Handbook of Paper and Paperboard Packaging Technology (2^nd Ed.)

The definitive industry reference on the paper and paperboard packaging sector.

Now in a fully revised and updated second edition, this book discusses all the main types of packaging based on paper and paperboard. It considers the raw materials, the manufacture of paper and paperboard, and the basic properties and features on which packaging made from these materials depends for its appearance and performance. The manufacture of twelve types of paper- and paperboard-based packaging is described, together with their end-use applications and the packaging machinery involved. The importance of pack design is stressed, as well as how these materials offer packaging designers opportunities for imaginative and innovative design solutions. Environmental factors, including resource sustainability, societal and waste management issues are addressed in a dedicated chapter.

The book is directed at readers based in companies which manufacture packaging grades of paper and paperboard, companies involved in the design, printing and production of packaging, and companies which manufacture inks, coatings, adhesives and packaging machinery. It will be essential reading for students of packaging technology and technologists working in food manufacturing who are users of paper and paperboard packaging products.

Praise for the First Edition

?This book is a valuable addition to the library of any forward-looking company by providing in-depth coverage of all aspects of packaging which involve the most ecologically acceptable material, namely paper and paperboard.??International Journal of Dairy Technology

?...a welcome contribution to a field where coverage was previously limited to subject-specific books... or to single chapters in textbooks on broader aspects of packaging technology.??Packaging Technology and Science

Contributors xv

Preface xvii

Acknowledgements xix

1 Paper and paperboard – raw materials, processing and properties 1
Daven Chamberlain and Mark J. Kirwan

1.1 Introduction – quantities, pack types and uses 1

1.2 Choice of raw materials and manufacture of paper and paperboard 6

1.3 Packaging papers and paperboards 20

1.4 Packaging requirements 25

1.5 Technical requirements of paper and paperboard for packaging 26

1.6 Specifications and quality standards 48

1.7 Conversion factors for substance (basis weight) and thickness measurements 48

2 Environmental and resource management issues 51
Daven Chamberlain and Mark J. Kirwan

2.1 Introduction 51

2.2 Sustainable development 53

2.3 Forestry 54

2.4 Environmental impact of manufacture and use of paper and paperboard 61

2.5 Used packaging in the environment 73

2.6 Life cycle assessment 79

2.7 Carbon footprint 81

2.8 Conclusion 84

3 Paper-based fl exible packaging 91
Jonathan Fowle and Mark J. Kirwan

3.1 Introduction 91

3.2 Packaging needs which are met by paper-based flexible packaging 94

3.3 Manufacture of paper-based flexible packaging 99

3.4 Medical packaging 109

3.5 Packaging machinery used with paper-based flexible packaging 114

3.6 Paper-based cap liners (wads) and diaphragms 118

3.7 Tea and coffee packaging 119

3.8 Sealing tapes 121

3.9 Paper cushioning 121

4 Paper labels 125
Michael Fairley

4.1 Introduction 125

4.2 Types of labels 128

4.3 Label adhesives 136

4.4 Factors in the selection of labels 139

4.5 Nature and function of labels 140

4.6 Label printing and production 145

4.7 Print finishing techniques 156

4.8 Label finishing 156

4.9 Label application, labelling and overprinting 159

4.10 Label legislation, regulations and standards 163

4.11 Specifications, quality control and testing 164

4.12 Waste and environmental issues 167

5 Paper bags 169
Smith Anderson Group Ltd, Fife, UK, and Welton Bibby & Baron Ltd, Radstock, Somerset, UK

5.1 Introduction 169

5.2 Types of paper bags and their uses 170

5.3 Types of paper used 175

5.4 Principles of manufacture 177

5.5 Performance testing 179

5.6 Printing methods and inks 180

5.7 Conclusion 181

6 Composite cans 183
Catherine Romaine Henderson

6.1 Introduction 183

6.2 Composite can (container) 185

6.3 Historical background 187

6.4 Early applications 189

6.5 Applications today by market segmentation 189

6.6 Designs available 190

6.7 Materials and methods of construction 194

6.8 Printing and labelling options 197

6.9 Environment and waste management issues 200

6.10 Future trends in design and application 200

6.11 Glossary of composite can-related terms 201

7 Fibre drums 205
Fibrestar Drums Ltd., Cheshire, UK

7.1 Introduction 205

7.2 Raw material 207

7.3 Production 208

7.4 Performance 212

7.5 Decoration, stacking and handling 214

7.6 Waste management 215

7.7 Summary of the advantages of fibre drums 215

7.8 Specifications and standards 216

8 Multiwall paper sacks 217
Mondi Industrial Bags, Vienna, Austria

8.1 Introduction 217

8.2 Sack designs 218

8.3 Sack materials 226

8.4 Testing and test methods 232

8.5 Weighing, filling and closing systems 237

8.6 Standards and manufacturing tolerances 248

8.7 Environmental position 250

9 Rigid boxes 253
Michael Jukes

9.1 Overview 253

9.2 Rigid box styles (design freedom) 254

9.3 Markets for rigid boxes 256

9.4 Materials 256

9.5 Design principles 257

9.6 Material preparation 258

9.7 Construction 259

9.8 Conclusion 263

10 Folding cartons 265
Mark J. Kirwan

10.1 Introduction 265

10.2 Paperboard used to make folding cartons 267

10.3 Carton design 268

10.4 Manufacture of folding cartons 277

10.5 Packaging operation 296

10.6 Distribution and storage 303

10.7 Point of sale, dispensing, etc. 306

10.8 Consumer use 307

10.9 Conclusion 311

11 Corrugated fi breboard packaging 313
Arnoud Dekker

11.1 Introduction 313

11.2 Functions 318

11.3 Board properties and test methods 321

11.4 Manufacturing 326

11.5 Corrugated fibreboard and sustainability 335

12 Solid board packaging 341
Mark J. Kirwan

12.1 Overview 341

12.2 Pack design 342

12.3 Applications 345

12.4 Materials 350

12.5 Water and water-vapour resistance 350

12.6 Printing and conversion 351

12.7 Packaging operation 352

12.8 Waste management 352

12.9 Good manufacturing practice 352

13 Paperboard-based liquid packaging 353
Mark J. Kirwan

13.1 Introduction 353

13.2 Packaging materials 357

13.4 Carton designs 361

13.5 Opening, reclosure and tamper evidence 369

13.6 Aseptic processing 374

13.7 Post-packaging sterilisation 375

13.8 Transit packaging 376

13.9 Applications for paperboard-based liquid packaging 378

13.10 Environmental issues 378

13.11 Systems approach 382

14 Moulded pulp packaging 385
Cullen Packaging Ltd, Glasgow, UK

14.1 Introduction 385

14.2 Applications 385

14.3 Raw materials 388

14.4 Production 389

14.5 Product drying 391

14.6 Printing/decoration 392

14.7 Conclusion 392

Website 392

Appendix: Checklist for a packaging development brief 393

Reference 398

Further reading 398

Index 399

Mark J. Kirwan is a Packaging and Paper Specialist with extensive experience in the paper and packaging industries. He is a Fellow of the Packaging Society, and is based in London, UK.