Packaging is the science, art and technology of enclosing or protecting products for distribution, storage, sale, and use. Packaging also refers to the process of designing, evaluating, and producing packages. Packaging can be described as a coordinated system of preparing goods for transport, warehousing, logistics, sale, and end use. Packaging contains, protects, preserves, transports, informs, and sells. In many countries it is fully integrated into government, business, institutional, industrial, and personal use.
The first packages used the natural materials available at the time: baskets of reeds, wineskins (bota bags), wooden boxes, pottery vases, ceramic amphorae, wooden barrels, woven bags, etc. Processed materials were used to form packages as they were developed: for example, early glass and bronze vessels. The study of old packages is an important aspect of archaeology.
The earliest recorded use of paper for packaging dates back to 1035, when a Persian traveler visiting markets in Cairo, Arab Egypt, noted that vegetables, spices and hardware were wrapped in paper for the customers after they were sold.
Tinplate boxes first began to be sold from ports in the Bristol Channel in 1725. The tinplate was shipped from Newport, Monmouthshire. By 1805, 80,000 boxes were made and 50,000 exported. Tobacconists in London began packaging snuff in metal-plated canisters from the 1760s onwards.
1914 magazine advertisement for cookware with instructions for home canning.
With the discovery of the importance of airtight containers for food preservation by French inventor Nicholas Appert, the tin canning process was patented by British merchant Peter Durand in 1810. After receiving the patent, Durand did not himself follow up with canning food. He sold his patent in 1812 to two other Englishmen, Bryan Donkin and John Hall, who refined the process and product and set up the world's first commercial canning factory on Southwark Park Road, London. By 1813, they were producing the first canned goods for the Royal Navy.
The progressive improvement in canning stimulated the 1855 invention of the can opener. Robert Yeates, a cutlery and surgical instrument maker of Trafalgar Place West, Hackney Road, Middlesex, UK, devised a claw-ended can opener with a hand-operated tool that haggled its way around the top of metal cans. In 1858, another lever-type opener of a more complex shape was patented in the United States by Ezra Warner of Waterbury, Connecticut.
Packing folding cartons of salt.
Set-up boxes were first used in the 16th century and modern folding cartons date back to 1839. The first corrugated box was produced commercially in 1817 in England. Corrugated (also called pleated) paper received a British patent in 1856 and was used as a liner for tall hats. Scottish-born Robert Gair invented the pre-cut paperboard box in 1890—flat pieces manufactured in bulk that folded into boxes. Gair's invention came about as a result of an accident: as a Brooklyn printer and paper-bag maker during the 1870s, he was once printing an order of seed bags, and the metal ruler, normally used to crease bags, shifted in position and cut them. Gair discovered that by cutting and creasing in one operation he could make prefabricated paperboard boxes.
Commercial paper bags were first manufactured in Bristol, England, in 1844, and the American Francis Wolle patented a machine for automated bag-making in 1852.
Packaging advancements in the early 20th century included Bakelite closures on bottles, transparent cellophane overwraps and panels on cartons. These innovations increased processing efficiency and improved food safety. As additional materials such as aluminum and several types of plastic were developed, they were incorporated into packages to improve performance and functionality.
In-plant recycling has long been common for producing packaging materials. Post-consumer recycling of aluminum and paper-based products has been economical for many years: since the 1980s, post-consumer recycling has increased due to curbside recycling, consumer awareness, and regulatory pressure.
Many prominent innovations in the packaging industry were developed first for military use. Some military supplies are packaged in the same commercial packaging used for general industry. Other military packaging must transport materiel, supplies, foods, etc. under severe distribution and storage conditions. Packaging problems encountered in World War II led to Military Standard or "mil spec" regulations being applied to packaging, which was then designated "military specification packaging". As a prominent concept in the military, mil spec packaging officially came into being around 1941, due to operations in Iceland experiencing critical losses, ultimately attributed to bad packaging. In most cases, mil spec packaging solutions (such as barrier materials, field rations, antistatic bags, and various shipping crates) are similar to commercial grade packaging materials, but subject to more stringent performance and quality requirements.
Barrier protection – A barrier to oxygen, water vapor, dust, etc., is often required. Permeation is a critical factor in design. Some packages contain desiccants or oxygen absorbers to help extend shelf life. Modified atmospheres or controlled atmospheres are also maintained in some food packages. Keeping the contents clean, fresh, sterile and safe for the duration of the intended shelf life is a primary function. A barrier is also implemented in cases where segregation of two materials prior to end use is required, as in the case of special paints, glues, medical fluids, etc.
Containment or agglomeration – Small objects are typically grouped together in one package for reasons of storage and selling efficiency. For example, a single box of 1000 pencils requires less physical handling than 1000 single pencils. Liquids, powders, and granular materials need containment.
Information transmission – Packages and labels communicate how to use, transport, recycle, or dispose of the package or product. With pharmaceuticals, food, medical, and chemical products, some types of information are required by government legislation. Some packages and labels also are used for track and trace purposes. Most items include their serial and lot numbers on the packaging, and in the case of food products, medicine, and some chemicals the packaging often contains an expiry/best-before date, usually in a shorthand form. Packages may indicate their construction material with a symbol.
Security – Packaging can play an important role in reducing the security risks of shipment. Packages can be made with improved tamper resistance to deter manipulation and they can also have tamper-evident features indicating that tampering has taken place. Packages can be engineered to help reduce the risks of package pilferage or the theft and resale of products: Some package constructions are more resistant to pilferage than other types, and some have pilfer-indicating seals. Counterfeit consumer goods, unauthorized sales (diversion), material substitution and tampering can all be minimized or prevented with such anti-counterfeiting technologies. Packages may include authentication seals and use security printing to help indicate that the package and contents are not counterfeit. Packages also can include anti-theft devices such as dye-packs, RFID tags, or electronic article surveillance tags that can be activated or detected by devices at exit points and require specialized tools to deactivate. Using packaging in this way is a means of retail loss prevention.
Convenience – Packages can have features that add convenience in distribution, handling, stacking, display, sale, opening, reclosing, using, dispensing, reusing, recycling, and ease of disposal
Portion control – Single serving or single dosage packaging has a precise amount of contents to control usage. Bulk commodities (such as salt) can be divided into packages that are a more suitable size for individual households. It also aids the control of inventory: selling sealed one-liter bottles of milk, rather than having people bring their own bottles to fill themselves.
Branding/Positioning – Packaging and labels are increasingly used to go beyond marketing to brand positioning, with the materials used and design chosen key to the storytelling element of brand development.
Various types of household packaging for foods
Packaging may be of several different types. For example, a transport package or distribution package can be the shipping container used to ship, store, and handle the product or inner packages. Some identify a consumer package as one which is directed toward a consumer or household.
Custom packaging is an evolutionary use of modern materials. Thermoforming and vacuum forming allow for expanded capabilities for large trays, displays, and specialty needs. Thermoforming is a method which uses vacuum, heat, and pressure to form the desired material into a shape determined by its mold. This type of packaging is often used by the cosmetic and medical industry.
It is sometimes convenient to categorize packages by layer or function: "primary", "secondary", etc.
Primary packaging is the material that first envelops the product and holds it. This usually is the smallest unit of distribution or use and is the package which is in direct contact with the contents.
Secondary packaging is outside the primary packaging, and may be used to prevent pilferage or to group primary packages together.
These broad categories can be somewhat arbitrary. For example, depending on the use, a shrink wrap can be primary packaging when applied directly to the product, secondary packaging when used to combine smaller packages, or tertiary packaging when used to facilitate some types of distribution, such as to affix a number of cartons on a pallet.
"Print & Apply" corner wrap UCC (GS1-128) label application to a pallet load
Technologies related to shipping containers are identification codes, bar codes, and electronic data interchange (EDI). These three core technologies serve to enable the business functions in the process of shipping containers throughout the distribution channel. Each has an essential function: identification codes either relate product information or serve as keys to other data, bar codes allow for the automated input of identification codes and other data, and EDI moves data between trading partners within the distribution channel.
Elements of these core technologies include UPC and EAN item identification codes, the SCC-14 (UPC shipping container code), the SSCC-18 (Serial Shipping Container Codes), Interleaved 2-of-5 and UCC/EAN-128 (newly designated GS1-128) bar code symbologies, and ANSI ASC X12 and UN/EDIFACT EDI standards.
RFID labels for shipping containers are also increasingly used. A Wal-Mart division, Sam's Club, has also moved in this direction and is putting pressure on its suppliers to comply.
Shipments of hazardous materials or dangerous goods have special information and symbols (labels, placards, etc.) as required by UN, country, and specific carrier requirements. On transport packages, standardized symbols are also used to communicate handling needs. Some are defined in the ASTM D5445 "Standard Practice for Pictorial Markings for Handling of Goods" and ISO 780 "Pictorial marking for handling of goods".
Transport packaging needs to be matched to its logistics system. Packages designed for controlled shipments of uniform pallet loads may not be suited to mixed shipments with express carriers.
An example of how package design is affected by other factors is its relationship to logistics. When the distribution system includes individual shipments by a small parcel carrier, the sorting, handling, and mixed stacking make severe demands on the strength and protective ability of the transport package. If the logistics system consists of uniform palletized unit loads, the structural design of the package can be designed to meet those specific needs, such as vertical stacking for a longer time frame. A package designed for one mode of shipment may not be suited to another.
With some types of products, the design process involves detailed regulatory requirements for the packaging. For example, any package components that may contact foods are designated food contact materials.Toxicologists and food scientists need to verify that such packaging materials are allowed by applicable regulations. Packaging engineers need to verify that the completed package will keep the product safe for its intended shelf life with normal usage. Packaging processes, labeling, distribution, and sale need to be validated to assure that they comply with regulations that have the well being of the consumer in mind.
Sometimes the objectives of package development seem contradictory. For example, regulations for an over-the-counter drug might require the package to be tamper-evident and child resistant: These intentionally make the package difficult to open. The intended consumer, however, might be handicapped or elderly and unable to readily open the package. Meeting all goals is a challenge.
Package development involves considerations of sustainability, environmental responsibility, and applicable environmental and recycling regulations. It may involve a life cycle assessment
which considers the material and energy inputs and outputs to the package, the packaged product (contents), the packaging process, the logistics system,waste management, etc. It is necessary to know the relevant regulatory requirements for point of manufacture, sale, and use.
The traditional “three R’s” of reduce, reuse, and recycle are part of a waste hierarchy which may be considered in product and package development.
Prevention – Waste prevention is a primary goal. Packaging should be used only where needed. Proper packaging can also help prevent waste. Packaging plays an important part in preventing loss or damage to the packaged product (contents). Usually, the energy content and material usage of the product being packaged are much greater than that of the package. A vital function of the package is to protect the product for its intended use: if the product is damaged or degraded, its entire energy and material content may be lost.
Minimization (also "source reduction") – The mass and volume of packaging (per unit of contents) can be measured and used as criteria for minimizing the package in the design process. Usually “reduced” packaging also helps minimize costs. Packaging engineers continue to work toward reduced packaging.
Reuse – Reusable packaging is encouraged. Returnable packaging has long been useful (and economically viable) for closed loop logistics systems. Inspection, cleaning, repair and recouperage are often needed. Some manufacturers re-use the packaging of the incoming parts for a product, either as packaging for the outgoing product or as part of the product itself.
Recycling – Recycling is the reprocessing of materials (pre- and post-consumer) into new products. Emphasis is focused on recycling the largest primary components of a package: steel, aluminum, papers, plastics, etc. Small components can be chosen which are not difficult to separate and do not contaminate recycling operations. Packages can sometimes be designed to separate components to better facilitate recycling.
Disposal – Incineration, and placement in a sanitary landfill are undertaken for some materials. Certain US states regulate packages for toxic contents, which have the potential to contaminate emissions and ash from incineration and leachate from landfill. Packages should not be littered.
Sustainability is the fastest-growing driver for packaging development, particularly for packaging manufacturers that work with the world's leading brands, as their CSR (Corporate Social Responsibility) targets often exceed those of the EU Directive.
Choosing packaging machinery includes an assessment of technical capabilities, labor requirements, worker safety, maintainability, serviceability, reliability, ability to integrate into the packaging line, capital cost, floorspace, flexibility (change-over, materials, multiple products, etc.), energy requirements, quality of outgoing packages, qualifications (for food, pharmaceuticals, etc.), throughput, efficiency, productivity, ergonomics, return on investment, etc.
Packaging machinery can be:
purchased as standard, off-the-shelf equipment
purchased custom-made or custom-tailored to specific operations
manufactured or modified by in-house engineers and maintenance staff
^Soroka (2002) Fundamentals of Packaging Technology, Institute of Packaging Professionals ISBN1-930268-25-4
^Diana Twede (2005). "The Origins of Paper Based Packaging"(PDF). Conference on Historical Analysis & Research in Marketing Proceedings. 12: 288–300 . Archived from the original(PDF) on July 16, 2011. Retrieved March 20, 2010. Cite uses deprecated parameter |deadurl= (help)
^Brown, P.J. (1988), "Andrew Yarranton and the British tinplate industry", Historical Metallurgy, 22 (1), pp. 42–48
^King, P.W. (1988), "Wolverley Lower Mill and the beginnings of the tinplate industry", Historical Metallurgy, 22 (2), pp. 104–113
^Y. Schneider; C. Kluge; U. Weiß; H. Rohm (2010). "Packaging Materials and Equipment". In Barry A. Law, A.Y. Tamime (ed.). Technology of Cheesemaking: Second Edition. Wiley-Blackwell. p. 413. ISBN978-1-4051-8298-0.
^Yoxall, A.; Janson, R.; Bradbury, S.R.; Langley, J.; Wearn, J.; Hayes, S. (2006). "Openability: producing design limits for consumer packaging". Packaging Technology and Science. 16 (4): 183–243. doi:10.1002/pts.725.
^Zabaniotou, A; Kassidi (2003). "Life cycle assessment applied to egg packaging made from polystyrene and recycled paper". Journal of Cleaner Production. 11 (5): 549–559. doi:10.1016/S0959-6526(02)00076-8.