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TX63061 6633119944 ccaasseewwrraapp..iinndddd 11 1122//1199//0066 1111::1166::2200 AAMM HANDBOOK OF PACKAGE ENGINEERING THIRD EDITION TThhiiss ppaaggee iinntteennttiioonnaallllyy lleefftt bbllaannkk HANDBOOK OF PACKAGE ENGINEERING THIRD EDITION Joseph F. Hanlon Medical Packaging Engineer Robert J. Kelsey, CPMIMH Packaging Production Engineer and Manager Consultant for Packaging and Systems Development Hallie E. Forcinio Technical Writer I Editor, Specialist in Packaging and Automation Research CRC PRESS Boca Raton London New York Washington, D.C. CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 1998 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works Version Date: 20150112 International Standard Book Number-13: 978-1-4987-3193-5 (eBook - PDF) This book contains information obtained from authentic and highly regarded sources. Reason- able efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged please write and let us know so we may rectify in any future reprint. Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers. For permission to photocopy or use material electronically from this work, please access www. copyright.com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organiza- tion that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com CONTENTS Preface xi Acknowledgments xiii Chapter 1. Elements of Packaging 1 Introduction .. .. ........... ........ .... .. .... ..... ........ .. 1 Fields of Packaging ... .... .. ......... ..... .... .. ....... .. ..... 6 State of the Art .. ..... ....... ....... ... ..... ... ...... ..... ... 7 The Newest Challenge .... ... .. 11 0 •••••• ••• •• • 0 • •• 0 • 0 • • • • •• • ••• The Packaging Function .. ... 11 0 • •• • ••• 0 •• • 0 • •• 0 •••• 0 0 • • 0 •••• 0 • • Preparation for a Packaging Career .... ....... ..... .. 15 0 • • ••• • • • •• The Packaging Professional ... .... .. 16 0 ••• • ••• •• •• •• • • • • •• 0 0 • • •• Successful Package Design . 18 0 • • 0 ••• 0 •• •• 0 •••••••• ••••• • • • ••• •• Handbook Structure. 0 •••• • 0 • 0 • •••• • ••••••• • • • 1. •. .. .... 0 •• 0 •• 30 References . 30 0 ••• •••• •• • 0 • • •• 0 • •• 0 • ••• 0 ••• • •••• •• •• • • •• • ••• • Chapter 2. Paper and Paperboard 31 History ... ..... 31 0 ••• 0 0 0 •• •• •• •• ••• •• •• ••• • 0 0 • • 0 • ••••• •• 0 •••• The Structure of Wood ... 32 0 • • • • 0 •••••• 0. 0 ••• •• •• 0 • • • • • • •• •• ••• Making Pulp .... ... 34 0 • • • •• ••• 0 •• • 0 •••••••• • • •• 0 • 0 • • •••• •• ••• Processing Pulp ... 35 0 • • •• • •••• 0 0 • •• 0 •• •• • • ••• •••• • 0 • •••••• 0 • 0 • Papermaking ....... 37 0 0 ••••• 0 0 •• •• 0 •• • •••• •• 0 0 • 0 • •••• •••••••• Papermaking Machines ...... 38 0 • ••• 0 •• ••••• • 0 0 • ••• 0 •• •••• 0 •••• Types of Paper .. 44 0 0 ••••• • 0 • 0 0 0 ••••• 0 • • • ••• 0 •• • • • • • 0 • • •• 0 • •• • Types of Paperboard .... 49 0 •• •• • • ••• 0 •• 0 0 0 0 • 0 0 •••••••••• 0 • • ••• • References .. .. 57 0 •• •••• 0 0 0 •• • ••••••• 0 0 0 0 •• 0 • •••• ••••• 0 0 0 •••• v vi Contents Chapter 3. Films and Foils 59 Introduction ........ ... ................ ... ........ .. ... .... 59 Film Production Methods ...... .. ...... ....... ... .. .. .. ...... 60 Common Packaging Films and Uses .. ....... .. .. .. ...... .... ... 77 Specialty Films ....... ...... ... .... ...... ...... ............. 96 Metal Foils .... ...... .... .. .. .... .. ... .... ... .. .. .......... 99 References ................ ......... ....... .... .... ....... 1 03 Chapter 4. Coating and Lamination of Flexible Materials 105 Introduction .. .... .. ...... ... .......... ... ....... ... .. ... . 1 05 History ....... ... .... .. ... ... .... .. ... .... ..... .. .... .. .. 1 07 Coating Techniques .. .... .... ....... .... ... ....... .... .. ... 108 Coating Materials ... ... .. .............. ... ..... .. .. ..... ... 112 Laminations ... ... ......... .. .......... ... ... ..... ... ..... 124 References .......... ...... ... .................. ... ... .... 127 Chapter 5. Bags, Sacks and Pouches 129 Introduction .... .. .. ... ... .. ..... ... .... .. ... .. ... .. ... .. . 129 Advantages and Disadvantages ... ....... ..... .. ... .... ... ... . 131 Types of Paper Bags .. ..... ......... ....... .. ....... ........ 132 Design Considerations ..... .. .. .... .... .. ......... ... .... .. . 140 Types of Plastic Bags .. .... ...... .. ............. ....... .... . 146 Filling Methods ...... ..... ..... .... .... .... .... .. ...... ... 148 Types of Pouches .... .... .. .... .. .... ... .. .. .... ..... ..... . 149 Pouch Applications .. ...... ...... ...... ..... ... ........ .. .. . 150 References ........ ........ .. .. .. ....... .. .... ...... .. .... 152 Chapter 6. Folding Cartons and Set-Up Boxes 153 Introduction ..... .... .... .. .... ... .. .. .. ..... ... ...... .... 153 History ... .. .. .. ..... .......... ........ ... .. .. ....... .... 154 Advantages and Disadvantages ... .. ....... .. ..... .. ......... . 156 The Materials .. ...... ....... ....... ... .. ..... .... .. ..... .. 156 Folding Carton Design ... ....... ... ......... ... ... .. ... ..... 160 Carton Manufacture ...... ...... .... ... .. ........ .......... . 171 Carton Filling .... .. .. ... .. .... ...... ... .... ... ... ..... .... 175 Printing Methods ... ... .. .... ... ... .......... .. ....... ..... 176 Set -up Boxes ........ .... ....... .......... ....... ... .. .. ... 180 References ..... .... ... ....... .......... .... ... ... ... .... . 185 General References ......... .... .. .. ... .. .... ... ..... ..... . 185 Contents vii Chapter 7. Fibre Tubes, Cans and Drums 187 Introduction .... .... .. .... .... .. ....... ...... ...... ....... 187 History ........ ..... .... ........... .. ...... ..... ..... .... 187 Forms and Modifications ..... ...... .... ..... ...... .......... 189 Advantages and Disadvantages ... ... .... .... ..... ... ..... .... 196 Materials and Processes .... .... ... ... ..... .... ..... .... ..... 196 Fibre Drums ......... .... .............. ..... ...... ........ 201 References ..... ....... .... ..... ... .. .. .... ..... ..... .... . 206 Chapter 8. Plastics 207 General Background .. ..... .. .. ....... ... ..... ......... .... 207 History ..... .. ...... ............... ... ........ .. ... ...... 208 General Chemistry .. ... .. ... ...... ... .. .... .... ... ..... .. .. 210 General Properties and Testing ... ...... .. .... ..... ...... ..... 215 Plastic Properties ... ... .... ......... ............ ...... ... .. 220 Plastic Additives .. .. ....... .. ..... .. .. .. ..... ......... ..... 226 Selected Plastics for Packaging ... ..... ..... .... ... ..... ..... . 228 Plastic Processes ............ .... ... ...... .... .... .......... 262 Plastic Drums ....... ... ... .. ... ..... ...... ... ...... ... .... 294 Coatings and Coextrusion ..... ... ............... ....... ..... 295 Decoration ...... ..... ............. ..... .... .... .. .. ...... 295 Testing ... .... .. ... .. .......... ... ...... .. .... .. .... .. .... 296 References .............. ...... ..... ................... ... 296 General References ......... ... ..... ....... ... .... ..... .... 297 Chapter 9. Glassware 299 History .... ... ...... ............ ... ... ... ........... ..... 299 Advantages and Disadvantages .... .... ....... ......... ....... 301 Chemistry of Glass ............ ....... .. .. ............ .... .. 302 Mechanical Properties of Glass ..... .......... ... ........ ..... 306 Design Considerations .. ......... ... ..... ....... ....... ..... 309 Finishes ... ............... ..... .... .. ... .... .... .... ...... 314 Manufacturing ... .. ..... .. ... .. ...... ..... .. ......... .... . 318 Labeling ....... ....... ..... .. .. ...... .. ..... .... ..... ... . 324 Decorating ..... .. .... .. .. .. ... ....... ... ... ... .. .... .... . 325 Tubing Products ....... ... .. .... .... .. ... .... ..... ......... 325 References .. ........ ...... ........... ......... .. .. .... ... 327 Chapter 10 . Metal Containers 329 History .... .... ... ............. .. ... .. ..... .... .. ....... . 329 Advantages and Disadvantages .... ........ .. .. ............... 331 Can Materials .... ..... ... ....... ... .. ........ .. .... ... ... . 332 viii Contents Can Manufacturing .. .. .. ........... .... ...... ...... ....... 338 Types of Cans ... ....... .... ..... ............ ........ .. .. .. 346 Decorating .......... ..... ...... ..... .... .. ....... ...... .. 349 Aluminum Trays ...... .. ..... ... ............. .. ..... ..... .. 350 Collapsible Tubes ... ... ... ..... .. ............ ... ..... ...... 350 Steel Drums and Pails .............. ... ... ....... ........... 354 References .... ........ .. ....... ..... .... ........... .... .. 359 Chapter 11. Pressurized Packaging 361 History ... .............. .... ...... ...... ............. .... 361 Advantages and Disadvantages .... ... .. ..... .... ...... ..... .. 363 Principles of Operation ....... .. ..... ........ .... .... .. ..... 364 Selection Criteria ........ ........ .... ... .. ............ ..... 367 Labels .. .... ... ... ............. ... ...... ...... ...... ... .. 391 Filling Processes .... .... ....... .. ... ............ ....... .. .. 391 Specifications ... .... .. ... ..... ..... .... ..... ....... ... ... . 392 Testing ...... .. .... ..... ......... ... ......... ..... ...... .. 392 Pumps and Sprayers .......... ... ... .... ......... .... ....... 394 References ....... ... .. ...... ..... ....... ........... ... ... 398 Chapter 12. Labeling and Decorating 399 Introduction ....... .. ... ....... ...... ...... ... ..... ....... 399 History ... ........ ......... .... ... .... .. .... ..... .. ... ... 399 Label Materials ... .. ..... ....... ... ....... .. .. .. .. .. .... ... 403 Label Storage ...... ...... ........ .. .... ....... ..... ....... 407 Types of Labels ........... ....... ....... .... ..... ... ....... 408 Printing/Decorating Processes .. ..... .... ... ... ..... ........ .. 409 Label Design ......... ... .... ......... .. .......... .. .. .... 423 Label Costs .... .............. ...... ... .............. ...... 425 Adhesives ..... .... .... ... .... .... ....... .... ..... ....... . 426 References ....... .... ... ... .... .. ... .... ................. 433 Chapter 13. Caps and Seals 435 Introduction ..... .... ........... ... .... .. ..... ... ... ..... . 435 History .... ...... .......... ...... .......... .... .... .... .. 435 Screw Caps ....... ..... ......... ....... .... .... .......... . 437 Lug Caps ....... ... ... .. ... ... ............. .... .... .... ... 442 Crowns ... .... ...... .... ....... ....... .. .. ....... ........ 443 Dispensing Caps .... .. ..... ......... .... ............ .... ... 443 Special Functions .. ....... .. ..... ... ...... ... ...... ...... .. 446 Corks ... ......... .... ... ........................ .. ... .... 450 Rubber Closures ........ ... ..... ... .. ... .... ..... ....... ... 451 Contents ix Cap Liners .. ......... ...... ... ................ ........ ... 452 Inner Seals .. .... ..... .......... .......... .... .... .. .. ... . 458 Container Seals .... ... ........ ... ............ .............. 459 References .... ..... ............. ................. ........ 461 Chapter 14. Corrugated Fibreboard 463 History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 463 Box Construction .. .... ... .. ..... .... ... .. .... ..... .. ..... . 463 Board Construction ...... .. ..... .. .. ... ... ... ...... ..... .. . 467 Design Considerations ... .. .. ... .... ... ... .. .... ... ... .. .. .. 4 7 4 Closing and Sealing ........ ...... .. ....... ...... ... ...... .. 481 Testing .. .. ... .. .... ..... ...... .... .. ... .... ..... ..... .... 483 General References .. .... ... .. ..... ... .... ........... ... ... 483 Chapter 15. Wood Containers 485 Introduction ........ .. ... ..... .. ........ ..... ... ... ..... .. 485 History and Statistics .. .... .... .. ............... .. .......... 485 Characteristics of Wood .... .. .... ... ... ....... .. ... .... ..... 486 Advantages and Disadvantages ............ ... ...... ... ....... 486 Selection Criteria ... ...... ... .... ..... .... ... .. ... ......... 487 Nailed Boxes .. ... ....... .. .... ..... ..... ..... ...... ...... . 488 Wirebound Boxes and Crates ......... .... ...... ........... .. 492 Crates .... .. .. .. .... .. .... ... .... ..... ...... ..... ...... .. 495 Baskets .... ... ............ .... ............. .. ... ...... .. . 498 Barrels ... ... .......... ... ... ....... .......... .... ...... .. 499 Pallets .... .......... .... .. ... ...... .. .. .. ... .... ... ..... . 501 Pallet Containers ........... ................... .. .... ...... 51 0 References .... .... ........... ............ .... .. .... ...... 512 Chapter 16. Cushioning 513 Histmy .. ... .. ... ... ... ......... ...... .... ... ....... .... . 513 Required Data ... .... .... ....... .. .... ... ..... ............ 513 Cushioning Materials ...... .. .... ... ......... ........ ... ... . 519 Selecting a Cushioning Method .. ......... .... ... ..... ... ... .. 529 References ..... ... ....... .. .. .... .... .. ... .. .. ... ...... .. 536 Chapter 17. Machinery Selection and Specification 537 General Considerations .... ... .... ....... .. ..... ..... ....... 537 The Systems Approach .... ....... .. ....... ... ..... ... .. ..... 538 Selection of Equipment ... .... .... ... .... ... ...... .. ........ 542 Line Layout .. ......................... .. .. ..... ...... ... . 544

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TX63061 6633119944 ccaasseewwrraapp..iinndddd 11 1122//1199//0066 1111::1166::2200 AAMM HANDBOOK OF PACKAGE ENGINEERING THIRD EDITION TThhiiss ppaaggee iinntteennttiioonnaallllyy lleefftt bbllaannkk HANDBOOK OF PACKAGE ENGINEERING THIRD EDITION Joseph F. Hanlon Medical Packaging Engineer Robert J. Kelsey, CPMIMH Packaging Production Engineer and Manager Consultant for Packaging and Systems Development Hallie E. Forcinio Technical Writer I Editor, Specialist in Packaging and Automation Research CRC PRESS Boca Raton London New York Washington, D.C. CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 1998 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works Version Date: 20150112 International Standard Book Number-13: 978-1-4987-3193-5 (eBook - PDF) This book contains information obtained from authentic and highly regarded sources. Reason- able efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged please write and let us know so we may rectify in any future reprint. Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers. For permission to photocopy or use material electronically from this work, please access www. copyright.com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organiza- tion that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com CONTENTS Preface xi Acknowledgments xiii Chapter 1. Elements of Packaging 1 Introduction .. .. ........... ........ .... .. .... ..... ........ .. 1 Fields of Packaging ... .... .. ......... ..... .... .. ....... .. ..... 6 State of the Art .. ..... ....... ....... ... ..... ... ...... ..... ... 7 The Newest Challenge .... ... .. 11 0 •••••• ••• •• • 0 • •• 0 • 0 • • • • •• • ••• The Packaging Function .. ... 11 0 • •• • ••• 0 •• • 0 • •• 0 •••• 0 0 • • 0 •••• 0 • • Preparation for a Packaging Career .... ....... ..... .. 15 0 • • ••• • • • •• The Packaging Professional ... .... .. 16 0 ••• • ••• •• •• •• • • • • •• 0 0 • • •• Successful Package Design . 18 0 • • 0 ••• 0 •• •• 0 •••••••• ••••• • • • ••• •• Handbook Structure. 0 •••• • 0 • 0 • •••• • ••••••• • • • 1. •. .. .... 0 •• 0 •• 30 References . 30 0 ••• •••• •• • 0 • • •• 0 • •• 0 • ••• 0 ••• • •••• •• •• • • •• • ••• • Chapter 2. Paper and Paperboard 31 History ... ..... 31 0 ••• 0 0 0 •• •• •• •• ••• •• •• ••• • 0 0 • • 0 • ••••• •• 0 •••• The Structure of Wood ... 32 0 • • • • 0 •••••• 0. 0 ••• •• •• 0 • • • • • • •• •• ••• Making Pulp .... ... 34 0 • • • •• ••• 0 •• • 0 •••••••• • • •• 0 • 0 • • •••• •• ••• Processing Pulp ... 35 0 • • •• • •••• 0 0 • •• 0 •• •• • • ••• •••• • 0 • •••••• 0 • 0 • Papermaking ....... 37 0 0 ••••• 0 0 •• •• 0 •• • •••• •• 0 0 • 0 • •••• •••••••• Papermaking Machines ...... 38 0 • ••• 0 •• ••••• • 0 0 • ••• 0 •• •••• 0 •••• Types of Paper .. 44 0 0 ••••• • 0 • 0 0 0 ••••• 0 • • • ••• 0 •• • • • • • 0 • • •• 0 • •• • Types of Paperboard .... 49 0 •• •• • • ••• 0 •• 0 0 0 0 • 0 0 •••••••••• 0 • • ••• • References .. .. 57 0 •• •••• 0 0 0 •• • ••••••• 0 0 0 0 •• 0 • •••• ••••• 0 0 0 •••• v vi Contents Chapter 3. Films and Foils 59 Introduction ........ ... ................ ... ........ .. ... .... 59 Film Production Methods ...... .. ...... ....... ... .. .. .. ...... 60 Common Packaging Films and Uses .. ....... .. .. .. ...... .... ... 77 Specialty Films ....... ...... ... .... ...... ...... ............. 96 Metal Foils .... ...... .... .. .. .... .. ... .... ... .. .. .......... 99 References ................ ......... ....... .... .... ....... 1 03 Chapter 4. Coating and Lamination of Flexible Materials 105 Introduction .. .... .. ...... ... .......... ... ....... ... .. ... . 1 05 History ....... ... .... .. ... ... .... .. ... .... ..... .. .... .. .. 1 07 Coating Techniques .. .... .... ....... .... ... ....... .... .. ... 108 Coating Materials ... ... .. .............. ... ..... .. .. ..... ... 112 Laminations ... ... ......... .. .......... ... ... ..... ... ..... 124 References .......... ...... ... .................. ... ... .... 127 Chapter 5. Bags, Sacks and Pouches 129 Introduction .... .. .. ... ... .. ..... ... .... .. ... .. ... .. ... .. . 129 Advantages and Disadvantages ... ....... ..... .. ... .... ... ... . 131 Types of Paper Bags .. ..... ......... ....... .. ....... ........ 132 Design Considerations ..... .. .. .... .... .. ......... ... .... .. . 140 Types of Plastic Bags .. .... ...... .. ............. ....... .... . 146 Filling Methods ...... ..... ..... .... .... .... .... .. ...... ... 148 Types of Pouches .... .... .. .... .. .... ... .. .. .... ..... ..... . 149 Pouch Applications .. ...... ...... ...... ..... ... ........ .. .. . 150 References ........ ........ .. .. .. ....... .. .... ...... .. .... 152 Chapter 6. Folding Cartons and Set-Up Boxes 153 Introduction ..... .... .... .. .... ... .. .. .. ..... ... ...... .... 153 History ... .. .. .. ..... .......... ........ ... .. .. ....... .... 154 Advantages and Disadvantages ... .. ....... .. ..... .. ......... . 156 The Materials .. ...... ....... ....... ... .. ..... .... .. ..... .. 156 Folding Carton Design ... ....... ... ......... ... ... .. ... ..... 160 Carton Manufacture ...... ...... .... ... .. ........ .......... . 171 Carton Filling .... .. .. ... .. .... ...... ... .... ... ... ..... .... 175 Printing Methods ... ... .. .... ... ... .......... .. ....... ..... 176 Set -up Boxes ........ .... ....... .......... ....... ... .. .. ... 180 References ..... .... ... ....... .......... .... ... ... ... .... . 185 General References ......... .... .. .. ... .. .... ... ..... ..... . 185 Contents vii Chapter 7. Fibre Tubes, Cans and Drums 187 Introduction .... .... .. .... .... .. ....... ...... ...... ....... 187 History ........ ..... .... ........... .. ...... ..... ..... .... 187 Forms and Modifications ..... ...... .... ..... ...... .......... 189 Advantages and Disadvantages ... ... .... .... ..... ... ..... .... 196 Materials and Processes .... .... ... ... ..... .... ..... .... ..... 196 Fibre Drums ......... .... .............. ..... ...... ........ 201 References ..... ....... .... ..... ... .. .. .... ..... ..... .... . 206 Chapter 8. Plastics 207 General Background .. ..... .. .. ....... ... ..... ......... .... 207 History ..... .. ...... ............... ... ........ .. ... ...... 208 General Chemistry .. ... .. ... ...... ... .. .... .... ... ..... .. .. 210 General Properties and Testing ... ...... .. .... ..... ...... ..... 215 Plastic Properties ... ... .... ......... ............ ...... ... .. 220 Plastic Additives .. .. ....... .. ..... .. .. .. ..... ......... ..... 226 Selected Plastics for Packaging ... ..... ..... .... ... ..... ..... . 228 Plastic Processes ............ .... ... ...... .... .... .......... 262 Plastic Drums ....... ... ... .. ... ..... ...... ... ...... ... .... 294 Coatings and Coextrusion ..... ... ............... ....... ..... 295 Decoration ...... ..... ............. ..... .... .... .. .. ...... 295 Testing ... .... .. ... .. .......... ... ...... .. .... .. .... .. .... 296 References .............. ...... ..... ................... ... 296 General References ......... ... ..... ....... ... .... ..... .... 297 Chapter 9. Glassware 299 History .... ... ...... ............ ... ... ... ........... ..... 299 Advantages and Disadvantages .... .... ....... ......... ....... 301 Chemistry of Glass ............ ....... .. .. ............ .... .. 302 Mechanical Properties of Glass ..... .......... ... ........ ..... 306 Design Considerations .. ......... ... ..... ....... ....... ..... 309 Finishes ... ............... ..... .... .. ... .... .... .... ...... 314 Manufacturing ... .. ..... .. ... .. ...... ..... .. ......... .... . 318 Labeling ....... ....... ..... .. .. ...... .. ..... .... ..... ... . 324 Decorating ..... .. .... .. .. .. ... ....... ... ... ... .. .... .... . 325 Tubing Products ....... ... .. .... .... .. ... .... ..... ......... 325 References .. ........ ...... ........... ......... .. .. .... ... 327 Chapter 10 . Metal Containers 329 History .... .... ... ............. .. ... .. ..... .... .. ....... . 329 Advantages and Disadvantages .... ........ .. .. ............... 331 Can Materials .... ..... ... ....... ... .. ........ .. .... ... ... . 332 viii Contents Can Manufacturing .. .. .. ........... .... ...... ...... ....... 338 Types of Cans ... ....... .... ..... ............ ........ .. .. .. 346 Decorating .......... ..... ...... ..... .... .. ....... ...... .. 349 Aluminum Trays ...... .. ..... ... ............. .. ..... ..... .. 350 Collapsible Tubes ... ... ... ..... .. ............ ... ..... ...... 350 Steel Drums and Pails .............. ... ... ....... ........... 354 References .... ........ .. ....... ..... .... ........... .... .. 359 Chapter 11. Pressurized Packaging 361 History ... .............. .... ...... ...... ............. .... 361 Advantages and Disadvantages .... ... .. ..... .... ...... ..... .. 363 Principles of Operation ....... .. ..... ........ .... .... .. ..... 364 Selection Criteria ........ ........ .... ... .. ............ ..... 367 Labels .. .... ... ... ............. ... ...... ...... ...... ... .. 391 Filling Processes .... .... ....... .. ... ............ ....... .. .. 391 Specifications ... .... .. ... ..... ..... .... ..... ....... ... ... . 392 Testing ...... .. .... ..... ......... ... ......... ..... ...... .. 392 Pumps and Sprayers .......... ... ... .... ......... .... ....... 394 References ....... ... .. ...... ..... ....... ........... ... ... 398 Chapter 12. Labeling and Decorating 399 Introduction ....... .. ... ....... ...... ...... ... ..... ....... 399 History ... ........ ......... .... ... .... .. .... ..... .. ... ... 399 Label Materials ... .. ..... ....... ... ....... .. .. .. .. .. .... ... 403 Label Storage ...... ...... ........ .. .... ....... ..... ....... 407 Types of Labels ........... ....... ....... .... ..... ... ....... 408 Printing/Decorating Processes .. ..... .... ... ... ..... ........ .. 409 Label Design ......... ... .... ......... .. .......... .. .. .... 423 Label Costs .... .............. ...... ... .............. ...... 425 Adhesives ..... .... .... ... .... .... ....... .... ..... ....... . 426 References ....... .... ... ... .... .. ... .... ................. 433 Chapter 13. Caps and Seals 435 Introduction ..... .... ........... ... .... .. ..... ... ... ..... . 435 History .... ...... .......... ...... .......... .... .... .... .. 435 Screw Caps ....... ..... ......... ....... .... .... .......... . 437 Lug Caps ....... ... ... .. ... ... ............. .... .... .... ... 442 Crowns ... .... ...... .... ....... ....... .. .. ....... ........ 443 Dispensing Caps .... .. ..... ......... .... ............ .... ... 443 Special Functions .. ....... .. ..... ... ...... ... ...... ...... .. 446 Corks ... ......... .... ... ........................ .. ... .... 450 Rubber Closures ........ ... ..... ... .. ... .... ..... ....... ... 451 Contents ix Cap Liners .. ......... ...... ... ................ ........ ... 452 Inner Seals .. .... ..... .......... .......... .... .... .. .. ... . 458 Container Seals .... ... ........ ... ............ .............. 459 References .... ..... ............. ................. ........ 461 Chapter 14. Corrugated Fibreboard 463 History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 463 Box Construction .. .... ... .. ..... .... ... .. .... ..... .. ..... . 463 Board Construction ...... .. ..... .. .. ... ... ... ...... ..... .. . 467 Design Considerations ... .. .. ... .... ... ... .. .... ... ... .. .. .. 4 7 4 Closing and Sealing ........ ...... .. ....... ...... ... ...... .. 481 Testing .. .. ... .. .... ..... ...... .... .. ... .... ..... ..... .... 483 General References .. .... ... .. ..... ... .... ........... ... ... 483 Chapter 15. Wood Containers 485 Introduction ........ .. ... ..... .. ........ ..... ... ... ..... .. 485 History and Statistics .. .... .... .. ............... .. .......... 485 Characteristics of Wood .... .. .... ... ... ....... .. ... .... ..... 486 Advantages and Disadvantages ............ ... ...... ... ....... 486 Selection Criteria ... ...... ... .... ..... .... ... .. ... ......... 487 Nailed Boxes .. ... ....... .. .... ..... ..... ..... ...... ...... . 488 Wirebound Boxes and Crates ......... .... ...... ........... .. 492 Crates .... .. .. .. .... .. .... ... .... ..... ...... ..... ...... .. 495 Baskets .... ... ............ .... ............. .. ... ...... .. . 498 Barrels ... ... .......... ... ... ....... .......... .... ...... .. 499 Pallets .... .......... .... .. ... ...... .. .. .. ... .... ... ..... . 501 Pallet Containers ........... ................... .. .... ...... 51 0 References .... .... ........... ............ .... .. .... ...... 512 Chapter 16. Cushioning 513 Histmy .. ... .. ... ... ... ......... ...... .... ... ....... .... . 513 Required Data ... .... .... ....... .. .... ... ..... ............ 513 Cushioning Materials ...... .. .... ... ......... ........ ... ... . 519 Selecting a Cushioning Method .. ......... .... ... ..... ... ... .. 529 References ..... ... ....... .. .. .... .... .. ... .. .. ... ...... .. 536 Chapter 17. Machinery Selection and Specification 537 General Considerations .... ... .... ....... .. ..... ..... ....... 537 The Systems Approach .... ....... .. ....... ... ..... ... .. ..... 538 Selection of Equipment ... .... .... ... .... ... ...... .. ........ 542 Line Layout .. ......................... .. .. ..... ...... ... . 544

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