.
z Maybe lack sufficient heat resistance.
z draws dust
z not always airtight
z Plastic pollution has become a worldwide
concern
z The plastics offer a wide range of appearance
and performance properties.
z Resistant to many types of compounds: not
veryy reactive with inorganic
g chemicals ((acids,
Alkaline) and organic solvents.
z May absorb some food constituents, such as
oils and fats => Check all food applications for
absorption and migration.
z Do not support the growth of microorganisms

Use of plastics in food packaging Use of plastics in food packaging

z Gases (O2, CO2, N2), water vapor and organic z Rigid plastic containers: bottle, jars, pots,
solvent permeate through plastics. tubs and trays
z The rate of permeation depends on:
z Type
yp of p
plastic
z Thickness and surface area
z Method of processing
z Concentration or partial pressure of the permeant
molecule
z Storage temperature

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Use of plastics in food packaging
z Flexible plastic film: bags, sachets,
pouches, …
Use of plastics in food packaging
z Plastic lids and caps
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Use of plastics in food packaging
z Combination with paper board: Liquid
packaging carton
Type of plastics used in food packaging
z polyethylene (PE)
z polypropylene (PP)
z polyesters (PET, PEN, PC) (note: PET is referred to as PETE in some markets)
z ionomers
z ethylene vinyl acetate (EVA)
z polyamides (PA)
z polyvinyl chloride (PVC)
z polyvinylidene
l i lid chloride
hl id (PVdC)
z polystyrene (PS)
z styrene butadiene (SB)
z acrylonitrile butadiene styrene (ABS)
z ethylene vinyl alcohol (EVOH)
z polymethyl pentene (TPX)
z high nitrile polymers (HNP)
z fluoropolymers (PCTFE/PTFE)
z cellulose-based materials
z polyvinyl acetate (PVA).
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PET or PETE (#1) HDPE (#2)

Polyethylene Terephthalate High Density Polyethylene

z A clear, tough, polymer with exceptional z Used in milk, juice and water containers in
gas and moisture barrier properties
properties. order to take advantage of its protective
barrier properties

z PET’s ability to contain carbon dioxide

z Its chemical resistance properties make it a
(carbonation) make it a good choice in soft good choice as container for household
drink bottles. chemicals and detergents.

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Vinyl (#3) LDPE (#4)

Polyvinyl chloride, or PVC or V Low density polyethylene

Excellent clarity, puncture resistance z Makes bottles that requires flexibility

y
and cling z Produces grocery bags and garbage
z Film vinyl can breathe, making it ideal bags, shrink and stretch film and the
for meats coating for milk cartons

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PP (#5) PS (#6)
Polypropylene Polystyrene
z In its crystalline form, it is a colorless plastic that
z High tensile strength, ideal for caps and can be clear and hard.
lids with threaded openings z It can also
l be
b foamed
f d to
t provide id exceptional
ti l
z High melting point so can be hot-filled with insulation properties. Foamed or expanded
products that then will cool polystyrene (EPS) is used for products such as
z Also used for products that need to be meat trays, egg cartons and coffee cups.
incubated, such as yogurt z It is also used for packaging and protecting
appliances, electronics and other sensitive
products

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OTHER (#7) WHAT THIS MEANS FOR YOUR EVERYDAY PLASTIC USE

z Other resins z Seriously consider the use of plastics numbered 1, 3,

6 and 7 (polycarbonate): all of which have been shown
z Combined structures to leach dangerous chemicals. This does not
necessarily mean the others are completely safe, just
that theyy have been studied less to date.
z So if you have to use plastic, it is safest to stick to
numbers 2, 4, 5 and 7 (other than polycarbonate)
whenever possible.
z If an item does not have a plastic code on it, or if the
type of plastic is unclear from the code (e.g., with #7, it
likely will not say it is polycarbonate), Ask the
manufacturer!!!
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Manufacture of plastic packaging Manufacture of plastic packaging

Extruder
- The plastic raw material, resin, is usually
supplied by the polymer manufacturer in
the form of p
pellets.
- The first major step is to change the
pellets from solid to liquid or molten phase
in an extruder.
z The plastic is melted by a combination of high
pressure, friction and externally applied heat.
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Manufacture of plastic packaging Manufacture of plastic packaging

Extrusion Processing of plastic packaging
-In the manufacture of film and sheet: the
molten plastic is forced to flow through a - Molten plastic packaging.
die orifice to provide long g continuous
product.
- Rigid plastic packaging.
-In the manufacture of rigid packaging,
such as bottles and closures: the molten
plastic is forced into shape using a
precisely machined mould.
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Manufacture of molten plastic packaging Manufacture of molten plastic packaging

z Plastic film z Methods of processing the molten

z less than 100 mm thick. plastic
z Used to wrap product, to overwrap z The cast film process:
packaging,
p g g, to make sachets,, bags
g and
z the blown,
blown or tubular,
tubular film process:
pouches.
z Plastic Sheet
z Thicknesses up to 200 mm.
z Used to produce semi-rigid packaging
such as pots, tubs and trays.

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Manufacture of molten plastic packaging Manufacture of molten plastic packaging

The cast film process: the molten plastic is extruded The blown, or tubular, film process:
through a straight slot die onto a cooled cylinder, ¾ The molten plastic is
known as the chill roll continuously extruded
through a die in the form of
a circular
i l annulus,
l so that
th t it
emerges as a tube.

¾ The tube is prevented from

collapsing by maintaining air
pressure inside the tube or
A die configurations for extruding sheet & film.
bubble

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Packaging manufacture Manufacture of plastic pouch

9 Made from laminates.
z Plastic bags are made by folding, cutting and 9 The pouches travel
sealing with welded seams which are also cut horizontally on the
machine with the
in the same operation. product filled vertically.
z Pouches are usually made from laminates. 9 Sealing (inside face to
inside face) on three
z F
Free-flowing
fl i products
d t (granules
( l and d powders)
d ) sides prior to filling and
can be filled vertically on form, fill, seal closing.
machines where the film is fed vertically from
the reel.
z Solid products (chocolate bars, biscuits) are
packed horizontally on form, fill, seal machines.

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Manufacture of plastic pack Manufacture of plastic pack

z Solid products
9 Free-flowing products such as
such as granules and chocolate bars
powders can also be are packed
filled vertically on form, horizontally on
fill seal machines.
fill, machines form, fill, seal
machines.
9 These packs are
z Biscuits can be
formed around a tube,
packed in this
through which the
way, provided
previously apportioned they are collated
product passes. in a base
(plastic) tray

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Manufacturing of plastic packaging Manufacturing of Rigid plastic packaging

Extrusion blow moulding:

z See movie 1, 2, 3, 4, 5!
- Used to make bottles.
- Used for milk bottles (HDPE) and wide mouth jars.

I j ti blow
Injection bl moulding:
ldi
- Used to make more precision neck finish of container
- a two-stage process: Injection moulding and blow
moulding.
- Injection stretch blow moulding is used to make PET
bottles for carbonated beverages.
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Extrusion blow moulding Injection Blow Molding

(1) parison is injected and molded around a blowing rod.

™ A thick tube of plastic is extruded into a bottle mould which closes
around the tube.
™ Air pressure is then used to force the plastic into the shape of the mould.
™ After cooling, the mould is opened and the item removed.
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(2) injection mold is opened and parison is transferred to a blow mold.
(3) Then blow moulded in a second operation, while retaining the
accurate dimension of the neck finish.
(4) blow mold is opened and blown product is removed.
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Thermoforming Manufacturing of Rigid plastic packaging

z There are many food applications for z See movie 6, 7, 8!

rigid and semi-rigid thermoformed
containers.
z A wide range of dairy products,
products yoghurts
yoghurts,
z Thermoforming can be combined with
packing on in-line thermoform, fill and
seal machines.

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Environmental Problems
z Plastic is a growing disaster.
z Most plastics are made from petroleum, a non-
renewable resource extracted and processed
using energy-intensive techniques that destroy The end!
fragile ecosystems.
z Plastic packaging – especially the ubiquitous
plastic bag – is an enormous source of landfill
waste and is regularly eaten by numerous marine
and land animals, to fatal consequences.

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Plastic Tips
z Here are some simple tips to help you in working
toward a life without plastic, or a life of safer, more
informed plastic use.
z Avoid polycarbonate (#7) baby bottles and sippy cups.
For baby bottles,
bottles try and use glass,
glass polyethylene or
polypropylene instead. Sippy cups made of stainless
steel (e.g., Kleen Kanteen, Purica), or of polypropylene
or polyethylene are safer. Be sure to check the bottle or
cup to be sure of the type of plastic it contains. As for
baby bottle nipples, try and use silicone which does not
leach the carcinogenic nitrosamines that can be found
in latex.
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Plastic Tips
z Try to avoid heating foods in plastic containers,
especially in the microwave oven, which can cause the
plastic to degrade and leach chemicals faster. As well,
leaching increases when plastic comes into contact
with oilyy or fatty
y foods,, or when the p
plastic is scratched,,
worn, cracked, or sticky.
z Use plastic wraps with caution, especially in the
microwave, and try to keep the plastic from touching
the food. Alternatives include wax paper or paper
towels.
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Plastic Tips
z Ifyou must use polycarbonate (#7) bottles, avoid heating
food and drink in the bottle. Heat it in a separate container
and transfer it to the bottle once it is warm enough for the
child to eat or drink. If the plastic is showing signs of wear
– scratched, cloudy – discard the container.
z For
F d i ki water, try and
drinking d avoidid plastic
l i bottles.
b l If you do
d
use plastic bottles made from #1 or #2 plastic try not to
reuse them as they are intended only for single use. One
alternative is a stainless steel water bottle. For storing
large quantities of water, glass and stainless steel
containers are also available. If you use a #1 water bottle,
try to consume the contents as soon as possible because
leaching of antimony increases with time.
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Plastic Tips
z Try and use alternatives to plastic packaging and
storage containers. Cloth, paper or cardboard are
possibilities for transporting groceries. Stainless steel
and glass food storage containers are available.
z Avoid plastic dishes and utensils for meals.
meals Alternatives
include glass, ceramic, wood, stainless steel, and
lacquer ware. Offer your child or grandchild a non-
plastic dish set made of either stainless steel or wood
(safely coated with a non-toxic lacquer).
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Plastic Tips
zThese days, plastic is so omnipresent it
can be difficult to imagine life without
plastic. Yet, our ancestors managed just
fine without itit. All it takes is a little
imagination, determination and discipline.

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