What is a Plastic?

 A plastic is defined as an organic material that has

the ability to flow into a desired shape when heat
and pressure are applied and to retain that shape
when they are withdrawn.
 Composed primarily of a binder with-
• Plasticizers
• Fillers
• Pigments
• Other additives
 Industry Overview
 World sales of primary packaging materials estimated to
be $434 billion in 2001.
• Up 12.5% from $385 billion in 1997.
 World sales of finished packaging materials is estimated
to be $800 billion.
 Four main categories of raw packaging materials:
• Paper and Board
• Glass
• Metal
• Plastic
 Over the past few years, plastic has become increasingly
popular.
 Why Plastics?
 A wide variety of different qualities-
– Rigid vs. Flexible
– Clear vs. Opaque

 Lightweight
 Strong
 Cost
 Which Plastics are Used?
 Six resins account for almost 97 percent of
all plastic used in packaging.
 Polyethylene terephthalate (PET) – 9%
 High-density polyethylene (HDPE) – 29%
 Low-density polyethylene (LDPE) – 32%
 Poly-vinyl chloride (PVC) – 5%
 Poly-propylene (PP) – 11%
 Polystyrene (PS) – 11%
 Polypropylene
 Physical Properties
– Durable
 High elongation
– 300%
 High Tensile Strength
– 4500 psi
 High Yield Strength
– 4000 psi
– High Melting point
– Low Density
 Lowest density of all plastics used in packaging
 Why Polypropylene?
 Practicality
– Inexpensive
– Chemically resistant
– Ideal for holding hot liquids
– Stretchy vs. rigid
 Many everyday uses
– Ketchup bottles
– Peanut butter jars
 Polyvinyl Chloride
 Need Title
 Chemically non-reactive
 Flexible vs. Rigid
 Self Extinguishing
 Plasticized vs. Unplasticized
– Plasticized is more flexible
 Why PVC
 Versatile
– Can be machined with standard metal working tools
 Self Extinguishing
– Used to house electrical wiring
 Many forms
– Sheet
– Tubing
– Piping
 Polyvinylidene Dichloride
 Discovered in 1933
– Accidental Discovery
– Original use was to stop corrosion on airplanes
– After a green color and a pungent smell had
been removed it was used for food storage.
 Most common form of PVDC is Saran
Wrap®
 Why PVDC
 PVDC is a very effective food preservation
method.
– Co-polymerization used in synthesis creates a
very tight molecular chain
 Provides good barrier against air and moisture.
 Chemically non-reactive
– Ensures that food won’t taste like plastic
Plastic vs. The Alternatives
Stress Strengths
Stress Strengths of Packaging Materials

1000
1000

800 550
Stress Strength
600
(M Pa)
400 Minimum
100
50 19 25
200 100 30 Maximum

0
Aluminum Glass Wood Plastic
Alloy (Oak) (PE)
M aterial
 Plastic vs. The Alternatives
 Incredibly lightweight
 2 lbs of plastic can deliver 1000 oz. of liquid. To
carry the same amount it would take:
• 3 lbs of aluminum
• 8 lbs of steel
• 27 lbs of glass
 Compared to glass, plastic drink bottles allow a
distribution truck to carry up to 63% more drink and
83% less packaging.
 Compared to paper, 7 trucks are needed to deliver
the same quantity of paper bags contained in one
truckload of plastic bags.
 Plastic vs. The Alternatives
 Cost
 As of mid-2000, PET was selling for app. $.62/lb.
 Around the same time, aluminum alloy was selling
for app. $1.28/lb.
– Plastic reduces distribution costs-
• Decrease in necessary truckloads
• Fuel savings
– Reduces lost inventory costs.
 Plastic vs. The Alternatives
 Environmental Impact
 Plastic also has a positive impact on the
environment. Consider the following fact:
– When comparing the manufacturing processes of
polystyrene and paper cups, it was found the the paper
cups use:
• 15 times more chemicals.
• More than 6 times more steam.
• 13 times more electricity.
• 30% more cooling water.
• 170 times more process water.
 The lightweight nature of plastics results in fewer
truckloads and less fuel usage.
 Recycle (cont.)
 Recycling process
– Collection
– Sorting
– Reclamation
 Recycle (cont.)
 Benefits
– Less landfill waste
– Environmentally friendly
 Recycle
 Statistics
– >80% of all US households have access to plastic
collection and recycling programs
– In 1998 plastic bottle packaging amassed 1.45 billion
pounds by volume
 Commonly recycled plastics
– Plastic Grocery Bags
– Plastic Milk Jugs and Detergent Bottles
– Plastic Beverage Containers
 Reuse (cont.)
 Good Examples
– Large reusable containers
 Small packages of concentrated product are bought

and diluted to large container

 Reduces product packaging cost, landfill space

– Reusable Plastic Shipping Containers (RPSC’s)

 Replaces single use containers
 Reduces shipping/receiving costs, landfill space
Reusing and Recycling Plastic
Packaging
 Reuse
– Statistics
– Commonly reused plastic packaging
– Benefits
– Good Examples
 Recycle
– Statistics
– Commonly recycled plastic packaging
– Recycling Process
– Benefits
 Reuse
 Statistic
– A 1997 survey found 80% of Americans reuse
plastic products and packaging
 Common Reusable Packaging
– Plastic Grocery Bags
– Plastic Milk Jugs and Detergent Bottles
– Plastic Beverage Containers
 Reuse (cont.)
 Benefits
– Good Properties
 Long lasting

 Durable

 Chemically inert

– Delays filling of landfills

– Lowers cost of garbage disposal
 In Summary
 Plastics

– Lighter …..…………………………….

– Cheaper …………...

– More Durable ………………………

Questions???