Credits: (3-L:0-0) 3

Prerequisite(s): FOOD 3010 or consent of instructor

Instructor: TBA

Lecture: 10:00AM Tuesday, Thursday, 344 Ellis Building

Office hours:

Objectives
Introduction to the physical principles and technology of packaging for the food industry with emphasis on the consequences to food stability and quality. Prerequisite: FOOD 3010 (or 078.301) or consent of instructor.

HW and lab report Homework and lab report should be submitted on the assigned due date before class starts. Homework should be typewritten double-spaced with 2.5cm (or 1in) margins. Tables and figures should be attached at the end of paper with table title and figure captions. Late reports and homework will lose 10% of credit for submission after the due and 10% for each additional day late. Every sentence, which is NOT in your own words, has to be correctly cited and the original should be listed. They could be journal articles or personal communications, including discussion with classmates.

Grading
Calculation 1 Calculation 2
Midterm exam 35% 30%
Final exam (comprehensive) 40% 35%
Homework 15% 20%
Lab report 5% 10%
Attendance 5% 5%
The better score of both calculation methods will be the final score.

100 – 90 A+ 89.9 – 80 A
79.9 – 75 B+ 74.9 – 70 B
69.9 – 65 C+ 64.9 – 60 C
59.9 – 50 D 50 > F

Textbook: None

Selected References (available on reserve in Science and Dafoe Libraries)

Food Product - Package Compatibility (1987) edited by J.I. Gray, B.R. Harte & J. Miltz. Technomic Publishing Co. Inc., Lancaster, Pa.
Modern Processing, Packaging and Distribution Systems for Food (1987) edited by F.A. Paine. Blackie Academic and Professional, Glasgow.
Food Packaging (1990). edited by T. Kadoya. Academic Press, New York.
Food Packaging and Preservation (1982) edited by M. Mathlouthi. Elsevier Applied Science, Barking.
Flexible Food Packaging Questions and Answers (1991) A. Hirsch. Van Nostrand Reinhold, New York.
Principles and Applications of Modified Atmosphere Packaging of Foods (1993) edited by R.T. Parry. Blackie Academic and Professional, Glasgow.
Emerging Technologies in Plastics Recycling (1992) edited by G.D. Andrews & P.M. Subramanian. American Chemical Society, Washington, DC.
Aseptic Processing and Packaging of Particulate Foods (1993) edited by E.M.A. Willhoft. Blackie Academic and Professional, Glasgow.
Packaging Foods with Plastics (1991) W.A. Jenkins. Technomic Publishing Co. Inc., Lancaster, Pa.
Food Packaging: Principles and Practice (1993) G.L. Robertson. Marcel Dekker, New York.
Food and Packaging Interactions II (1991) edited by S.J. Risch & J.H. Hotchkiss. American Chemical Society, Washington DC.
Edible Coatings and Films to Improve Food Quality (1994) edited by J.M. Krochta, E.A. Baldwin & M.O. Nisperos-Carriedo. Technomic Publishing Co. Inc., Lancaster, Pa.
Food Science Reviews: Volume 2 Chemical Migration from Food Packaging (1993) edited by D.H. Watson & M.N. Meah. Woodhead Publishing, Abington, GB.
Innovations in Food Packaging (2005) edited by J.H. Han. Elsevier Academic Press., Amsterdam, The Netherlands.

Periodicals:
Journal of Food Science, Food Technology, Food Research International, Journal of Agricultural and Food Chemistry, Journal of Food Process Engineering, Journal of Food Processing and preservation, Journal of Food Engineering, Packaging Technology & Science, Trends in Food Science and Technology.

Homework Assignment:

1. Collect the packages of three food products one from different product groups (i.e., cereal, processed meats, dairy, drink/beverage, confectionary, can, snack, …) and identify information on the packages (e.g., brand name, net content, nutrition label, ….) as many as possible. Attach the collected packages or their photos to the end of your homework.

2. Name the polymer materials and draw chemical structures of following abbreviations: ABS, EVA, EVOH, HDPE/MDPE/LDPE/LLDPE, PA, PAN, PC, PCTFE, PET (PETE), PP, PS, PTFE, PU (PUR), PVA, PVC, PVDC

3. Explain the printing processes of (1) flexography, (2) lithography, and (3) rotogravure

4. Collect most recent statistics of: (1) total solid wastes (paper, aluminum, glass and metals) in North America (or US, Canada only); (2) recycling ratio of the solid wastes to total wastes; (3) landfill ratio to total wastes; (4) incineration ratio to total wastes; and (5) packaging wastes ratio to total landfill. Conclude with your suggestion to reduce total wastes with respect to packaging wastes.

5. Summarize about bar-code system including types, data reading systems, benefits and symbology

6. Determine the difference between two drinks’ labels which will be provided during class, and find the reason of the difference including regulation.

Laboratory:

1. Make two paperboard cartons and their engineering drawings of opened structure (nets) which can hold 4 of individual carton packages with identical size of 3 3/4 x 3 7/8 x 2 in3. (1) tuck top and Himes lock bottom; and (2) tuck top and 1-2-3 snap lock bottom.

2. Measure the water vapor permeability of plastic films. After place your test film on plastic cup provided, then measure the weight decrease with time. Plot weight vs. time chart, and calculate water vapor transmission rate from the slop of the plot. Determine the thickness of test film and calculate water vapor permeability.

3. You are in the new product development team, and in charge of package design. A new cereal bar has a dimension of 2 x 1/2 x 4 in3 (W x H x L). Choose the flexible pillow package material as a primary packaging, explain the reason you used the material, and complete the engineering drawing of opened structure (a net) of the pillow. Make one prototype of the design using Styrofoam, rice crispy or play dough for the cereal bar, and clear plastic film or paper for the pillow package.

4. Design a paperboard carton net for 12 cereal bars which were prepackaged by lab 3. This paperboard carton should also have a display function on the shelf of retail store. Also make one prototype of the carton without 12 cereal bars.

5. A corrugated box should have 24 pieces of cereal bar cartons which were designed by lab 4. Design the opened net of the corrugated box. Describe materials of corrugated box and the arrangement of 24 cartons in the box. Also describe the way to load the boxes on a standard pallet. Full credit will be given to the box design which can be loaded the most number of boxes on the standard pallet among all submitted design from the class.

Important Dates

September 13 First class October 27 Due of lab 3 report
September 22 Due of homework 1 November 3 Due of homework 4
September 29 Due of lab 1 report November 10 Due of lab 4 report
October 6 Due of homework 2 November 17 Due of homework 5
October 13 Due of lab 2 report November 24 Due of lab 5 report
October 20 Due of homework 3 December 1 Due of homework 6
October 25 Mid-term exam

LECTURE SCHEDULE
1. Overview
History, Packaging industry, Purposes

2. Graphic design, printing and decorating
Introduction to graphic design, Color and artwork, Printing methods, Other decoration techniques

3. Paper and paperboard
Paper manufacture, Paper characterization, Types and grades

4. Paperboard packaging
Folding carton, Setup boxes, Display packages

5. Glass containers
Glass types and manufacture, Bottle manufacture and design

6. Metal cans and containers
Cans, Can dimensions, Coating and decoration of cans

7. Basic polymer chemistry
Plastic chemistry fundamentals, Polymers and monomers, Polymer structures and properties, Thermoplastic and thermoset polymers

8. Shaping plastics
Extrusion, Blow molding and injection molding, Thermoforming, Combined methods

9. Plastic materials
Polyethylene (PE), Polystyrene (PS), Polypropylene (PP), Poly(ethylene terephthalate) (PET), Poly(vinyl chloride) (PVC), Poly(vinylidene chloride) (PVDC), Polyamides (Nylon), Other plastics, Plastic additives, Characterization of plastics

10. Aluminum foils and metallizing
Aluminum foil and manufacture, Foil coating and lamination, Pinholing and flex cracking, Vacuum metallizing

11. Flexible packaging
Laminates, Structures and properties, Laminating processes

12. Effect of Physical Properties of Packaging 1
Package strength, stiffness, toughness to prevent quality loss, Light transmissivity and prevention of chemical reactions, Specialized attributes, Effect of temperature on package/food interactions

13. Effect of Physical Properties of Packaging 2
Resistance to microorganisms, Food stability and package inertness, Gas permeability and produce respiration

14. Distribution packaging
Distribution systems, Warehouse, Load units, Corrugated boxes, Pallets and palleting, Shipping containers

15. Shock, vibration and compression
Shock and cushioning, Vibration, Compression

16. Food deterioration, shelf-life and reaction kinetics

17. Permeation in packages

18. Modified atmosphere packaging
Theory, gas permeation and respiration, beta-value of packaging film

19. Packaging for oxygen and moisture sensitive foods

20. Food package development

21. Retortable plastic containers and aseptic packaging

22. Package design for marketing
Enhancing product sales and consumer preference, Individual vs. bulk, Bag-in-box, Handling and dispense, Packaging planning strategy, Bar-code systems

23. Package design for safety and security
Tamper-evidence design, Traceability, Bioterrorism and packaging

24. Active packaging
Oxygen scavenging packaging, antimicrobial packaging, gas emitting/absorbing packaging, moisture control packaging

25. Intelligent packaging
Freshness indicator, RFID

26. Packaging as a waste material
Solid waste, Litter and landfills, Reuse and recycling of packaging, Biodegradation and biodecomposition

06/11

Policy on Plagiarism and Cheating (University Calendar)