Alexei Volkov
Flexible packaging has a long history, with its origins dating back over 1,500 years. Early humans used natural materials such as leaves, barks, and animal skin for packaging. Over time, the development of paper and paperboard packaging introduced more flexible options, with the Chinese using thin layers of mulberry bark for food storage as early as the first or second century BC. In the 1870s, the invention of foldable cartons and paper bags further advanced the concept of flexible packaging. However, it was in the 1950s and 1960s that plastics began to dominate the flexible packaging market, with the introduction of thin plastics, film lamination, and heat-seal coatings. Today, plastic films account for over 70% of the flexible packaging industry's revenue, with paper-based flexible packaging regaining some popularity due to environmental concerns.
| Characteristics | Values |
|---|---|
| Origins of flexible packaging | 1,500 years ago |
| Earliest forms of flexible packaging | Sewn packaging, natural materials like leaves, animal skin, and organs, bark |
| Paper packaging | Originated in China around 105 AD, made from bamboo and other plant fibres |
| Paper packaging in the UK | Introduced in 1310 |
| Plastic packaging | Discovered in the 19th century, widely used since the 1950s |
| Plastic packaging revenue | 70% of the industry's revenue comes from polymer materials |
| Plastic packaging products | Polyethylene, Polypropylene, Poly Vinyl Chloride, Polyamide, Ethylene Vinyl Alcohol |
| Plastic packaging innovations | VCI flexible packaging, bubble wrap, gas flush bags, Polyfresh Plus hot fill bags |
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What You'll Learn
Plastic packaging's ancient origins
The history of flexible plastic packaging is a rich one, with roots stretching back to ancient civilizations and evolving through centuries of innovation.
In the early days of humanity, when humans were nomadic hunter-gatherers, materials such as leaves, animal skins, nuts, and gourds were used to store and transport items. As villages and families became more self-sufficient, they continued to use natural materials such as woven grasses, hollowed logs, and animal organs for containers.
The ancient Chinese are credited with inventing flexible packaging due to their innovations in developing paper. In the first or second century BC, the Chinese began to use thin layers of treated mulberry bark to cover food items, providing one of the earliest examples of flexible packaging. Over the next 1,500 years, the paper-making process progressed and spread to the Middle East, Europe, and eventually the United Kingdom in 1310.
In the 18th century, Napoleon Bonaparte offered a reward for innovative packaging solutions to preserve food for his army, sparking a wave of experimentation that laid the groundwork for flexible packaging products. In the 19th century, collapsible metal tubes were first used for artist's paints in 1841, and later for toothpaste in the 1890s.
The late 19th century saw the development of semi-flexible packaging by Brooklyn printer and paper-bag maker Robert Gair. The first paperboard carton was created when a metal rule used to crease bags shifted and cut the bag instead. This new form of packaging was soon adopted by the Kellogg brothers for their health food cereals.
The early 20th century saw the invention of cellophane, a thin, transparent sheet with low permeability to air, grease, and bacteria. This material closely resembles today's plastic wrap and marked a major advancement in plastic packaging. In the 1940s, VCI (Vapour Corrosion Inhibitor) flexible packaging was introduced, providing protection against corrosion for metal parts. The 1950s brought further innovations with the introduction of bubble wrap and heat-shrinkable films developed from blending styrene with synthetic rubber.
Plastic packaging products have come a long way since their ancient origins, with modern plastic packaging playing a vital role in global commerce and various industries, including food, automotive, and electronics.
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Plastic packaging's military use
The use of plastics in military applications dates back to the 19th century when they were first developed. However, it was during World War II that the military began to extensively utilise plastic packaging to meet their unique requirements. The expansion of the plastics industry during the war was driven by the need to preserve scarce natural resources and provide synthetic alternatives. This resulted in a 300% increase in plastic production in the United States during that period.
One of the earliest uses of plastic in military packaging was polyethylene film wraps, which were exclusively used by the military during World War II. These wraps were employed to protect cables due to their smooth, non-abrasive surface. Submarine telephone cables and radar cables benefited from the protective qualities of polyethylene film. Additionally, drug tablet packaging during the war also utilised this type of plastic wrapping.
The versatility of plastics allowed them to replace traditional materials in various military applications. For instance, nylon, invented in 1935, was used for parachutes, ropes, body armour, and helmet liners. Plexiglas, another plastic, served as an alternative to glass in aircraft windows. The durability, corrosion resistance, lightweight nature, and ease of formation of plastics made them ideal for use in armoured vehicles, ambulances, and supply trucks.
Today, plastics continue to play a significant role in military packaging. High-performance plastic packaging solutions are often tailored to meet unique and challenging requirements. For example, Griffolyn® custom laminate packaging by Reef Industries is engineered to protect equipment and machinery in a variety of circumstances. Military packaging guidelines, such as MIL-SPEC standards, ensure that packages are properly labelled, marked, and able to withstand the rigours of transport and storage.
In addition to packaging, plastics are also used in the construction of military aircraft. Polycarbonate, a strong plastic, is employed in armoured window glazing, providing both protection and visibility. Plastics offer design versatility in terms of colour, texture, and pattern, while also being fully compliant with flame, smoke, toxicity, and heat release requirements. The use of plastics in aircraft construction helps to reduce weight, lower fuel consumption, and decrease maintenance requirements.
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Plastic packaging's evolution
Plastic packaging has evolved significantly over the years, from the ancient use of natural materials to the modern innovations of flexible plastic packages.
In ancient times, early humans used materials found in nature, such as leaves, gourds, barks, animal skin, and organs, to store and transport food. The Chinese are credited with the first use of flexible packaging materials, using thin layers of mulberry bark to cover food items as early as the first or second century BC. This technique gradually spread to the Middle East, Europe, and eventually to England in 1310 and America in 1690.
During the 19th century, plastics were discovered, but their use was primarily limited to the military and wartime applications. It wasn't until the late 1970s and early 1980s that plastics began to significantly impact the packaging industry. The development of new plastic materials and converting equipment played a crucial role in this transformation.
In the 1940s, the invention of VCI (Vapour Corrosion Inhibitor) flexible packaging was a notable milestone, as it prevented corrosion and was ideal for storing and transporting metal parts. The 1950s brought further innovations, including bubble wrap and Styrofoam, which provided cushioning and protection for delicate items during transportation. During this period, biaxially-oriented films, extrusion coatings, film lamination, polymer adhesives, and heat-seal coatings also emerged, enhancing the functionality of plastic packaging.
Today, plastic films dominate the flexible packaging market, accounting for over 70% of the industry's revenue. Common plastic films include Polyethylene, Polypropylene, Poly Vinyl Chloride, Polyamide, and Ethylene Vinyl Alcohol. These materials are used in a variety of applications, from food packaging to industrial components, offering protection, shelf-life extension, and brand differentiation.
While plastic packaging has revolutionized the way we store and transport goods, there is a growing trend towards more sustainable materials, with designers responding to environmental concerns by exploring alternatives to plastic.
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Plastic's competition with paper
Plastic is the youngest packaging material, discovered in the 19th century. However, its use in packaging only became significant in the 1950s and 1960s, with the advent of thin plastics, biaxially-oriented films, and other innovations. Plastic's dominance in the packaging industry is due to its many advantages, such as its ability to efficiently contain and protect products during shipment and delivery.
Paper, on the other hand, is likely the most ancient form of flexible packaging. The Chinese used thin layers of mulberry bark to cover food items as early as the first or second century BC. Over the next 1500 years, the paper-making process spread to the Middle East, Europe, and eventually the world. Paper and paperboard packaging increased in popularity well into the 20th century, with the development of glued paper bags and paper cartons revolutionizing the industry.
However, with the rise of plastic packaging in the late 1970s and early 1980s, paper began to lose its dominance. Paper packaging faced challenges due to its limitations in shape and flexibility compared to plastic. Additionally, plastic's ability to be moulded into various forms and its durability made it a preferred choice for many industries.
In recent years, there has been a growing trend of consumers and companies opting for paper-based packaging over plastic due to environmental concerns. Paper is widely considered a more sustainable and environmentally friendly alternative to plastic. It is made from renewable resources, is easily recyclable, and does not contribute as significantly to greenhouse gas emissions as plastic.
To address the environmental impact of plastic packaging, manufacturers have been working on developing more sustainable plastic-based flexible packaging solutions. These include using a higher percentage of recycled materials and optimizing designs for recyclability. Additionally, researchers have been exploring the use of thermoformable paper, which can be processed into shapes that were previously only achievable with plastic.
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Plastic's advantages and disadvantages
Flexible packaging has been around for over 1500 years, with early humans using sewn packaging for food transportation and storage. The first paper products were made by the Chinese out of thin layers of mulberry bark from the first or second century BC. Paper-based flexible packaging is still widely used today, although plastic films now dominate the market, accounting for over 70% of the industry's revenue. The use of plastic in packaging began in the 1950s and 1960s, with the first plastic products being discovered in the 19th century.
Plastic has become an integral part of our lives, with its low density, strength, user-friendly designs, fabrication capabilities, long life, low weight, and low cost. It has transformed our world with its versatility and unique properties. However, it is important to address its environmental impact.
Plastics have numerous advantages, including:
- Low production cost
- Easily moulded into various shapes
- Lightweight
- Resistant to corrosion
- Can be made translucent, transparent, or opaque
- Poor conductor of heat and electricity
- Strong thermal and electric insulating properties
- Water-resistant
- Durable
However, there are also several disadvantages to using plastic, including:
- Natural decomposition can last from 400-1000 years, with some types being non-biodegradable
- Clogs waterways, oceans, seas, and lakes
- Harmful to wildlife, with over 90% of seabirds having plastic pieces in their stomachs
- May contain toxic chemicals which can be harmful to humans, with links to cancer, tumours, birth defects, compromised immunity, and endocrine system disturbance
- The creation and recycling of plastic produce toxic gases and residues which cause air, water, and land pollution
- Additives such as phthalates, which are added to prevent structural damage, may cause serious hormonal imbalances in males and females
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Frequently asked questions
Plastic packaging was introduced in the 1950s and 1960s, with the invention of thin plastics, biaxially-oriented films, and other innovations.
Before plastic packaging, packages were made of materials such as paper, metal, glass, and natural materials such as leaves, gourds, and animal skin. Paper packaging, in particular, increased in popularity well into the 20th century.
The earliest forms of flexible packaging can be traced back to ancient China, where thin layers of mulberry bark were used to cover food items from the first or second century BC.
Vinyl Chloride, discovered in 1835, was one of the first plastics used for packaging. It was used for molded deodorant squeeze bottles and heat-shrinkable films.
Flexible packaging has evolved significantly since its introduction, with new materials and constructions continuing to emerge. Today, plastic films dominate the market and account for over 70% of the industry's revenue.
