Manufacturing Flexible Packaging

Efficiently and profitably delivering quality flexible packaging to the marketplace requires designing and manufacturing products that are both "fit-to-use" and "fit-to-make". The engineering function in a flexible packaging enterprise must attend to these dual design challenges. Flexible Packaging discusses the basic processes used to manufacture flexible packaging products, including rotogravure printing, flexographic printing, adhesive lamination, extrusion lamination/coating; and finishing/slitting. These processes are then related to the machines used to practice them, emphasising the basics of machines’ control systems , and options to minimize wasted time and materials between production jobs. Raw materials are also considered, including the three basic forms: Rollstock (paper, foil, plastic films); Resin; and Wets (inks, varnishes, primers). Guidance is provided on both material selection, and on adding value through enhancement or modification of the materials’ physical features. A ‘measures’ section covers both primary material features – such as tensile, elongation, modulus and elastic and plastic regions – and secondary quality characteristics such as seal and bond strengths, coefficient of friction, oxygen barrier and moisture vapour barrier. Helps engineers improve existing raw material selection and manufacturing processes for manufacturing functional flexible packaging materials. Covers all aspects of delivering high value packaging to the customer – from the raw materials, to the methods of processing them, the machines used to do it, and the measures required to gauge the characteristics of the product. Helps engineers to minimize waste and unproductive time in production.

Multilayer Flexible Packaging, Second Edition, provides a thorough introduction to the manufacturing and applications of flexible plastic films, covering materials, hardware and processes, and multilayer film designs and applications. The book gives engineers and technicians a better understanding of the capability and limitations of multilayer flexible films and how to use them to make effective packaging. It includes contributions from world renowned experts and is fully updated to reflect the rapid advances made in the field since 2009, also including an entirely new chapter on the use of bio-based polymers in flexible packaging. The result is a practical, but detailed reference for polymeric flexible packaging professionals, including product developers, process engineers, and technical service representatives. The materials coverage includes detailed sections on polyethylene, polypropylene, and additives. The dies used to produce multilayer films are explored in the hardware section, and the process engineering of film manufacture is explained, with a particular focus on meeting specifications and targets. In addition, a new chapter has been added on regulations for food packaging – including both FDA and EU regulations. Provides a complete introduction to multilayer flexible packaging, assisting plastics practitioners with the development, design, and manufacture of flexible packaging for food, cosmetics, pharmaceuticals, and more Presents thorough, well-written, and up-to-date reviews of the current technology by experts in the field, making this an essential reference for any engineer or manager Includes discussion and analysis of the latest rules and regulations governing food packaging

The Science and Technology of Flexible Packaging: Multilayer Films from Resin and Process to End Use, Second Edition provides a comprehensive guide on plastic films in flexible packaging, covering scientific principles, materials properties, processes and end use considerations. Sections discuss the science of multilayer films in a concise and impactful way, presenting the fundamental understanding required to improve product design, material selection and processes. In addition, the book includes information on why one material is favored over another and how film or coating affects material properties. Descriptions and analysis of key properties of packaging films are provided from engineering and scientific perspectives. With essential scientific insights, best practice techniques, environmental sustainability information and key principles of structure design, this book provides information aids in material selection and processing, how to shorten development times and deliver stronger products, and ways to enable engineers and scientists to deliver superior products with reduced development time and cost. Provides essential information on all aspects of multilayer films in flexible packaging, including processing, properties, materials and end use Bridges the gap between scientific principles and practical challenges Includes explanations to assist practitioners in overcoming challenges Enables the reader to address new challenges, such as design for sustainability and eCommerce

There has been considerable recent growth in the use of flexible pouch packaging for heat preserved foods, which has generated new opportunities for presentation of products ranging from meats, vegetables, and rice and pasta ready-foods to sauces, desserts and pet food. Such products can be ambient stable or chilled and include many of the socalled REPFEDs (refrigerated pasteurised foods of extended durability). These developments have created the need for up-to-date guidance on in-pack heat processing of such products, to encourage and enable the adoption of good manufacturing practice. This document provides this guidance Based on CCFRA's long established Guidelines on GMP for sterilisable flexible packaging operations for low acid foods (Technical Manual No. 4), this extensively revised and updated guide has been developed by a group of representatives actively involved in the manufacture and development of these types of products. It takes in packaging requirements (preformed, reel fed and secondary), filling techniques, sealing conditions, processing (both pasteurisation and sterilisation) and transportation. It also includes information on recommended quality assurance checks and on pouch defects. Written with a strong practical stance, the guide will be of use to both food and packaging companies using flexible sterilisable packaging for food and drink products.

Recycling of Flexible Plastic Packaging presents thorough and detailed information on the management and recycling of flexible plastic packaging, focusing on the latest actual/potential methods and techniques and offering actionable solutions that minimize waste and increase product efficiency and sustainability. Sections cover flexible plastic packaging and its benefits, applications and challenges. This is followed by in-depth coverage of the materials, types and forms of flexible packaging. Other key discussions cover collection and pre-treatment, volume reduction, separation from other materials, chemical recycling, post-processing and reuse, current regulations and policies, economic aspects and immediate trends. This information will be highly valuable to engineers, scientists and R&D professionals across industry. In addition, it will also be of great interest to researchers in academia, those in government, or anyone with an interest in recycling who is looking to further advance and implement recycling methods for flexible plastic packaging. Presents state-of-the-art methods and technologies regarding the processing of flexible plastic packaging waste Addresses the challenges currently associated with both waste management and available recycling methods Opens the door to innovation, supporting improved recycling methods, manufacturing efficiency and industrial sustainability

A comprehensive and highly practical survey of the materials, hardware, processes and applications of flexible plastic films. Aimed at a wide audience of engineers, technicians, managers, purchasing agents and users, Multilayer Flexible Packaging provides a thorough introduction to the manufacturing and applications of flexible plastic films, covering: Materials Hardware and Processes Multilayer film designs and applications The materials coverage includes detailed sections on polyethylene, polypropylene and additives. The dies used to produce multilayer films are explored in the hardware section, and the process engineering of film manufacture explained, with a particular focus on meeting specifications and targets. The section includes unique coverage of the problematic area of bending technology, providing a unique explanation of the issues involved in the blending of viscoelastic non-Newtonian polymeric materials. About the author John R. Wagner, Jr. is President of Crescent Associates, Inc., a consulting firm that specializes in plastic films and flexible packaging. He graduated from the University of Notre Dame with a BS and MS in Chemical Engineering.

Food Processing Technology: Principles and Practice, Fifth Edition includes emerging trends and developments in food processing. The book has been fully updated to provide comprehensive, up-to-date technical information. For each food processing unit operation, theory and principles are first described, followed by equipment used commercially and its operating conditions, the effects of the operation on micro-organisms, and the nutritional and sensory qualities of the foods concerned. Part I describes basic concepts; Part II describes operations that take place at ambient temperature; Part III describes processing using heat; Part IV describes processing by removing heat; and Part V describes post-processing operations. This book continues to be the most comprehensive reference in the field, covering all processing unit operations in a single volume. The title brings key terms and definitions, sample problems, recommended further readings and illustrated processes. Presents current trends on food sustainability, environmental considerations, changing consumer choices, reduced packaging and energy use, and functional and healthy/plant-based foods Includes highly illustrated line drawings and/or photographs to show the principles of equipment operation and/or examples of equipment that is used commercially Contains worked examples of common calculations

Flexible packaging: the fastest growing packaging market in the world is the subject of the new book by Instituto de Embalagens In Brazil, the performance of the flexible packaging industry also continues to expand. In 2021, gross sales reached BRL 43.6 billion, according to a Maxiquim study carried out for ABIEF (Brazilian Association of the Flexible Plastic Packaging Industry). The result represents growth of more than 55% in relation to the previous year. The food industry remains the main market for flexible plastic packaging in Brazil (42% share) and globally (75.5%) in 2021. The fastest-growing end-use markets include meat, fish and poultry, and frozen foods, with an average annual growth rate of 5.9% globally. Flexibility, as the name implies, is one of the great differentials of flexible packaging that is present in various categories of consumer products, addressing convenience, practicality, safety, and environmental, economic, and social sustainability. The growth of stand-up pouches around the world and in Brazil is notable, adding lids and accessories, and gaining market share in new segments. "Innovation brings an avenue of opportunities to develop better flexible packaging for a better world", highlights Assunta Napolitano Camilo, director of the Packaging Institute. Sustainability - The Smithers study also points out that revisiting various stages of the packaging journey, from design to recycling, will be important for the circularity of plastic and will also be one of the subjects addressed in the new bilingual book on Flexible Packaging by the Instituto de Embalagens. In Western Europe, there is increasing pressure to replace difficult-to-recycle plastics in many important applications. This is already driving the evolution of flexible paper packaging and, in particular, structures that can provide adequate barrier protection. Alternatives under development within plastics include: • Use of more recycled plastic content without compromising material performance; • Improve the recyclability of current packaging options with more mono-material constructions; • Identification of suitable markets for flexible biopolymers. An emerging trend in the post-Covid world has been the use of refill packs for household and personal care products. This has unlocked new potential for flexible plastic refill packaging that minimizes size and weight in transit. The new bilingual book on Flexible Packaging brings updated content, covering, market information, trends, design, innovations, processes, equipment, and sustainability.