Paperboard Packaging Research Articles

Progress in Biopolymer Coatings for Achieving Sustainable Paper and Paperboard Packaging for Food Applications: A Brief Review

ABSTRACTPaper and paperboard are cellulosic materials used to manufacture food packaging. However, their low resistance to water and fat, as well as their poor barrier properties have limited their packaging applications as food contact materials. The current review analyses the use of biopolymeric coatings as an alternative to improve surface and barrier properties in paper and paperboard with focus in food sector application. Advances in coated paper (board) can be classified into three groups: (1) coatings manufactured with a single biopolymer; (2) coatings manufactured with composite biopolymers; and (3) biopolymeric coatings incorporated with bioactive molecules or nanoparticles. The use of a single or composite biopolymer coating improved the mechanical, barrier properties, and grease resistance. In contrast, the use of chemical compounds and nanoparticles has imparted active properties (antibacterial and ethylene scavengers) in the resulting coating paper (board). The water vapour transmission rate has been reduced with the use of biopolymeric coatings. Future studies should focus on applying coated paper (board) in foods with a special interest in food self‐life, migration, and toxicity.

Numerical Modelling of Corrugated Paperboard Boxes

Numerical modelling of corrugated paperboard is quite challenging due to its waved geometry and material non-linearity which is affected by the material properties of the individual paper sheets. Because of the complex geometry and material behaviour of the board, there is still scope to enhance the accuracy of current modelling techniques as well as gain a better understanding of the structural performance of corrugated paperboard packaging for improved packaging design. In this study, four-point bending tests were carried out to determine the bending stiffness of un-creased samples in the machine direction (MD) and cross direction (CD). Bending tests were also carried out on creased samples with the fluting oriented in the CD with the crease at the centre. Inverse analysis was applied using the results from the bending tests to determine the material properties that accurately predict the bending stiffness of the horizontal creases, vertical creases, and panels of a box under compression loading. The finite element model of the box was divided into three sections, the horizontal creases, vertical creases, and the box panels. Each of these sections is described using different material properties. The box edges/corners are described using the optimal material properties from bending and compression tests conducted on creased samples, while the box panels are described using the optimal material properties obtained from four-point bending tests conducted on samples without creases. A homogenised finite element (FE) model of a box was simulated using the obtained material properties and validated using experimental results. The developed FE model accurately predicted the failure load of a corrugated paperboard box under compression with a variation of 0.1% when compared to the experimental results.

Bio-production of fire retardant and hydrophobic packaging paperboard with enhanced tensile strength through coating with modified cellulose nanofiber

Bio-production of fire retardant and hydrophobic packaging paperboard with enhanced tensile strength through coating with modified cellulose nanofiber

Valorization of food processing waste: Utilization of pistachio shell as a renewable papermaking filler for paperboard

Valorization of non-edible parts of food is an important method of reducing food processing waste. This study presents a potential application of nutshell wastes as a renewable and organic papermaking filler in paperboard packaging. Five pistachio shells particle (PSP) samples with different particle size distributions were prepared and their performance as a papermaking filler was examined relative to a conventional ground calcium carbonate (GCC) mineral filler. PSP fillers dispersed well in aqueous suspensions and showed better retention in handsheets compared to that of GCC, due to the improved retention by the larger particle sizes of PSPs. When PSP fillers had smaller particles than the pore sizes in the paper fiber network and their particle size distribution were narrow, they showed comparable mechanical properties in handsheets compared to that of GCC. Future research is suggested for successful applications of this organic and renewable filler in papermaking.

Effect of Coating and Coated Paperboard Packaging on the Quality of Grapes and Apple during Storage

Edible coatings and active packaging have become more prevalent in response to changing consumption patterns and market trends to enhance the quality and safety of fresh products. In this work, we investigated the effect of aloe vera gel (AVG) coating and paraffin wax-coated paperboard (PWB) packaging on the postharvest quality attributes of both grapes and apples during storage. The fruits were coated with 50% AVG concentrations, and the inner wall of the corrugated paperboard was coated with paraffin wax emulsion. The grapes and apples were stored for 12 and 35 days, respectively, at ambient conditions (25 ± 3°C and 80–85% relative humidity). The physicochemical properties, microbiological attributes, and decay incidence of the fruits were analyzed at intervals during storage. Both fruits treated with AVG and PWB packaging retained better qualities than the control at the final day of the storage period. Particularly, PWB packaging provided considerably superior quality from the control sample in terms of weight loss (≈54% and 32%), firmness (≈48% and 68%), and color difference (≈30% and 28%) for both grapes and apples. These findings would introduce a novel approach for preserving the quality attributes of both climacteric and nonclimacteric fruits for a prolonged storage period at ambient temperature by PWB packaging and AVG coating.

Creasing and folding of paper-based sandwich material–Phenomena and modelling

Creasing and folding are fundamental steps in many manufacturing processes of multi-material paperboard packaging. The complex structure of these materials, which comprise layers of cellulose fibres, aluminium, and polyethylene, coupled with the growing complexity of packaging designs, make these process operations essential to ensure the required structural integrity for packaging as well as their functionality in daily life. This paper introduces an approach for modelling damage in paper-based sandwich materials by integrating fibre-based and cohesive numerical modelling techniques. The results prove the effectiveness of the proposed methodology, opening new possibilities for process design and optimization in packaging manufacturing.

Barrier, converting, and tray‐forming properties of paperboard packaging materials coated with waterborne dispersions

AbstractIn this work, different food‐contact experimental and commercial aqueous polymeric dispersions were applied to paperboard via rod coating technology to achieve <5% non‐cellulosic content. Barrier (water, moisture and grease), mechanical (tensile and bending) and converting (heat‐sealing and creasing) properties were analysed before tray formation trials on pilot‐scale equipment. Dispersion‐coated samples were compared against polyethylene terephthalate (PET) extrusion‐coated paperboard, the principal industrial material used for food trays. Results show that, within the investigated properties, waterborne dispersions can achieve similar barrier properties compared with PET, yet at lower dry coat grammage (12 g/m2 vs. 40 g/m2 of PET‐coated paperboard). Additionally, the investigated coatings heat‐sealed at temperatures as low as 80–90°C, almost 100°C less than PET; however, lower seal forces could be achieved (15–20 N/(25 mm) vs. 23 N/(25 mm) of PET‐coated paperboard). Paperboard delamination occurred at the highest seal forces. Dispersion‐coated trays were obtained at 4.5–5.0% blank moisture content. Formed trays at industrial processing parameters showed critical coating damage during converting due to tensile stresses. This work shows that milder processing conditions allow a reduction in coat defects.

Sustainable plastic packaging waste management strategy based on a circular economy

Indonesia’s waste volume produced 71 thousand tons in 2022 and reached 26 million tonnes/year. Waste plastic is in second position at 18.37%. With a growth rate of 5%, the worldwide packaged food market is valued at 1.9 trillion in 2020 and is expected to reach 3.4 trillion by 2030. The growth of the packaging industry is predicted to grow by 6% - 8% annually, with the most considerable contribution from flexible plastic packaging, paperboard packaging and rigid plastic packaging. The potential of this packaging makes manufacturers confident in producing because of the rapid growth of the digital market, which makes product mobility even higher. From an economic and durability point of view, this type of packaging makes it a better choice. Flexible plastic packaging was the most produced of the total packaging products (46.73%). The goal of this study is based on a review of literature, analysis of data, and demonstration research, and it is necessary to collect and analyse a large amount of data to develop further accuracy in managing waste plastic in a circular economy to minimise waste generation and improve the environment with an interpretative structural modelling (ISM).

Creep behaviour of day‐old chicken corrugated paperboard packaging under different uniaxial compression loads—An experimental study

AbstractOne of the most important elements for animal transportation is the packaging that ensures the safety and health of the transit. During the transport of live small animals, such as day‐old chickens, the animals may only stay in the boxes for a very limited period, in this case, 48 h. Therefore, it is important to be able to model the strength behaviour of these boxes concerning packaging material requirements and sustainability. The aim of this study was to determine the short‐ and relatively long‐term strength of day‐old chicken packages to better estimate packaging design and to use these data to establish an analytical creep model with suitable parameters that adequately approximate the measured data. Two types of packages were tested, and two types of creep models were used to model the creep strain‐time graphs. The creep behaviour of the two samples was tested at four different uniaxial load cases, with consistent environmental conditions during the tests (23°C and 50% relative humidity [RH]). At the two highest loads, both samples failed before the 48‐h cycle, indicating a significant difference in box strength between short‐term and long‐term load tests. The secondary creep strain rate increases with the magnitude of the compressive load. When comparing the two creep models for both box types, the Power law provided the best accuracy at the 50% of box compression test (BCT) load case, while at the other three load cases, the Andrade law showed better predictions.

Effectiveness of aloe vera gel coating and paraffin wax-coated paperboard packaging on post-harvest quality of hog plum (Spondius mangifera L.)

In this research work, hog plum (Spondius mangifera L.) was treated with Aloe vera gel (AVG) coating and paraffin wax-coated box (PWB) packaging and stored at ambient condition (25 ± 3 °C and 80–85% relative humidity) for 12 d to evaluate their impact on postharvest quality and storability. The physicochemical properties, microbiological analysis, and decay evaluation were analyzed throughout the storage period. The AVG and PWB coating treatments both demonstrated a significant effect on the quality of fruits during storage. The results showed that fruits with AVG coating and PWB packaging exhibited lower decay rates, weight loss, color difference, total microbial population, total soluble solids, titratable acidity, and higher fruit firmness and pH than uncoated (control) fruits. The AVG coating was the most effective treatment, followed by the PWB packaging treatment. Our findings show that the AVG coating and PWB packaging treatment can be a promising solution for preserving the quality of hog plums and also helps in increasing the lifetime of hog plums during storage.

Compressive Strength of Corrugated Paperboard Packages with Low and High Cutout Rates: Numerical Modelling and Experimental Validation

The finite element method is a widely used numerical method to analyze structures in virtual space. This method can be used in the packaging industry to determine the mechanical properties of corrugated boxes. This study aims to create and validate a numerical model to predict the compression force of corrugated cardboard boxes by considering the influence of different cutout configurations of sidewalls. The types of investigated boxes are the following: the width and height of the boxes are 300 mm in each case and the length dimension of the boxes varied from 200 mm to 600 mm with a 100 mm increment. The cutout rates were 0%, 4%, 16%, 36%, and 64% with respect to the total surface area of sidewalls of the boxes. For the finite element analysis, a homogenized linear elastic orthotropic material model with Hill plasticity was used. The results of linear regressions show very good estimations to the numerical and experimental box compression test (BCT) values in each tested box group. Therefore, the numerical model can give a good prediction for the BCT force values from 0% cutout to 64% cutout rates. The accuracy of the numerical model decreases a little when the cutout rates are high. Based on the results, this paper presents a numerical model that can be used in the packaging design to estimate the compression strength of corrugated cardboard boxes.

Sustainable Coating Paperboard Packaging Material Based on Chitosan, Palmitic Acid, and Activated Carbon: Water Vapor and Fat Barrier Performance.

Synthetic polymer coatings impact the biodegradable behavior of cellulosic packaging material. The environmental consequences of food packaging disposal have increased consumer concern. The present study aimed to use natural polymer coatings incorporating palmitic acid and activated carbon applied to paperboard surfaces as a sustainable alternative to improve cellulosic packaging material's moisture and fat barrier properties, minimizing the environmental impact. The coating formulation was defined using a Factorial Experimental Design with independent variables: chitosan, palmitic acid, activated carbon concentrations, and the number of coating layers. The highest concentration of chitosan (2.0% w/w) filled the pores of the cellulosic paperboard network, supporting the compounds incorporated into the filmogenic matrix and improving the fat resistance. The water vapor permeability of the coated paperboard material (range: 101 ± 43 to 221 ± 13 g·d-1·m-2) was influenced by the hydrophobicity effect of palmitic acid, the non-polar characteristic of activated carbon, and the number of applied layers. The coating formulation selected was a chitosan concentration of 2.0% (w/w), a palmitic acid concentration of 1.8% (w/w), an activated carbon concentration of 1.2% (w/w), and an application of three layers. The coating provides the potential for a paperboard surface application, improving the cellulosic packaging material's fat and moisture barrier properties and maintaining biodegradability and recyclability.

Composite technology for the production of paper and cardboard including synthetic fibers

In the modern world, the importance and volumes of packaging produced are constantly increasing. It is a powerful means of promoting goods on the market, but at the same time, the role of its quality increases. Currently, paper and paperboard packaging is not only a significant part of paper and paperboard market in general, but also a large part of the world’s packaging consumption. Currently, the world pays special attention to the use of secondary paper waste for the production of paper and cardboard and increase the volume of their processing. The article is devoted to the production of new types of multilayer paper and cardboard with the addition of chemical fiber and secondary waste, as well as high-quality paper and cardboard that can be used in the printing industry, in order to save valuable cotton cellulose in the country. However, the article shows in what proportions it is advisable to use secondary fibers in combination with cellulose in the production of multilayer composite paper and cardboard for the printing and paper industries.

About Gas Barrier Performance and Recyclability of Waterborne Coatings on Paperboard

For preserving food packed in environmentally friendly and recyclable paperboard packages, it is important to have sufficient gas barrier performance of the paperboard container. Paperboard has poor intrinsic barrier properties and to overcome this deficiency, so a barrier coating is needed that does not hinder the recycling of the paperboard substrate. However, the gas barrier properties and the recyclability of such coatings have been rarely studied. Here, both the gas barrier performance and the removal of an alkali-soluble resin (ASR)-stabilized waterborne barrier coatings from paperboard are investigated. For barriers for gases, such as nitrogen, carbon dioxide, and oxygen, defect-free coatings are needed which is achieved by applying three coating layers. The oxygen transmission rate (OTR) of the three-layered coating on paperboard was 920 cm3/(m2∙day). For water vapor barriers, two coating layers already show a strong improvement, as water follows a different penetration mechanism than the other tested gases. The water vapor transmission rate WVTR of double coated paperboard was 240 g/(m2∙day). Preliminary results show that the coating is removed by immersion of the coated paperboard in an aqueous alkaline solution at room temperature. This causes de-protonation of the carboxylic acids of the ASR and subsequent re-dispersion of the coating in water. Removing double-layer coatings from the paperboard is more challenging, possibly due to the coating/coating interface between the two coating layers and enhanced adhesion between coating and paperboard.

Torsional and compression loading of paperboard packages: Experimental and FE analysis

The present study investigates torsional and compressive loading of a paperboard package. Finite element (FE) analyses simulating the tests were performed to improve understanding of the stresses and deformations in the paperboard during loading. A simple experimental characterization of the necessary material properties could be performed to represent the multi‐ply paperboard as a single‐ply structure. The results from the single‐ply model were compared with a laminate model, and the differences between the models were small. Comparing experimental and FE simulations of box compression and torsion showed that the FE models could accurately predict the response curves. However, in the simulations, there was an overprediction of the maximum compressive force and maximum torque, which was expected since geometrical imperfections and the heterogeneous internal structure of the material were not accounted for in the material model or the FE model. Local yield lines formed at the onset of non‐linearities in the package load–displacement curves. Therefore, the strength of the paperboard affects the maximum compressive strength and maximum torque, and the bending stiffness of the paperboard only had a minor effect. When a first local maximum was reached, the number of FE that reached the failure stress increased exponentially. The simulations also showed that box compression was not an effect of package height, but higher packages had a lower maximum torque.

Combining experiments and mechanistic modeling to compare ventilated packaging types for strawberries from farm to retailer

Soft fruits like strawberries are highly perishable and susceptible to postharvest decay caused by fungal infestation. Mold growth is favored by elevated temperatures in the cold chain or when water vapor condenses in the packaging induced by temperature fluctuations at high relative humidity. Optimal packaging for these products is required to improve homogenous fruit cooling and ventilation inside the package along the entire supply chain. This study analyzed three packaging types (top sealed paperboard, open and closed plastic clamshell) through laboratory storage experiments and simulations. We tested the different packages in a climate chamber, with conditions representing an actual supply chain from farm to retailer. We evaluated the performance of these packages by quality measurements. We measured the fruit mass loss, total soluble solids and acidity content, firmness, color change, and incidence of decay. We also developed physics-based models for the strawberries and packaging to gain complementary information that is difficult to quantify experimentally. These models rely on mechanistic simulations and sensor data to capture fruit’s hygrothermal and physiological evolution. To this end, we used monitored sensor data from the lab experiments as input for these physics-based digital fruit twins. We quantified in-silico the time of wetness due to condensation, respiration-driven overall fruit quality, and remaining shelf life along the simulated supply chain. Altogether, our simulation findings revealed that the top sealed paperboard packaging had the best performance in terms of respiration-dependent quality, mass loss and time of wetness. Furthermore, this package showed the least heterogeneities of fruit quality attributes inside the packaging, most likely due to the presence and position of ventilation holes. No clear differences were observed during laboratory experiments in rot incidence and traditional measured quality metrics (i.e., total soluble solids, acidity, color). Combining experiments with mechanistic modeling provides a deeper understanding of how fruit evolves in a supply chain. Also, it can capture packaging evaluating metrics, including moisture loss, time of wetness, or risk for microbial decay in a spatiotemporal manner.

Improvement of Package Properties with Formed Functional Surface Features

Paperboard package properties can be improved by embossing functional features on package surfaces. Embossing is used in package manufacturing as an additional tool to improve the appearance of the packages. It can also be used to increase product safety by improving functionality and identifiability of packages. Creation of features directly on the base material without implementing additional components improves the sustainability level of package applications. To evaluate functionality of features, such as protective surface patterns, in the applicable practice, the following steps need to be gone through; design phase, tool manufacturing phase, pattern production phase and analysis phase. Bespoken toolsets were designed and manufactured to form a protective frame around commercial radio-frequency identification tag (RFID). The essential process parameters in the embossing experiments were the pressing force and the plate temperature which were optimized in preliminary tests. Methods for evaluating the performance of created embossed patterns were wear testing of package surfaces, topography measurement with a 3D profilometer and SEM-imaging for more detailed analysis. The results show that embossing is a suitable manufacturing method for creating targeted functional features on paperboard surfaces. With the formed surface features, the functionality of the packages was improved by protecting the identification labels.

Modelling the Effect of Barrier Layers on the Tensile Properties of Paperboard Materials for Liquid Packaging

Investigations of the mechanical behaviors of the paperboard packaging materials has propelled to the forefront of the packaging industries owing to the anisotropic behavior of the paperboard materials. Paperboard materials undergo tensile forces during the creasing and folding operation. Therefore, the knowledge of the material tensile properties it is undeniably important to perform the operation without tearing the layers. Anisotropic behavior of the paperboard material is required to be addressed for the packaging material to be used effectively and efficiently. Paperboard material being anisotropic in nature have different properties in the Machine Direction (MD) and Cross Direction (CD). The paper focuses on the modelling of double layered paperboards with barrier elements either in aluminum or in Ethylene vinyl alcohol copolymers (EVOH). A numerical model of the packaging material was developed in LS-DYNA environment showing good fitting with the physical tests.

PRODUCTION OF SELECTED PACKAGING IN POLAND

This paper discusses the latest data on the production of selected paper and paperboard, plastic, glass, wood and metal packaging. During the study period 2016-2020/2021, there was an increase in the production of selected paper and paperboard packaging compared to 2016. There has been an increase in the production of paper sacks and bags, cartons made of paper or paperboard other than corrugated and cartons made of paper or paperboard. Among plastic packaging, the production of plastic bags and sacks played a significant role and has been growing steadily since 2016. The production of glass packaging (clear glass bottles with a capacity of less than 2.5 liters for beverages and food) increased between 2016 and 2021. Flat pallets were the dominant product among wood packaging in 2020. The decline in box pallet production was significant not only relative to 2019, but also relative to 2016. In the group of metal packaging with a capacity not exceeding 300 liters, the highest production was recorded for barrels and similar containers for any material (excluding gas), made of aluminium. It reached 93228 tonnes in 2020 and was 2.4% higher than in 2019. The packaging market in Poland and worldwide has been gradually increasing its value over the past years. The production of packaging in Poland in the coming years should grow dynamically, although not as fast as before. Undoubtedly, today the biggest challenge for the packaging industry is the rising prices of raw materials, which can negatively affect the profitability and liquidity situation of manufacturers. In particular, the prices of plastics have gone up considerably, but the costs of pulp, metals, wood and glass are also increasing, so the raw material pressure is now affecting the entire packaging industry.

A Green High Barrier Solution for Paperboard Packaging based on Potato Fruit Juice, Poly(lactic acid), and Poly(butylene adipate terephthalate)

The potential of using potato fruit juice (PFJ), a byproduct from the potato starch industry, was investigated as a barrier paper-coating material. The paperboard was initially hand-coated with PFJ (with and without glycerol as plasticizer) and then extrusion-coated with poly(lactic acid) (PLA) or a blend of PLA and poly(butylene adipate terephthalate) (PBAT). The multilayer coated paperboard was homogeneous in appearance with a glossy finish. The coated paperboard showed, at the most, a ca. 95% reduction in specific water vapor transmission rate compared to the uncoated paperboard. In the presence of the PFJ layer, the extrusion-coated paperboard experienced, at the most, a 98% reduction in oxygen permeability. The grease resistance of the paperboard was also improved significantly with this multilayer coating. PLA- and PFJ-coated samples showed better barrier properties, whereas PFJ with PLA/PBAT layers exhibited better adhesion and heat-sealing properties. The peel strength of the coated samples was moderately good for paper converting applications. The developed coated paperboard also exhibited good creasing properties which is yet again an advantage for packaging applications. The presented barrier properties make the developed multilayer coatings on paperboards a sustainable competitive alternative to several of today’s coatings.