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SE2127 Packaging Materials, 7.5 creditsStudy period 3, spring semester 2011

Department of Solid Mechanics in cooperation withDepartment of Fibre and Polymer Technology and Innventia AB

Examiner: Sören Östlund

Learning objectivesAfter the course, the student should be able to

describe the components of the packaging value chain, and d t t h th i fl th d i f kdemonstrate how these influences the design of packagesdiscuss important applications in packaging technology using correct terminology from physics, mechanics and chemistryselect suitable material and technology for manufacturing of a particular type of packagingexplain the properties of a packaging material based on the structure and chemistry of the materialrelate the results from mechanical testing of packaging materials to relevant fundamental solid mechanics parameters, anddemonstrate the value of modelling and numerical calculations for design of packages

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Course content• The packaging value chain

– Packaging logistics– Packaging ergonomics

• Solid mechanics and the finite element method for packaging design• Manufacturing of packaging• Wood fibre based packaging materials

– Converting and end-use properties– Design of paper and paperboard packaging

• Plastics• Plastics– Design of plastic packaging– Barriers

• Optical, printing and closing properties• Glass and metal packaging

Facts• Credits: 7.5 ECTS credits

Level: Advanced• Level: Advanced• Grades: A-F• Language: English• Course structure:

– Lectures 38 h, laboratory 16 h, 2 laboratory reports, home assignment, design project

• Web pages– https://www.kth.se/social/course/SE2127– http://www.kth.se/sci/institutioner/hallf/gru/kurser/SE2127/VT11-1

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InstructorsSören Östlundsoren@kth se

Mikael Hedenqvist (MH)mikaelhe@kth.sesoren@kth.se

tel. 08-790 7542@

tel. 08-790 7645

Chris Dominic (CD)chris.dominic@innventia.comtel. 08-676 7000

Mikael Magnusson (MM)mima@kth.setel. 08-790 7552

Laboratory• Laboratory 1 is based on the software CAPE PACK for

packaging logistics and will take place in the Student’s p g g g pComputer Room at Solid Mechanics on Tuesday, February 1 at 13.15-17.00. REPORT

• Laboratory 2 is a one-day study visit to Korsnäs - Frövi Paperboard Mill and Packaging Lab on Tuesday, February 8.

• Laboratory 3 deals with testing of mechanical properties• Laboratory 3 deals with testing of mechanical properties of paper and paperboard and will take place at Innventia on Tuesday, February 15 at 13.15-17.00. REPORT

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Design Project• Design, in groups of (2)3 students, a package made from a

paperboard plastic composite materials. This design should include analysis of strength and stiffness, as well as artistic design, printing, manufacturing, logistics and cost considerations.

• The design project will be assessed regarding content, analysis, written and oral presentation, and will affect the final grade.

• Well ahead of to the oral presentation, each group should give the examiner a short status report (preliminary design review) on the project work in order to clarify possible misunderstandings and to check details in the analysis.

Assessment of Design Project• Preliminary design review• Short paper A full text paper is not expected, but the short paper p p p p p , p p

should be written as a complete report. You can write the short paper in English or Swedish at your own choice, but the presentation should be in English.

• Presentation on Friday, March 12. You should preferably present your design using Power Point. A computer and projector will be available. Each group will only have approximately 10 minutes for their presentation.

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Examination

• Written exam (TEN1, 4 credits)Monday 14/3, 14-18 in V35

• Laboratory (LAB1, 2 credits)• Design project (ÖVN1, 1,5 credits)

• Final grade is given by a combination of TEN1, LAB1 and ÖVN1.

GradingThe final grade on the course is given by a combination of TEN1, LAB1 and ÖVN1.

The score on the paper testing laboratory and the design project is added to the score on the written exam (when passed) to give the overall score that is used to give a grade on the course.

The maximum score on the written exam is 60 and a score of 30 is required to pass the exam.

The laboratory reports can give an additional score between ‐1 and 3, and the design project can give an additional score between ‐3 and 6.design project can give an additional score between  3 and 6.

As a result they can change the final grade of the course both upwards and downwards (but not below E in case you have passed the written exam).

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Literature I• (PBoP) Pocket book of packaging• (FoPT) Walter Soroka, Fundamentals of packaging technology, 3rd

Edition, Institute of,• packaging professionals, Naperville, Illinois, USA, 2002.• (BOA) Paperboard Reference Manual, Iggesund Paperboard AB (1993)• (CCC7) Twede, D. and Selke, S. E. M., Cartons, Crates and Corrugated

Board – Handbook of Paper and Wood Packaging Technology (Chapter 7), DEStech Publications, Inc., Lancaster, Pennsylvania, USA, 2005.

• (LJU) Pulp and Paper Chemistry and Technology - Volume 4, Paper Products Physics and Technology, Chapters 1, 2, 3, 4, 9, 10, 11, 12, 66.

• (FRAC) Östlund, S. and Mäkelä, P., Fracture properties, KTH, 2011.• (HPT) R. E. Mark, C. C. Habeger, Jr., J. Borch and M. B. Lyne (Editors),

Handbook of Physical Testing of Paper (Chapter 11), 2nd Edition, Marcel Dekker, New York, NY, USA, 2002.

Literature II• (BPM) Barrier packaging materials, M. S. Hedenqvist, Chapter 26, 547-

563, in Environmental Degradation of Materials, Ed. M. Kutz, William ( )Andrew Publ., Norwich, NY (2005).

• (LOG) Johansson, K., Olsmats, C., Tiliander, L. and Lorentzon-Karlsson, A., Packaging Logistics, Packforsk, Kista 1997, pages 9-15, 33-45.

• (CDO) Chris DominicPackaging Networks – A Study on Swedish Packaging Industry.Emergent structures in Supply/Demand Chain Management.

• Supply/Demand Chain Management• Supply/Demand Chain ManagementSummary of published papers

• (MET) Metal Packaging, Metal Packaging Manufacturers Association, www.mpma.org.uk (2006).

• Magnusson, M. S. and Östlund, S., Problems with Selected Solutions, KTH, 2011.

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A folder containing 3‐12 will be sold at in the student office of the Department of Solid Mechanics for SEK 150.  Additional material will be handed out during the lectures for free.

The book, 2 (FoPT) Walter Soroka, Fundamentals of packaging technology, 3rd Edition, Institute of Packaging Professionals, Naperville, Illinois, USA, 2002, will be provided by the department during the course for SEK 500. If you want to keep the book after the course, the price is SEK 700; otherwise you will have to return the book in undamaged conditions and you will get your SEK 500 back.

Reading adviceIt is suggested that the lecture notes form the basis forindividual studies. In the literature the concepts covered at theindividual studies. In the literature the concepts covered at thelectures are covered in more detail, sometimes at severallocations, and by finding and using this information it shouldbe possible to get a thorough understanding of the concept.

Please, note that the assessment of the course content isf d t l d t di th th tifocused on conceptual understanding rather than repeatingfacts, and knowledge of the underlying fundamentals isimportant.

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Course evaluation• A web-based evaluation of the course will be made after the written

examination.

• Excerpts from last year’s course evaluation• THE STUDENTS SHOULD EDIT THEIR REPORTS AND COMMENT ON THE FEED-BACK

FROM THE INSTRUCTOR ON THE REPORT FROM THE PAPER AND BOARDMATERIALS TESTING LABORATORY.

• DEVELOP AND INTRODUCE A COMPUTATIONAL HOME ASSIGNMENT ON LAMINATETHEORY.

• ADD 2 HOURS OF TEACHING TIME IN ORDER TO INCREASE FLEXIBILITY IN THECOURSE PLANNING.

• TAKE AWAY AT LEAST TWO ITEMS IN THE LITERATURE LIST AND CONCENTRATEON THE PARTS OF THE LITERATURE THAT IS APPRECIATED AND USE LECTURENOTES FOR OTHER PARTS. ONLY SUCCEEDED WITH ONE.

Program – weeks 1, 21 Tuesday 18/1, 13-15,

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SÖ Course introduction. Overview of packaging materials and applications. P k i i d l h i

FoPT Ch. 1 and 2 LJU Ch. 10 PboP, (pp. 4-43)

Packaging industry, value chain, primary, secondary and tertiary packaging, trends.

2 Thursday 20/1, 10-12, D35

SÖ Paper and paperboard based packaging, overview of different types of materials.

BOA (pp. 11-36, 51-57) LJU Ch. 10 HPT (pp. 564-576)

3 Friday 21/1, 8-10, D35

CD Packaging logistics, functional demands, transport testing.

LOG, CDO

4 Tuesday 25/1, 13-15 D33

CD Packaging logistics, functional demands, transport testing. Introduction to CAPE PACK.

LOG, CDO

5 Wednesday 26/1, 8-10, E32

SÖ Paper physics, fundamentals of solid mechanics for paper materials.

LJU Ch. 1 and 2 BOA (p. 84-112)

6 Friday 28/1, 8-10, E34 SÖ Paper physics, laminate theory LJU Ch. 2, 11

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Program – weeks 3, 47 Monday 31/1, 15-17,

D33 MM Tutorial 1

Paper stress-strain curve Laminate theory program HOME ASSIGMENT

Examples: 1.1.1, 1.1.8 1.2.1, 1.1.2, 1.2.13 1.2.3 1.2.4 & 1.1.3HOME ASSIGMENT 1.2.3, 1.2.4 & 1.1.3

Tuesday 1/2, 13-17, Solid Mechanics Student Computer Room

CD Laboratory 1 CAPE PACK

8 Thursday 3/2, 8-10, D33

SÖ Manufacturing of paperboard and corrugated board, quality parameters.

FoPT Ch. 5 and 15 BOA (p. 31-44) CCC Ch 7 HPT (pp. 564-576)

9 Monday 7/2, 8-10, E33 SÖ Manufacturing of paperboard and d b d k i

LJU Ch. 9, 10 BOA ( 157 225) corrugated board packaging,

converting operations: printing, creasing, folding, gluing Intro to DESIGN PROJECT.

BOA (p. 157-225) FoPT Ch. 4, 6, 15 and 18

Tuesday 8/2, 8-17 Laboratory 2 Company visit 10 Friday 11/2, 8-10, E53

MH Polymer based materials and

packages, overview of different types of materials.

FoPT Ch. 9-11

Program – weeks 5, 611 Monday 14/2, 8-10,

E33 MH Barrier materials I BPM, FoPT Ch. 14

Tuesday, 15/2, 13-17, Innventia AB

Laboratory 3 Experimental determination of someInnventia AB,

Drottning Kristinas väg 61

determination of some mechanical properties of paper and board.

12 Thursday 17/2, 15-17, E34

MH Barrier materials II Handed out material BPM

13 Tuesday 22/2, 13-15, E33

MH Plastic packaging – Other properties

FoPT Ch. 13-14

14 Thursday 24/2, 8-10, E34

SÖ Design of paper and board packaging: stacking, analytical

h d

LJU Ch 10 BOA (pp. 119-128) F PT Ch 15 17 methods.

Company software such as Billerud Box Design, Korsnäs Optipack and EUPS.

FoPT Ch. 15, 17 HPT (pp. 576-652) Example: 1.3.3

15 Friday 25/2, 8-10, E33 SÖ Design of paper and board packaging: dynamic loads and shocks, mechanosorptive creep

FoPT Ch. 17 LJU Ch. 4, p. 144

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Program – weeks 7, 816 Monday 28/2, 15-17,

E34 SÖ Design of paper and board

packaging, advanced concepts, FEM fracture mechanics

HPTLJU Ch. 2, 11, 12 FRACFEM, fracture mechanics FRAC

17 Tuesday 1/3, 13-15, D35

MM Tutorial 2 Examples: 1.1.9, 1.1.10, 1.1.11, 1.3.5

18 Tuesday 8/3, 13-15, E53

SÖ Sackpaper. Glass and metal packaging. Environmental issues, life cycle analysis, packaging ergonomics. The future of paper and paperboard packaging.

FoPT Ch. 7, 8 & p. 505-509, MET FoPT Ch. 1 and 2 LJU Ch. 66

19 Th d 10/3 13 15 SÖ P i f DESIGN19 Thursday 10/3, 13-15, D41

SÖ, MH, CD

Presentation of DESIGN PROJECTS

Monday 14/3, 14-18, V35

Written examination

After Lecture 1 you should be able to

• describe what packaging is• give examples of efficient packaging systems• give examples of efficient packaging systems• describe how the industrial revolution lead to

modern packaging• discuss the relations between packaging and the

development of a country• describe the two major divisions within thedescribe the two major divisions within the

packaging industry• give examples of packages made from the most

common packaging materials

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Literature• Lecture notes

f• Fundamentals of packaging technology –Chapters 1-2

• Pulp and Paper Chemistry and Technology -Volume 4, Paper Products Physics and Technology - Chapter 10

• Pocket book of packaging – Pages 4-43

Packaging, everybody know what it is?

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What is packaging?• A coordinated system of preparing goods for

transport, distribution, storage, retailing and use.transport, distribution, storage, retailing and use.• Packaging is a

– complex– dynamic– scientific– artistic

t i l– controversial

business function• Needs a PRODUCT!

Definition Packaging *“Packaging” shall mean all products made of any materials of any nature to be used for the containment, protection, handling, delivery and presentation of goods, from raw materials to processed goods, from the producer to the user or the consumer.

“Non-returnable” items used for the same purposes shall also be considered to constitute packaging.

* Directive 94/62/EC on packaging and packaging waste

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Packaging functions range from technical to marketing

Technical Functions Marketing FunctionsTechnical Functions• contain• protect• preserve• measure• dispense (sv. dela ut, i.e. medicin)

Marketing Functions• communicate• display• inform• promote• sellp

• transport• store

• motivate

Typical protect, transport and storage problems• Vibration• Mechanical shock• Abrasion• Deformation• High/low temperature

R l ti h idit• Relative humidity• Water• Tampering

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Packaging- a part of a system -

Product

Packaging

Distributionenvironment

Functions of packaging systems

1. Product flow - Handling - Transport - Storage

2. Protection - Mechanical - Barrier

3. Runnability - Stiffness - Flatness

4. Environment - Material savings - Environmental concern

5. Communication - Information - Promotion

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Different levels of a packaging system

Consumer/Sales packaging – primary packaging

Retail/Group packaging – secondary packaging

Transport packaging – tertiary packaging

Pallet

Packaging in the distribution chain

RAW MATE

PACKAGING END-

INDUSTRIAL PRODUCTS

CONSUMER PRODUCTSPRODUCER/

WasteDisposal

MATE-RIALS

MANUFAC-TURERS R

ETAILER

USERCO SU O UC S

WH

OLE-

SALER

PRODUCER/CONVERTER

REUSE MATERIAL RECYCLING

REQUIREMENTS AND DEMANDS

Bur-ningBurning

REQUIREMENTS AND DEMANDS

PACKAGING DESIGN

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Different levels along the chain

MANUFACTURER/PACKING

WHOLE-SALERWHOLESALER RETAILER END-USER/

CONSUMER

PRIM

SEK

TERT

Handlingmanual X%

Building up ofpackage system TransportBreaking down of

package system

Filling of primary packagemanual X%

Storage

The modern packaging industrymetal cansglass bottlespaper cartons

fillerscase packers

photographymarketinglegal

The packaging industry

Suppliers

raw materialsconverters machinery services

paper cartonsplastic containersflexible materials

case packersdate coders

legalconsumer testingconsultants

Usersconsumer industrial Institutional

foodpharmaceuticaltoyshardwarepersonal care

automotivemachinerybulk foodchemicals

foodnon-foodmilitarymedical devices

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What is an efficient packaging?

forenvironmentfor

human

Effective packaging

for

human

for logistics

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Packaging & Unit load© IKEA of Sweden AB

Example of packaging logistics

IKEA of Sweden

GlimmaTea lights

Forecast 15,000,000 bags of 100 tea lights

New Glimma - Old Glimma Packaging & Unit load© IKEA of Sweden AB

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Glimma today

Packaging & Unit load© IKEA of Sweden AB

Glimma future

(Photo is of the test prototype)

252 bags of tea lights

360 bags of tea lights30 % less unit loadIf one pallet takes 5 min to unpack almost 200 working days in the stores will be saved

In store• Fast unpacking time

Packaging & Unit load© IKEA of Sweden AB

• Easy to handle• Could be used as

multiple sale solution• More commercial• Less corrugated board

visiblevisible• Less space/100 pack =

more space for other products

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IKEA

Outbound gods will be reduced ith 300 t k

Packaging & Unit load© IKEA of Sweden AB

with 300 trucks30 % less pallets to store in the distribution chain30 % less pallets to handleReduce costSafe transport

History of packagingPrimitive packaging

• We do not know what the first package was– Containment and carrying devices

– Fabricated sacks, baskets and bags made from materials of plant or animal origin

– Hollow glass objects in about 1500 B.C.

– Marking of olive oil amphora in Greece about 250 B.C.g p

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From Rome to Renaissance

• Glass blow pipe invented in about 50 B.C.• Paper made in China in about 105 A.D.• Printing from woodcuts in about 700-800

A.D.

Industrial revolution• Rural agricultural workers migrated into cities

I i d d d b• Inexpensive mass-produced goods became available to a large segment of the population

• Factory workers needed products and food• Many new shops and stores opened• Some industries located in non-agricultural g

areas

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The evolution of new packaging roles

• RURAL COMMUNITIES – Barrels

• CITY DWELLERS – Smaller quantities requiredCITY DWELLERS Smaller quantities required

• Shops adapt the bulk delivery system

• First pre-packaged products – medicines, cosmetics, teas, liquors and other expensive products

• Individual packaging – quality producers wished to identify their particular product for exampleidentify their particular product, for example

Schweppes (1792)Perrier (1863)Colgate (1873)

The evolution of new packaging roles

• Early packages or wrappings for higher cost gods applied the evolving printing andgods applied the evolving printing and decorating arts

• Plastic packages occur in the early 1900s– Cellulose films (1911)– Cellophane (1927)

I d t t t ith th d f d t• In department stores with thousands of products staff people had little knowledge of the products – The package had to inform the purchaser– The package had to sell the product

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Packaging in the late 20th century

• 1950s– fast food outlets appearpp– convenience and prepared food packages– plastics available as packaging material

• 1970s– child-resistant closures, tamper (sv. manipulera) evident closures,

labelling laws– microwave food, yoghurt, bottled water

• Last decades of the 20th century to now– ageing population– smaller families, single person house-holds– convenient and fast for the urban inhabitant

Modern packaging• High increase in number of goods/products

P k i f d t th l f h ti ti– Packaging forced to the role of purchase motivation rather than just presenting the product

– Marketers aimed at features and advantages beyond the product itself

– New concern is removal of debris generated by i t d i t lconsumer society and impact on ecology

– Sustainable development of packages

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Packaging and the modern industrial society

• Packages are a requirement for everyday enjoyment of hi ll d ll ifi f dgeographically and seasonally specific food

• Central processing allows value recovery of what would normally be waste.– Use of by-products (i.e. chicken feathers used as fill material,

gelatine, animal food)

– Packaging materials recycledPackaging materials recycled

• Economical manufacture of durable goods requires good packaging, c.f. TV sets, computers, furniture etc.

Science of packaging is in a continuous state of changeScience of packaging is closely connected with everything we do in society For examplewe do in society. For example …

Oil:1) bulk to service stations into glass jars2) metal cans3) foil/fibre composite cans4) plastic bottles

Milk:1) glass bottles2) plastic bottles3) flexible bags4) aseptic paperboard cartons

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World packaging

• Development of the packaging level is an i di t f th lth f th tindicator of the wealth of the country

• Packages– reduce food prices– preserve, protect and transport food

Value of packaging materials usage in different branches

SEK/billions

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fMost frequently used packaging materials

The total turnover of the global packaging market is more than 500 billion dollars

Metals

Glass

PaperBoardCorrugated

Machinery

Others

PlasticsSource:WPO

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Usage (percent by weight) of different packaging materials in a typical shopping

basket year 2000

SteelWood

Glass

Aluminum

Paper

Corrugated

Paperboard

Plastics

Which materials are used for storage of CD discs?

• Stiff plastics• Stiff plastics• Soft plastics• Paperboard• Paperboard/plastics composites• Metal• Wood

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Packaging of carbonated drinks

• Glass– beer, soft drinks,

champagne• Plastics

– soft drinks, water, cider, beer

Metal• Metal– beer

• Paperboard– ?

Milk in plastic bottle or paperboard packaging?

• When asked about drink choices at school 51% of those• When asked about drink choices at school, 51% of those surveyed said that they would choose milk over other beverage options when milk was presented in a plastic bottle.

When milk was presented in a paper carton, only 24% of the students said they would choose milk over the other options.

• Students described the milk in plastic bottles as cool, trendy, stylish, new and fun to drink.

They described the paperboard carton as old fashioned.

• Kids drink more milk when the right package is offered.

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Cans• Metal• GlassGlass• Paperboard

– Tetra Recart

Transport packaging

• Wood• Corrugated board

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Paper and Paperboard

Inherent weaknesses of paper and board in packaging applications

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Fail in a brittle mannerFailure load of shopping bags

Paper bag Plastic bagPaper bag Plastic bag

Reference 1000 N 250 N

On wet surface 250 N 250 N

Rapid loading 500 N

Poor creep properties(particularly in varying moisture climates)

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Difficult to form into complex shapes

Past Now Future

Paper based composites

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Plastics

Plastics based composites

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Metals

Glass

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After Lecture 1 you should be able to

• describe what packaging is• give examples of efficient packaging systems• give examples of efficient packaging systems• describe how the industrial revolution lead to

modern packaging• discuss the relations between packaging and the

development of a country• describe the two major divisions within thedescribe the two major divisions within the

packaging industry• give examples of packages made from the most

common packaging materials