Plastics in Packaging
Scott H. Boyle
Brian D’Amico
Janine Horn
Mark Przybylski

What Will be Discussed
 Definition of a plastic.
 Overview of the packaging industry.
 Why plastics are used in packaging.
 A detailed look at the different types of
plastics used in packaging.
 How plastics compare to alternative
materials.
 Environmental Impacts

What is a Plastic?
 A plastic is defined as an organic material that has
the ability to flow into a desired shape when heat
and pressure are applied and to retain that shape
when they are withdrawn.
 Composed primarily of a binder with-
• Plasticizers
• Fillers
• Pigments
• Other additives

Industry Overview
 World sales of primary packaging materials
estimated to be $434 billion in 2001.
• Up 12.5% from $385 billion in 1997.
 World sales of finished packaging materials is
estimated to be $800 billion.
 Four main categories of raw packaging materials:
• Paper and Board
• Glass
• Metal
• Plastic
 Over the past few years, plastic has become
increasingly popular.

Why Plastics?
 A wide variety of different qualities-
– Rigid vs. Flexible
– Clear vs. Opaque
 Lightweight
 Strong
 Cost

Which Plastics are Used?
 Six resins account for almost 97 percent of
all plastic used in packaging.
 Polyethylene terephthalate (PET) – 9%
 High-density polyethylene (HDPE) – 29%
 Low-density polyethylene (LDPE) – 32%
 Poly-vinyl chloride (PVC) – 5%
 Poly-propylene (PP) – 11%
 Polystyrene (PS) – 11%

Polypropylene
 Physical Properties
– Durable
 High elongation
– 300%
 High Tensile Strength
– 4500 psi
 High Yield Strength
– 4000 psi
– High Melting point
– Low Density
 Lowest density of all plastics used in packaging

Why Polypropylene?
 Practicality
– Inexpensive
– Chemically resistant
– Ideal for holding hot liquids
– Stretchy vs. rigid
 Many everyday uses
– Ketchup bottles
– Peanut butter jars

Polyvinyl Chloride
 Need Title
 Chemically non-reactive
 Flexible vs. Rigid
 Self Extinguishing
 Plasticized vs. Unplasticized
– Plasticized is more flexible

Why PVC
 Versatile
– Can be machined with standard metal working tools
 Self Extinguishing
– Used to house electrical wiring
 Many forms
– Sheet
– Tubing
– Piping

Polyvinylidene Dichloride
 Discovered in 1933
– Accidental Discovery
– Original use was to stop corrosion on airplanes
– After a green color and a pungent smell had
been removed it was used for food storage.
 Most common form of PVDC is Saran
Wrap®

Why PVDC
 PVDC is a very effective food preservation
method.
– Co-polymerization used in synthesis creates a
very tight molecular chain
 Provides good barrier against air and moisture.
 Chemically non-reactive
– Ensures that food won’t taste like plastic

Plastic vs. The Alternatives
Stress Strengths
100
550
30
1000
50
100
19 25
0
200
400
600
800
1000
St ress St rengt h
( M Pa)
Aluminum
Alloy
Glass Wood
(Oak)
Plastic
(PE)
M at erial
Stress Strengths of Packaging Materials
Minimum
Maximum

Plastic vs. The Alternatives
 Incredibly lightweight
 2 lbs of plastic can deliver 1000 oz. of liquid. To
carry the same amount it would take:
• 3 lbs of aluminum
• 8 lbs of steel
• 27 lbs of glass
 Compared to glass, plastic drink bottles allow a
distribution truck to carry up to 63% more drink and
83% less packaging.
 Compared to paper, 7 trucks are needed to deliver
the same quantity of paper bags contained in one
truckload of plastic bags.

Plastic vs. The Alternatives
 Cost
 As of mid-2000, PET was selling for app. $.62/lb.
 Around the same time, aluminum alloy was selling
for app. $1.28/lb.
– Plastic reduces distribution costs-
• Decrease in necessary truckloads
• Fuel savings
– Reduces lost inventory costs.

Plastic vs. The Alternatives
 Environment Impact
 Plastics are recycled less frequently than glass and
aluminum.
 Plastics are not biodegradable.

Plastic vs. The Alternatives
 Environmental Impact
 Plastic also has a positive impact on the
environment. Consider the following fact:
– When comparing the manufacturing processes of
polystyrene and paper cups, it was found the the paper
cups use:
• 15 times more chemicals.
• More than 6 times more steam.
• 13 times more electricity.
• 30% more cooling water.
• 170 times more process water.
 The lightweight nature of plastics results in fewer
truckloads and less fuel usage.

Recycle (cont.)
 Recycling process
– Collection
– Sorting
– Reclamation

Recycle (cont.)
 Benefits
– Less landfill waste
– Environmentally friendly

Recycle
 Statistics
– >80% of all US households have access to plastic
collection and recycling programs
– In 1998 plastic bottle packaging amassed 1.45 billion
pounds by volume
 Commonly recycled plastics
– Plastic Grocery Bags
– Plastic Milk Jugs and Detergent Bottles
– Plastic Beverage Containers

Reuse (cont.)
 Good Examples
– Large reusable containers
 Small packages of concentrated product are bought
and diluted to large container
 Reduces product packaging cost, landfill space
– Reusable Plastic Shipping Containers (RPSC’s)
 Replaces single use containers
 Reduces shipping/receiving costs, landfill space

Reusing and Recycling Plastic
Packaging
 Reuse
– Statistics
– Commonly reused plastic packaging
– Benefits
– Good Examples
 Recycle
– Statistics
– Commonly recycled plastic packaging
– Recycling Process
– Benefits

Reuse
 Statistic
– A 1997 survey found 80% of Americans reuse
plastic products and packaging
 Common Reusable Packaging
– Plastic Grocery Bags
– Plastic Milk Jugs and Detergent Bottles
– Plastic Beverage Containers

Reuse (cont.)
 Benefits
– Good Properties
 Long lasting
 Durable
 Chemically inert
– Delays filling of landfills
– Lowers cost of garbage disposal

In Summary
 Plastics
– Lighter …..…………………………….
– Cheaper …………...
– More Durable ………………………

Questions???