Packaging!

ICE CREAM TECHNOLOGY COURSE

2018

Randhir Paul

1
Packaging
 VIDEO 1:

A WORLD WITHOUT PACKAGING

1:07
THE ROLE OF PACKAGING

An Excellent Functional Container

Contains
Protects
Informs
‘what you see
in a
supermarket !

5
BUT WITH SO MANY BRANDS.....
...FIGHTING IN THE SAME SATURATED MARKET SPACE.....
...FIGHTING IN THE SAME SATURATED MARKET SPACE.....

3 seconds
average time consumer scans a
product

70%
final purchase decisions made at POS

40000 SKUs
average number stocked in a western
supermarket
PACKAGING BEYOND BEING A CONTAINER

IT’S WHERE ALL THE INTANGIBLES OF

THE BRAND FINALLY TOUCH THE
CONSUMER.

PACKAGING IS ONE OF THE

MOST POWERFUL OPPORTUNITIES
TO CONNECT….THE FIRST CONSUMER
TOUCHPOINT
WINNING PACKAGING: BREAK MARKET TRENDS
WINNING PACKAGING: REFLECTING THE BRAND
PERSONALITY
WINNING PACKAGING: CREATING NEW NEWS FOR THE
CONSUMER, EVEN ON STANDARD PACKS
WINNING PACKAGING: DELIGHTFUL CONSUMER
EXPERIENCES
WINNING PACKAGING: DELIGHTFUL CONSUMER
EXPERIENCES

Jonathan Ives – head of Design at Apple:

"I love the process of unpacking something.
You design a ritual of unpacking to make the product feel special.
Packaging can be theater, it can create a story.“
WINNING PACKAGING
WINNING PACKAGING
OUR MISSION IN REFRESHMENT PACKAGING
 REFRESHMENT PACKAGING:
GLOBAL DESIGN CENTRE

REFRESHMENT
GDC PACKAGING

DESIGN &
BRAND PACKAGING
TECHNOLOGY

BRAND INNOVATION PROGRAMME DESIGN

BRAND PACKAGING ROADMAPS MATERIALS & TECHNOLOGY
PACKAGING EXCELLENCE
SUSTAINABILITY
REFRESHMENT PACKAGING
JUNE 2018
Sanjeev Das Kirsty Lawes
R&D Director Team Assistant
Packaging (Multiple Groups)
Colworth
Colworth

BRAND PACKAGING DESIGN & TECHNOLOGY

MATERIALS ENABLING
Design SUSTAINABILITY
TECH TECH

Poonam Kostas Jesus Aisa

Randhir Paul Lee Foster
Dharman Vacancy Michael Brink Jamie Bates Katsogiannias Suzanne Axe R&D
Senior Senior
Senior Packaging Ben & Jerry’s R&D Design Materials Technology Enabling Sustainability
Packaging Packaging
Packaging Manager Manager Excellence Leader Manager Technology Manager Manager
Manager Manager
Manager
Colworth Colworth Vermont, USA Colworth Colworth Colworth Colworth
Colworth Colworth

Reports to
R&D Director, B&J
Gareth Hay Alexandra
Senior Jhelum Ricardo Chumki Paul
Ghose-Biswas Senior King Hugo Barroux Li Wang
Packaging Goncalves
Packaging Packaging Packaging Materials Packaging
Technologist Junior
Technologist Technologist Technologist Technologist CAE Designer
Colworth Designer
Colworth Colworth Colworth Colworth Colworth Port Sunlight

Abi Olayiwola Ahmed

Tais Santos
Senior Daiane Goulart Ramadan
Packaging Ellie Simmons
Packaging Technologist Design &
Technologist Design Project
Technologist Simulation Engineer
Leader Colworth
Colworth Colworth Colworth
Colworth

Enrico Corti
Maria Betancor 1 Georgia
Packaging
Packaging Knight
Technologist
Technologist Apprentice
Colworth
Colworth Colworth
Ice cream packaging

overview

20
ICE CREAM PACKAGING: CONSIDERATIONS

10% 30%

Magnum CDO

Highly specific to filling line

high functionality Low % of total product cost Small changes can have big effect = capex
-18ºC!

Ice Cream Packaging Spend = €500M

 MAIN IC PACK TYPES

PRIMARY PACKAGING SECONDARY PACKAGING

For the consumer For the customer

FLOWWRAPS
PLASTIC TUBS / POTS

PLASTIC SHRINKFILM

SLEEVES WRAPPERS
PAPER TUBS / CUPS

WOODEN STICKS PAPERBOARD OUTER CASES

CARTONS
FLEXIBLE FILMS
• What are they made from
• How they are made
• How we fill & pack it
MATERIALS

Single layer films Multi layer films

Printing Printing

2nd Layer
Polypropylene glue
30 – 40 μ
Polypropylene
30 – 40 μ

Sealing layer Sealing layer

HOW ARE FLEXIBLES
MATERIALS MADE?
BLOWING FILM
Blow air through a CIRCULAR DIE into a stream
of molten plastic to form a big bubble
FILLING/PACKING:

VERTICAL: HORIZONTAL:
BAG FORMING FLOWWRAPPING
CONE SLEEVES

Aluminum foil + Paper

Made flat then rolled and glued to form sleeves

Rigid plastic tubs

31
PLASTICS POLYMERS
“Poly “ :many +” mer “:parts

large molecule, or macromolecule,

composed of many repeated subunits, known as monomers
POLYMERS IN IC

Main Material: POLYPROPYLENE (PP)

• Lightweight
• Strong & Tough
• Great temperature resistance
• Translucent

Other Materials:
Other Materials:
Polyethylene terephthalate
POLYSTYRENE (PS)
(PET)
• high transparency (glass like)
• high transparency
• hard & brittle
• lower low temperature
resistance
MANUFACTURING: INJECTION MOULDING

INJECT molten Plastic cools and

Melt plastic plastic into mould hardens to the
(high pressure) shape of the mould

Main materials: Polypropylene (PP)

Advantages: High precision, high volume
Disadvantage: expensive moulds, long leadtime
MANUFACTURING: THERMOFORMING

Take a sheet of Pull the soften

Place it over a
plastic and heat it material into the
mould
until it softens mould and cool

Main materials: High Impact Polystyrene (HIPS)

Polypropylene (PP)
Advantages: inexpensive moulds, shorter leadtime
Disadvantage: not high precision/dimensional components
(better for simple, lower volume items)
PLASTIC TUBS: PRINTING AND DECORATION
• Self-Adhesive Labels
– Plastic, Paper

• In-Mould Labelling (IML)

– Done during injection moulding process
– Label is fused into the plastic

Robot places Robot moves Mould closes and the Mould opens, and
label in mould out of the plastic is injected in; labelled container
way! label fuses to comes out
conatiner
 How to be a packaging geek…..

(Impress your friends and family!)

 Indented Smooth
bottom flat
(“injection bottom
gate”)

INJECTION MOULDING THERMOFORMING

 One thing to watch out for when you
impress your friends and family…..

........always make sure the pack is closed,

before you look at its’ bottom!
Paper & board

40
WHAT IS PAPER MADE FROM?
PAPER PACK FORMATS

TUBS & POTS CARTONS CORRUGATED OUTER CASES

PAPER TUBS/POTS
gsm = grams per sq m

Polyethylene
Printing •Moisture resistance
•Main structure •Sealing
•great printability Paper •12-15gsm
•320gsm

Polyethylene

Supplied as pre-made pot Supplied as separate pieces (side wall,

to Unilever SU base) then formed, sealed and filled
CARTONS
For Ice cream: typical carton materials are
FOLDING BOX BOARD and WHITE LINED CHIPBOARD

FOLDING BOX BOARD WHITE LINED CHIPBOARD

Virgin materials - no recycled material Use of recycled material
Suitable for direct food contact Not suitable for direct food contact
More expensive Less expensive
CORRUGATED CASES

One or more sheets of fluted paper adhered to one or more

liner papers using starch as glue

-Most typical Outer Cases

Compression

/printability
protection

surface
finish

-Shelf Ready packaging

-Cartons
sticks

46
WOODEN STICKS: MATERIALS

BEECH BIRCH

• One of the most crucial packaging materials in Unilever:

consumers put it in their mouths

• Made of natural material – Wood – so…..

• difficult to engineer as precisely as other materials
• Microbiological risks. Heavy metals risks
Region EU/Turkey NA/LATAM/ASIA
Colour White to Brown/Red Yellow/White
Taste None Slightly bitter • Sticks have a definite flavour profile
Odour None Some

Cost **** **
WOODEN STICKS
Format and sizes

Paddle stick Classic sticks Spoons

94mm*

93 mm 113 mm Others
*Magnum 100mm
140mm

Decoration Packing

Unique coded Branded

Loose Banded Single wrapped

Riddles
WOODEN STICKS: MANUFACTURING

Fine print: the actual process is a little more automated than shown in these diagrams!
Distribution
packaging

50
CORRUGATED CASES

Regular
Slotted
Case Machine Erecting Cases
•Wraparound
•Top Load
•Side Load

More material than shrinkwrap BUT gives a lot of protection

SHRINKWRAPPING
• Low Density Polyethylene (LDPE)
• 35 - 50 micron
• Tunnel at ~ 150ºC

• Cheap
• Very little material
• No physical protection
DISTRIBUTION PACKAGING
Pallet (wood)
– DIN (1200x1000x1710)
– EU (1200x 800x1650)
– UK (1200x1000x1500)

Palletisation
– different stacking patterns depending on
pack size and type

Wrapping Pallets:
• “Locks” the load onto the pallet
base and provides stability
• Stretchfilm - Linear Low density
Polyethylene (LLDPE)
SUMMARY
 The main types of
The role of Packaging
IC packaging