COURSE TITLE: PACKAGING TECHNOLOGY

COURSE NUMBER: FPR-222

BFSc 2nd year, 2nd sem (4th semester)

Course instructors:
Dr. Tanushri Ghorai
Assistant Professor, COF, Dholi
RIGID AND FLEXIBLE
PACK AGING
RIGID CONTAINER
• A rigid container is one that is incapable of expanding or contracting.

• Key properties include high stiffness, high barrier properties, heat

resistant and high impact strength.

• When gas is pumped into a closed rigid container, the pressure

increases. If the number of gas particles (molecules) is doubled, the
pressure doubles.

• This rigid packaging material can be used in any packaging related

application.

• Rigid containers hold their shape and stand upright.

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi
 GLASS AND METAL FOR RIGID CONTAINER
• Glass material have limited usage due to heavy weight and fragile
nature.

• Metal cans should register fastest gains in rigid packaging market over
the foreseeable future.

• A steel contester is an example of a rigid container.

• Rise ¡n packaged and canned food consumption owing to increasing working

demographics may drive industry growth.

• It offers long shelf life, durability, recyclability and cost effective

advantages beneficial for economic food packaging solutions.
Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi
 RIGID PLASTIC PACKAGING
• Plastic rigid , rigid plastic packaging includes cups, bottles, pots and also
closures.

• Plastic dominates rigid packaging markets and accounted for a larger chunk of
the demand of the total market share due to low cost, firmness, light
weight, and durability.

• A rigid plastic materials is defined as material exhibiting no elastic

deformation and perfect plastic deformation.

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

• Increasing environmental concerns regarding carbon emission should
promote bioplastics as upcoming material which may drive industry
growth.
• They are suitable for all food except those with irregular shapes, like a
whole chicken.
• Non-rigid containers are moisture- vapour resistant bags and sheet
materials.

• They may be used for dry pack fruits, vegetables, meats, poultry, fish and
sometimes liquid.

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

 FLEXIBLE
PACK AGING
FILMS
• Flexible packaging is at the forefront of important packaging trends in production
protection, packaging design and performance, consumer convenience,
and sustainability which positively impacts the environment, consumers
and businesses.

• Years ago, cellophane was the only clear film used for packaging.

• Since the 1960s, innovation and technology have led to the development of
printable substrates which helped to revolutionize lighter weight packaging that
includes continued enhancements in shelf appeal, strength, product
protection, and the ability to be sealed.
Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi
• As one of the fastest growing segments of the packaging industry, flexible packaging
combines the best qualities of plastic, film, paper and aluminum foil to
deliver a broad range of protective properties while employing a minimum of
material.

• Flexible packaging is defined as any package or any part of a package whose shape
can be readily changed.

• Flexible packages are used for consumer and institutional products and in industrial
applications, to protect, market, and distribute a vast array of products.

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

• The life cycle attributes of flexible packaging demonstrate many sustainable
advantages.

• Flexible packaging starts with less waste, greatly reducing landfill discards.

• Innovation and technology have enabled flexible packaging manufacturers to use

fewer natural resources in the creation of their packaging, and improvements in
production processes have reduced water and energy consumption,
greenhouse gas emissions and volatile organic compounds.

• Even more, lighter-weight flexible packaging results in less transportation-

related energy and fossil fuel consumption, and environmental pollution.

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

ADVANTAGES OF FLEXIBLE PACKAGING
• Flexible packaging is light-weight and easy to open, carry, store, and reseal

• Flexible packaging extends the shelf life of many products, especially food, and
has a positive sustainability profile

• Flexible packaging requires less energy to manufacture and to transport, and

generates smaller quantities of greenhouse gases on its way to market

• Flexible packaging ultimately results in less consumer waste being sent to

landfills

• Widely extendible into diverse product categories

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

ADVANTAGES OF FLEXIBLE PACKAGING
• Offers consumer conveniences

• Provides reclosure and dispensing options

• Is easily transported and stored

• Creates shelf appeal

• Enables visibility of contents

• Provides efficient product to package ratios

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi
DIFFERENT TYPES OF FLEXIBLE PACKAGING MATERIALS
AND THEIR APPLICATIONS
• Packaging refers to any material of any nature used for inhibition, safety, deliverance
and conservation of goods from the producer to consumer and final users.

• Packaging materials may include aluminum foils, plastic or paper.

• Today there are numerous numbers of packaging materials which include Vacuum
Pouches, Big Bag Liner, Inner Bulk Liner, Thermoforming Film, Top Lidding Film
and Lamination Film.

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

 1. VACUUM POUCHES
• Vacuum pouches are made from a combination of
nylon and polythene which enables them to be
high moisture barriers.

• Thus, they can be used for keeping ready food such as

meat or fish and some medical products.

• Most people use them together with vacuum sealers

but they can as well be used as normal bags since
they are wholly water proof.

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

 2. BIG BAG LINER
• Big bag liners on the other hand are made from woven
polypropylene fabrics with webbed elating straps treated
with ultraviolet and static inhibitors.

• These bags can accommodate both dry and semi moist

materials such as foodstuff, Agrochemicals, cement and feeds.

• They are useful in the management of waste products thus

providing a cleaner and healthier workplace.

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

• They also pose the materials to lesser damage risk compared to
other flexible containers due to polythene liner which makes
them moisture resistant.

• They have an enhanced appearance since they are white and

clean.

• Enables high quality printing of names and company logo

thereby making a positive representation.

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

 3. INNER BULK LINERS
• Inner bulk liners are hermetically sealed giving them a
stronger barrier against outside contaminants, moisture
and even some pests.

• Their strong nature makes them dependable for maintaining

freshness and good taste of the products for a long period of
time.

• These bulk liners always offer consistency for safer

stacking and safeguard of the packed products form
hazardous conditions such as the conditions of the
atmosphere and dust from sipping into the product.
Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi
4. THERMOFORMING FILMS
• Thermoforming films are used to protect products with
greater impact strength making them ideal for both
food and non food products such as vegetables and
dried fruits, dairy products and healthcare products.

• These films always have a strong mechanical property which makes them
puncture resistant and leakage proof.

• They are also able to restrain strength at freezing temperatures and possess an
excellent optical property for base forming films.

• They are available in various oxygen transmission rates which help in extending
the shelf life of materials.
Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi
 5. TOP LIDDING FILMS
• Top Lidding films include dual oven able Lidding films,
speciality Lidding films, breathable Lidding film and high
barrier Lidding film.

• They are ideal for packaging food and non food products such as
cheese, meat, poultry and marine products, bakery and
healthcare products.

• These films are puncture resistant and provide an extended

shelf life due to their wide range of oxygen transmission rates.

• They also have a quick sealing property for faster machines

and increased output.

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

• Dual oven able film is best for packaging of
frozen food or any product which requires
heating in an oven or microwave since they are
heat resistant.

• Specialty Lidding films are ideal for trays and

cups because they are lucid, metalized and in
retort able forms.

• High barrier is used to keep products safe from

harmful bacteria while breathable Lidding films are
used to control oxygen into the products.
Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi
 6. LAMINATION FILMS
• Lamination films on the other hand use an amalgamation of
warmth and force to lamination board and the film used in the
process is pre-coated on the base by extrusion outside layer.

• Bopp (Biaxially oriented polypropylene) thermal lamination

films are best for write on or wipe off applications thus useful
for making shopping bags and textbook covers.

• Polyester gloss laminating films on the other hand are used for
dust coats and presentational folders.

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi
 LAMINATED PACKAGING FILM
• General Laminated Film is made of multiple raw material layers chosen
depending on the needs.
• Made of multiple raw material layers with barrier properties that are chosen.
• With its increased efficiency, it is widely used in high speed production for
flexible packaging because of its advantages for quickly packaging as it increases
efficiency.
• The fine printing capabilities make the final product appear much more
attractive whereas the barrier properties extend shelf life.
• Laminated film is used in a wide range of flexible packaging applications such as
food (snacks, sugar, seasoning, noodles, beverages, and biotic liquid packaging),
pharmaceuticals, personal care products, cosmetics, and many more.

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

CO-EXTRUDED LDPE/LLDPE FILM
• LDPE/LLDPE film is coextruded by three multi layers;
• It has advantages of adding MVTR barrier properties.
• Stiffer core materials and the ability to limit the use of costly sealant
resins in one layer of the film are all LDPE film advantages.
• The top surface is also very good for printing, keeping the actual
ink away from the product.
• Common applications: LDPE films are generally used in rice packaging
and other edible products.
• Another common use is the packaging of electronic components.

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

LAMINATED ALUMINUM FOIL BAGS
• Laminated aluminium foil film and bags have great seal abilities, and
good chemical and water resistance;
• Its advantages are excellent as they are opaque, with good oxygen
barrier, well formed, and maintain fresh the content with long-term
preservation.
• Laminated aluminium bag and rolls can be used on pizza wraps, beverage
packaging, coffee bags and snack food packaging, as well as cosmetic, facial
mask, bio medical packaging.

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

LAMINATED ALUMINUM PACKAGING FILM
• The laminated foil bag is made of nylon or PET/PE/AL films, and is
widely used in high speed production for flexible packaging because of
its advantages for as a quick solution for increasing efficiency.
• The laminated aluminium foil roll is resistant to water and many
chemical components.
• Combining materials on the foil makes it opaque and therefore, protects
sensitive products from light.
• It also has benefits such as being a good oxygen barrier, fine forming
properties, and that it can maintain the freshness of the product for a
long period.

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

LAMINATED BAGS WITH ONE-WAY VALVES
• Adding a one-way valve inside the bag, gasses are
released automatically and the bag is safe from bursting
and damage.
• Many food products release air which can amount to pressure
building up inside the bag.
• Since the valve is one-way, air can be released from within, but
exterior gasses cannot penetrate the packaging and corrupt the
product.
• This way, the original flavour and moisture are preserved.
• The product is also less likely to be damaged during transport.
• Common applications may include coffee beans, rice, powders of
all sorts, pet food, and more.

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

 MICROWAVEABLE
VACUUM-PACK BAGS
• Microwaveable vacuum bags offer outstanding preservation replacing
traditional microwave bags for different foods.
• These are made of two or three layers of material lamination that consist of
nylon and linear low density polyethylene.
• These high quality materials offer customers the finest solution for strong
and outstanding sealing, product protection and gorgeous transparency.
• When in low temperatures, such as on a shelf, the bags preserve food keeping
contents fresh and at the same time, are resistant when it comes time to
microwave heating.
• Withstanding rapid temperature change.

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

 RETORT POUCHES
• Retort pouches can resist the high temperature under the process of
cooking and is less bulky than traditional cans and jars.
• The pouches are also form-stable and can be sterilized under high
and low temperatures and microwaveable.
• Require no refrigeration to maintain products safe in normal
atmospheric temperatures.
• Larger surface areas for promotion, are easier for customers to open.
• Excellent sealing capabilities as well as excellent barrier properties
with regard to light, gasses, and moisture.
• Retort pouches are suitable for fish, soups, sauces, meat products,
tea, fruits, vegetables, or seasonings.
Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi
 STANDARD LAMINATED BAGS/POUCHES
• Laminated bags and pouches are used in a wide range of
flexible packaging applications, such as food products,
medical products, personal care products, cosmetics, etc.
Often, the bags result in a popular and simple solution for
candy, cookies, jerky, facial masks, and more.
• In accordance with specifications, best materials can be
used for this type of bags, such films as NY (Nylon, PA),
PET, LLDPE, Aluminium, Paper.
• Thus, the packaging has outstanding advantages with
regard to high levels of aroma preservation to protect
foodstuff flavours, as well as excellent rigidity and
transparency, and fine moisture resistance to ensure the
high quality of the contained goods.
Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi
STAND-UP ZIPPER POUCHES

• Stand up pouches and zipper pouches have become the

dominant packaging style in flexible packaging as they are
more rigid than others.
• These pouches are becoming the primary packaging solution
for the future as they have benefits such as easy carrying,
material savings, the possibility of repeated use, preserving
foods perfectly, and a large surface for branding.
• Common applications may include pet food, bird seed,
confectionary items, vegetarian food, sweets, cookies, coffee,
milk powder, snacks, etc.

Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi

VACUUM-PACK BAGS/POUCHES
• Vacuum bags and pouches are made of two or three layers
of nylon and linear low density polyethylene with finest
strong sealing ability and transparent product protection.
• Provide excellent gas barriers while allowing moderate
oxygen transpiration and prevent water vapour permeation.
• Good puncture resistance.
• Excellent protection to maintain and preserve the freshness
of the article. By reducing moisture loss they extend the
inner product's freshness.
• The exterior can also be customized to print a customer's
logo and artwork, attracting more consumers and still
maintaining other outstanding properties.
Dr. Tanushri Ghorai, Assistant Professor, COF, Dholi