DESIGN OF PACKAGING,EQUIPMENT

AND STORAGE OF
ALCOHOLIC BEVERAGES

SUBMITTED BY:
1.TARRANNUM KATARIA – CH15533

2.TARANPREET SINGH-CH15532

3.SUNANDITA PANDIT-CH15531
 Packaging Design
The packaging design and development framework:
● Product needs
● Distribution needs and wants
● Packaging materials, machinery and production
processes
● Consumer needs and wants
● Market needs and wants
● Environmental performance
 Key properties of glass
Inert with respect to foods

Transparent to light and may be coloured

Impermeable to gases and vapours

Rigid

Can be easily returned and reused

Brittle and breakable

Needs a separate closure

Widely in use for both single- and multi-trip packaging

 Key properties of tinplate and aluminium.

Rigid material with a high density for steel and a low density for aluminium

Good tensile strength

An excellent barrier to light, liquids and foods

Needs closures, seams and crimps to form packs

Used in many packaging applications: food and beverage cans, aerosols, tubes, trays and drums

Can react with product causing dissolution of the metal

 Key properties of paper and paperboard
Poor barriers to liquids, gases and vapours unless they are coated, laminated or wrapped

Good stiffness

Can be grease resistant

Absorbent to liquids and moisture vapour

Can be creased, folded and glued Tear easily

Not brittle, but not so high in tensile as metal

Excellent substrates for inexpensive printing

 Key properties of plastics
Wide range of barrier properties

Permeable to gases and vapours to varying degrees

Low-density materials with a wide range of physical and optical properties

Usually have low stiffness

Can be transparent

Functional over a wide range of temperatures depending on the type of plastic Flexible and, in certain cases,
can be creased
Performance requirements of packaging in
production may concern :-
Machinery for container forming

Materials handling Filling, check-weighing and metal detection

Sealing, capping or seaming

Food processing treatments

Labelling/coding

Shrink-wrapping; stretch-wrapping

Palletisation

Labour requirements
 PACKAGING OF ALCOHOLIC
BEVERAGES

The beverage industry is one among the front-liners where massive investments are being made for
expansion and technological upgradation.

The packaging of beverages both carbonated and non-carbonated, is a complex technological branch in the
Food Processing /Packaging industry. The traditional returnable glass bottle has given way to newer plastic
containers as well as cartons.

The current trend is to improve the conventional containers, extend their share in the large market, extend
the shelf-life of the products, provide greater consumer convenience and ultimately to produce economic
packages.
 Brandy and Whisky

These drinks are obtained by distillation of alcohol containing drinks. During distillation the aqueous part is
separated from the alcohol.

The distillates obtained are sold under several names like brandy, gin, whisky cognac, vodka, etc and have
different alcohol percentage.

Because of their high alcohol percentages, these liquors are mostly packed in glass bottles so that they can
be kept for an infinite time after opening.

The bottles are sealed to prevent alcohol from evaporating and to protect the contents of the bottles from
dirt and dust.
 Wine (Fruit/Sap based)

The most common form of packaging used for wines is the glass bottle sealed with natural cork. Since wines
are affected by sunlight, the bottles usually used are of coloured glass.

Bottled wine is normally stored in the horizontal position so that the cork is kept moist, thereby providing a
better barrier to the ingress of oxygen.

The most significant change in the packaging of wine resulted from the development of the bag-in-box
package: a flexible, collapsible, fully sealed bag made from one or more plies of synthetic films, a closure
and a tubular spout through which the contents are filled and dispensed, and a rigid outer box or container.
The bag is generally constructed from co-extruded film of EVA-BA-EVOH-BAEVA or LDPE-BA-EVOH-BA-LDPE.
The physical strength of the bag is of prime importance and must remain intact throughout distribution and
subsequent storage. Under normal circumstances, the bags are subjected to two forms of stress: hydraulic
shock (normally caused by sudden acceleration/deacceleration of the pack) and flex crack.By using
polymers, which have high flex resistance and improving the adhesion between the films, the strength of
the bag can be increased.

One problem associated with the packaging of wine into bag-in-box system is the decrease in shelf-life as
compared to that obtained using traditional glass bottles
By improving the barrier properties of the bag and the design of the tap the problem can be solved. A
special heat sealable membrane is partially attached to the gland during manufacture of the bag.

After filling but prior to insertion of the tap, this membrane is fully sealed to the gland and the potential
entry path is greatly reduced.

As a result the bag is completely sealed and is Alcohol Beverages in PET Bottles 172 totally independent of
the tap until the membrane is broached when the pack is just opened by the consumer.

Wines are also available in PET bottles and in stand-up pouches of metallised polyester laminates.
 Beer (Grain Based)

The traditional packaging media for beer is the glass bottle sealed with a crown closure. Recent
development is the use of PET bottles for packaging of beer. Types of PET beer bottles used are non-tunnel
pasterurised, one way tunnel pasterurised and returnable / re-fillable bottles.

Beer needs high performance in both CO2 and O2 barrier compared to PET used in carbonated soft drinks
(CSD) applications. The level required depends on the type of beer, container size, distribution channels and
environmental conditions (storage time, temperature and humidity levels).

Improvements in the barrier can be obtained via colourants, creating multi-layer bottles and scavengers.
 PACKAGING MACHINERY
A package is designed to protect and to sell the product it contains,and this generally requires a mechanical
process on a packaging line selected to carry out efficiently those operations necessary to put the product
into the package.

Majority of the operations on a packaging line are concerned with the package itself.

The line must put the product in the package economically ,in the desired condition,at the required speed ,
and to the stated quality.
Bottling
A bottling line can be a collection of automatic machines connected by a conveyer belt,or a group of highly
sophisticated ,fully automatic units.

Operating speeds on these vary from 30-60 units per minute.Above this speed , a fully automatic boiling line
is usually necessary,but before changing from semi to fully automatic equipment a stable container should
be considered which has a relatively large base area ,a low centre of gravity and parallel contact points on
each side,so that it does not topple ,cross section of the bottle should be such that it avoids jams and
breakages.
 Individual Bottling Process

● Bottle feeding
● Bottle cleaning
● Filling
● Closing
● Labelling
● Collecting and packing for transport
 Bottle feeding

New glasswares are now packed from the annealing conveyer directly into the cases in which the filled
bottles will eventually be shipped.This saves space ,labour and means that relatively simple devices can be
used to facilitate bottle feeding.

A rotatory unscrambling table is the simplest .

Once the filled cases have been inverted and the bottles pushed on a moving belt,they are conveyed away,
a line at a time,to the main slat chain conveyor.
 Bottle cleaning

The traditional method of cleaning glassware is to wash it on one of a range of bottle washers available.

Washers are generally of two types either hydro or soaker hydro ,the former employing liquid jets and the
latter complete immersion of the bottles,sometimes with addition of rotary brushers.Operating speed can
be from 20 to 600 per minute.

Where a one trip bottle is used,a much simpler means of cleaning is often employed,utilizing compressed
air.Particular attention to storage conditions,where temp or humidity variations may create condensation
causing dust to adhere to the container wall.

6o psi is the minimum air pressure for efficient cleaning.

Speed of operation of automatic air cleaners range from 60 to 600 per minute.
 Filling Liquids

Bottles-

Prinicples on which machines are based-

● Volume/weight based filling

● Time based filling

Four basic types of filling machines –

1. Vaccum fillers- these are further of 3 types-

Rotary,tray and automatic feed.
In vaccum system, a upply tank is required . vaccum is fed to this tank as the system starts. This creates a vaccum at
the lower end of the line, i.e. the suction point in the bottle. If the bottle is perfect, it draws liquid upto the overflow point
which breaks the vaccum and automatically stops the flow of liquid.
 2. Measured Dosing Method-
The height of the fill is not constant. Each individual filling unit consists of a system of cylinder and piston. As the
piston begins its downstroke, a valve opens allowing the passage of of fluid in the cylinder. At the end of stoke,the
cylinder is charged with measured quantity and when a container is aligned with filling point, the delivery valve will
open and supply valve closes. This happens in fraction of seconds.
3.Gravity Filling Machines-
Two types- one which fills on controlled time cycleand the other using a measuring chamber.
In the first, when container is aligned, liquid flows in the tank for a predetermined time. Valve closes and container is
taken away.
It depends on viscocity of product, orifice of the opening. In the second type, supply valve opens to a chamber which
further fills the containers. This is done pcharged into a container.

4.Pressure filling similar to time cycle gravity filling is done. Artifical head pressure is induce to the liq by a pump.
Statistical Recording – legal requirements

Packers in Europe are required to comply with EEC regulations.

In the simplest form of automatic machine a portion of product is measured into the container and then
passed onto for subsequent operations.

· The first step in automating the quality control check is to provide a simple check weighing
device with reject facilities towards the outfeed side of the automatic filling machine. To overcome the
problem of container weight variations it is possible to add a further check weighing machineto the infeed
side of the filling machine , and by cross linking the infeed and surfaced check weighers. This eliminates the
need for a product give away.
· To achieve more accuracy the container must be first weighed and it’s weight was recorded
before being passed on.
 Semi automatic weight control machines

Not every packer requires the outputs given by automatic machines and in some applications the size of
container is too great for automatic operation even when the size output requirement is not high.
· It is possible by placing a weighing system under a falling head to fill the product directly into the
container. Either rigid or flexible and when the desired gross weight ( product + container ) is
reached , a signal is given for the filling to stop. A visual indicative of the final weight is given to the
operator determine whether the desired weight has been achieved.
· Where a greater degree of filling accuracy is required , the container may be manually places at a
bulk filling head where the bulk of the producer is filled at a fast rate , the container is then
transferred to the fine filling section which compromises 2 filling head and weigh cell. Fine fill is
initiated and the balance of the product is slowly filled until the desired gross weight assured.
 Capping of bottles and jars

· For a speed of up to 60 per minute cap tightening alone is usually found to be adequate. For
this process the filled containers with pre-formed screw caps are presented either manually or
automatically to a rubber lined chuck which has a clutch set to operate and a fully automatic
capping machine is required and this is usually supplier with a cap assembly machine.
· This is normally supplied with a cap unscrambler for installing caps to the machine.
· Automatic capping machine - These fall into two main categories – a) inline and b) rotary . In
line cappers are simpler, incorporating the direct cap pick off principle. The bottles being held
by travelling belts while another set of belts operating sometimes on the top of the caps and
sometimes ok the skirt. Rotary cappers are more sophisticated holding the containers
individually while rotating Chucks screw home the caps.
· For a speed of up to 60 per minute cap tightening alone is usually found to be adequate. For
this process the filled containers with pre-formed screw caps are presented either manually or
automatically to a rubber lined chuck which has a clutch set to operate and a fully automatic
capping machine is required and this is usually supplier with a cap assembly machine.
· This is normally supplied with a cap unscrambler for installing caps to the machine.
· Automatic capping machine - These fall into two main categories – a) inline and b) rotary . In
line cappers are simpler, incorporating the direct cap pick off principle. The bottles being held
by travelling belts while another set of belts operating sometimes on the top of the caps and
sometimes on the skirt. Rotary cappers are more sophisticated holding the containers
individually while rotating chucks screw home the caps.
Automatic capping machine
· Roll on capping – it is in wide use of many bottling applications . In this the cap threads are
formed by rotary heads while the cap is in the position on the bottle. This type of cap can also
incorporate a pilfer proof device for R.O.P.P.
· Corking and plugging – The machines are similar in construction to rotary cappers. The corks
or plugs being fed from an unscrambling hopper to a chuck via a transfer arm or disc. The
chucks do not rotate but push the closure home with a downward thrust.
· Crown corks – The crown cork is widely used for beer bottles on filling lines operating at 600
per minute and is applied by a rotary capper usually an integral part of filling
machines.Pressure is exerted on the crown to compress the wall or liner while clinching heads
which corrugate skirt into a grove in the bottle neck.
 Labelling bottles or jars

· Upto speeds of 60 per minute semi automatic labelling machines are usually adequate. These
require an operative to present a bottle into machine which in turn glues and applies the label.
The three main methods of adhesive application are: a) adhesive is applied directly to the label
b) adhesive is applied to a plate which in turn applies it to label.
c) the bottles receive a pattern of adhesive slightly smaller than the
label itself.

· Case packing and sealing – After the bottles have been filled, capped and labelled , they are
often packed itni fibre board outers for transit to the wholesale depot. This process is preceded
or replaced by shrink wrapping. The case packing process is often performed manually ,
coupled with final inspection of the finished bottles .
· Shrink wrapping – The container is usually wrapped in a loosely fitting tube of shrink film
normally polyethylene which has been biaxiallyorientated and the pack is subsequently passed
through a heated tunnel which softens the film causing it to shrink and tightly envelop the
contents. A cooling section normally follows the heated tunnels so that the packs may be
handled immediately.

Palletizing – Pallets are flat platforms frequently made of timber with a space between the upper
and lower faces for the insertion of forks from fork lift trucks. Pallet loads are roughly cubic in
shape , being formed by layers of cases or goods which have been accurately placed to give a
good bond or interlock between layers . High output require automatic palletizing equipment.
Controlling the labels
Computer quality control
Packaging in boxes
Transport
Pallet transport to truck