Rochester Institute of Technology
RIT Scholar Works
Theses
Thesis/Dissertation Collections
1995
Improvement of packaging as one of the key terms
of the efficient economy development
Edward Goldberg
Follow this and additional works at:
http://scholarworks.rit.edu/theses
Recommended Citation
IMPROVEMENT OF
PACKAGING AS
ONE OF THE KEY TERMS OF THE
EFFICIENT
ECONOMY
DEVELOPMENT
(
Analysis
ofthe
experience ofthe USA
and problems ofRussia
)
By
Edward
Goldberg
A Thesis
submittedto the
Department
ofPackaging
Science
College
ofApplied
Science
andTechnology
of
the
Rochester
Institute
ofTechnology
in
partialfulfillment
ofthe
requirementsfor
the
degree
ofMASTER OF SCIENCE
Rochester Institute
ofTechnology
COLLEGE OF APPLIED SCIENCE AND TECHNOLOGY
ROCHESTER INSTITUTE OF TECHNOLOGY
ROCHESTER, NEW YORK
CERTIFICATE OF APPROVAL
M. S. DEGREE THESIS
TIlE M.S. DEGREE THESIS OF EDWARD GOLDBERp
HAS BEEN EXAMINED AND APPROVED
BY THE THESIS COMMITfEE AS SATISFACTORY
FOR THE THESIS REQUIREMENTS FOR TIlE
MASTER OF SCIENCE DEGREE
David
L. Olsson
Daniel
L.
A.
Title of Thesis:
"Improvement of Packaging as One Key Terms of the Efficient
Economy Development."
I, Edward Goldberg, hereby grant permission to the Wallace Memorial Library of
Rochester Institute of Technology, to reproduce my thesis
in
whole or
in
part.
Any
reproduction will not be for commercial use or profit.
ABSTRACT
1
THE PRESENT SITUATION
IN
THE RUSSIAN PACKAGING
INDUSTRY
2
PACKAGING
ROLE
AND
IMPORTANCE
IN
THE U.S. ECONOMY
1
1
What
a packagedoes
fortheconsumer1 1
Industrial/institutional
packaging
andretailpackaging
13
Food
protection and preservation14
Packaging'
s rolein
distribution
1 5
The
moderndistribution
system16
Modern packaging
asadirect
linkbetween
theproducerandtheconsumer17
Packaging
andthe1 990s quality
oflife
17
THE
MAIN
PRINCIPLES OF LOGISTICS
IN THE USA
27
Defining
Logistics
3 1
Scope
ofbusiness logistics
32
Elements
ofthelogistics
system. 32The Logistics Environment.
38
Logistics Management
39
The
significanceoflogistics in
theUSA
40
Contemporary
issues
andtrendsinlogistics
inUSA
42
Just-In-Time
(JIT)
as part ofcontemporary
logistics 44MainprincipalsofJIT
45
Reusable packaging 49
Logistics
Benchmarking
54Internal
Benchmarking
57
Competitive
Benchmarking
58
Functional
Benchmarking
58
Generic Process
Benchmarking
58
Objectives
ofBenchmarking
58
PACKAGING
AS AN IMPORTANT PART
OF LOGISTICS
60
Packaging
functions
61Utility
62Communication
62Performance
specificationsforpackaging
63
System
relationship
in packaging65
Logistics
elementsinthepackaging decisions
67
Protection in
packaging
67
Prepackaging
75
Handling
andtransportation76
Trends
inproducedistribution78
CONCLUSION
80
BIBLIOGRAPHY
82
ABSTRACT
This
paper presentsthe
analysisofthe
modernpackaging
technology
in
the
United
States,
summarizing
andfeaturing
the
important
points and aspectsthat
canbe
implemented
in
Russia.
The
paperemphasizesthe
important
role ofpackaging in
advertising, marketing,
distribution
andshipping
ofproducts,
as well asits necessity
in
orderto
maintainthe
productsand
packaging
integrity
during
shipment anddistribution.
The
level
ofpackaging
identity
in Russia
is
close ormay be
alittle
bit
abovezero;
the
paper givesthe
detailed
analysis of current state ofthe
Russian packaging
industry,
food distribution
andthe
currenttrends
in packaging
improvement.
The
Present
situation
in
the
Russian
Packaging
Industry
In
the
newly
independent
states ofthe
former
USSR,
there
is
a major concernabout
food
packaging.Never
recognizedas anindustry,
it has
been
part ofthe
ministriesof
food
production,
chemistry, medicine,
pharmaceuticals and so on.Practically
allUSSR
packaging
research anddevelopment
was20-25
yearsbehind
that
oftheWest.
Technology
introduced
in
the
'60s
in
the
West only
nowis
being
usedin Russia
andUkraine for
experimental production runs.Wide-scale
use of suchmaterials as shrinkand stretch
films
seemsto
be
in
the
distant
future.
During
the
Communist
era,
especially in
the
last
decade,
there
werenumerousparty
and government plansto
improve
packaging,
but
those
plansdid
not producesatisfactory
results.With
the
collapse ofthe
politicalsystem,
thesituationhas
grownworse.
For
decades food
preservation was nevera majorconcern,
whilethegovernment calledfor
moregrain,
fruits
and vegetablesto
be harvested
andmore meat and milkto
be
produced.
As
aresult,
rawfood losses for
years weremorethan30%
ofthe total.
At
present, the
country loses
about1
millionmetrictons
ofits
meat,
50%
ofits
grain,
45%
of
its
vegetables,55%
offresh
vegetables,70%
ofpotatoes,
and1
.5milliontons
offish
to
spoilage.In
1989,
the
USSR's
output ofpotatoes, milk, sugar,
butter
andfish
washigher
record amountof grain.
At 240
millionmetrictons,
the
Soviet
harvest
wasthe
biggest in
history.
But
as muchas45
milliontons
were wastedin
harvesting,
and35
million morerotted
in
storage andprocessing.About 40
million wentto
animalfodder. That
left only
about
half
the
harvest
for
human
consumption.1According
to
R.Andreas,
the
chairmanof
Archer Daniels
Midland
(ADM),
the
food-distribution
system needs100
newprocessing
plants and50
milliontons
of storage space.Although
enoughfood
is
being
produced and prices aresky-rocketing, there
is
still
too
little getting into
stores.The
main reasons are poorplanning,
lack
ofinvestment,
managerialincompetence,
corruption,
theft,
poor storage andrefrigeration,
inadequate processing
facilities,
and alack
of suitablepackaging
anddistribution
systems.
A
majoritem
ofthe
Commonwealth
ofIndependent States
(CIS)
shopping list
is
packaging,
whichis virtually
non-exist.Packaging
was neglectedby
the
centralplanners
for
morethan
70
years,
emphasizing
the
production offoods
without concernfor
preservation anddistribution. The Soviet
systemfailed
to
deliver food
to the
people.The
traditionalstructure ofthecountry'sfood packaging
andprocessing
industry
wasalways a problem.
Production
facilities for
most containers and containermaterialswere scattered and regulated
by
separate ministries.Tinned
steel consumptionfor
atypical
cannery in Russia
orUkraine
is
about50
to
200
tons
per year.The
antiquatedcanproducing
film
that
cannot competewithquality imports.
Production
ofcoextrudedlaminates,
stretchfilms,
oxygen-impermeable
polyesterfilms,
and copolymerfilms is
yetin
the
planning
stages.Despite its huge forest
resources,
Russia
stillimports 50%
of paperfor packaging
needs(Table
1-1).
% of
COUNTRY
Total1
U.S.A.
29.3%2
Japan
12.1%3
Canada
7.0%4
Germany
5.5%5
China
(P.R. of) 4.8%6 Former
U.S.S.R.
4.1%7 Finland 3.8%
8 Sweden 3.4%
9 France 3.2%
10
Italy
2.4%Total 10
Countries
75.6%COOO's
ofTonnes)
210.404Total World 100.0%
('OOO's of
Tonnes)
278,230
Source:
"Pulp
and PaperCapacities,
Survey
1991-1996"FAO ofthe United Nations.
Table 1-1
Ranking
of1991
Paper
andPaperboard
Capacities2Domestic
folding
cartons cannotbe
usedfor
automatichigh-speed
setup,
filling,
andclosing because
ofwarping,
exfoliation,
andlow
strength.In addition,
the
CIS
equivalent of
the
US federal Food
andDrug
Administration
(
FDA)
restrictsthe
use ofdomestic board for food packaging due
to the
shedding
offibers.
Domestic
label
stockis behind
in
quality,
having
questionable whiteness andasurface not smooth enough
for
printing.Printed
wax paperwrapsare stillbeing
Demand for
modernprocessing
andpackaging
equipmentis
stillvery
high,
withautomatedproduction
lines
for perishables, (like
groundmeat,
fruits
andvegetables)
atthe
top
ofthe
list.
The
majority
ofequipmentin
the
food
industry
is
imported
andhas
been
in operation,
onaverage,
about10
to
20
years.The
most advancedprocessing
andpackaging lines
werebought
from
England
in
the
late 1960s. Manual labor in packaging
is
44%;
equipment wearis
70%. This
situation causes shortagesin
packages andmaterials
already
availablein
the
industry.
Among
the
machinery
needed most arethe
following:
cartondie-cutting
andforming
equipment,
extruders and coextrudersfor packaging
films,
thermoforming
lines
for blister
packages,
machinery
to
produce polyethylene-coated paperfor
food
packaging, thermoformer
for
plastic cups andtrays,
tamper-resistant
closure equipmentfor
beverages
andcan-making lines. Even
today,
60%
of allfood is
soldunpackaged.3
One
ofthe
most urgent social and economic challengesfor
the
CIS
andEastern
European
countriesis
to
ensurethat the
people areadequately
supplied with goodquality food
stuffs.A
majorbarrier
to
achieving
this
goalis
not so muchfood
production
but food
spoilage on an enormousscale,
causedto
alarge
extentby
inadequate distribution
andpackaging
systems.Russia,
for
instance,
produces enoughbasic foodstuffs
such asgrain,
meat and potatoesto
feed
itself,
but
solittle
reachespartsof
the
CIS,
spoilageratesreach an averageof50%
across a range offoodstuffs,
according
to
Professor
David Pearce
ofLondon
University.4Modern
packaging
systems aredesperately
neededby
allthese countries,
whichthey
themselves
recognizenotonly
to
alleviatefood
shortages,
but
alsoto
enablethemto
producefood
for
exportand earn vitalhard currency
to
rebuildtheir
food
manufacturing
base.
The
CIS
realizesthat
a chroniclack
ofany
packaging
materialsis
one of
the
reasonsthat
it has
a production andsupply
problemwithbaby
foods
ofalltypes:
currently
it
is producing
only
18%
ofthe
required amount of milkbased
baby
food.
Aseptic
cartonpackaging
needslittle
refrigeration and will preservefood
and milkin
very
good condition overlong
distances
andtimes.
One
ofthe
mostimportant
causes of shortagesis food
spoilage.Each
yearone-third
ofRussia's
grain,
a milliontons
ofmeat,
and almost onehalf
of milk protein andpotatos are
lost.
Food
spoilage on such a vast scaleis
the
result ofinadequate
distribution
andpackaging
systems.Processing
andpackaging
systems could reducefood
spoilageto
between
two
andthree
percent asin
the
US
andWestern
Europe,
comparedwith
up
to
50% in
the
CIS.
In
terms
ofpackaging in
the
CIS
there
arefour
majorproblems,
whichare,
in
the
order of
importance:
Shortage
of suitablepackaging
materials of allkinds,
Shortage
of adequatepackaging machining
equipment,
Poor
outerdesign ofpackages.Help
andinvestment
by
Western
packaging
companiesis
essentialto
solvethese
problems
because
they
canbring
in
the
packaging
solutions of morethenahundred
yearsof experience.
There
is
anobviousandtremendous
needfor
modernpackaging
solutionsfor
awide range of
products, but
nowhereis
the
need morepressing
thanto
alleviatethe
chronic under-production of
baby
foods,
whethervegetable,
meat or milk-based.The
problem
for
the
Russian
republicis
particularly
acute asit has only
around30%
oftheCIS's existing
baby
food
production,
avery low
proportion givenRussia
has
by
far
the
biggest
baby
population.At
presentthe
production of milk-basedfoods,
withintheCIS
as a wholeis only
about
18%
of whatit
shouldbe,
baby
food
canscontaining fruit
or vegetablesis
43%
oftotal needs,
whilebaby
food
canscontaining fruit
or vegetablesis 43%
oftotal needs,
while
baby
food
canscontaining
meatis only 21%
ofthe
required amount.The
urgentneedfor packaging
materialsfor
allkinds
ofbaby
foods
meansthat the
CIS
has
notthe
luxury
atthis
point ofengaging in
overly
protracted arguments about whichpackaging
materialfor
baby
food has
the
best
environmentalprofile,
althoughthese
considerations will
become
moreimportant
whenthe
populationis
being
properly
fed.
The
remainderis distributed
in
bulk,
orworse,
it
goesnowherebecause
oflack
ofpackaging
andis
wasted.The bulk
distribution
is done
through
large
metal churns called"flyagy", typically
containing
20
to
50 liters.
The beverage
cartonis
avery
efficientandhygienic packaging
solutionfor
alleviating
the
CIS's food
shortagesfor
baby
foods
and other products.The
asepticpackage
is
particularly
ideal because
it
requireslittle
refrigeration and will preservefood
and milk over
long
periodsoftime,
andtherefore
can cope well with a poortransport
and
distribution
infrastructure.
Self-service
containerswhereconsumerscanfill
theirownbottles
withmilk orjuice
are often advocatedin
the
West
asbeing
the
mostecologically
soundpackaging
system.
The reality for
the
CIS
countriesis
thatscrew-lidsdo
not existfor
bottles
(
lids
for jars/bottles
are made oftin
and are notrecloseable),
so when consumersbring
their
own
jars
for
filling,
they
have
to
be
putinto
plastics pouches and carriedhome in
anuprightposition.
The
aseptic cartonbased packaging is
the
best
optioncurrently
available.Health
considerationsare seen as paramountin
terms
ofchoosing
packaging
systemsin
acountry
where1 1.5%
ofdairy
products cannotbe
guaranteed as safe and50%
ofchildrensuffer
from
achronic,figures
given out as a recent press.The
average glasspackaging
line
could use98
square meters-offloor
space and needs seven peopleto
runit,
whereas an aseptic cartonline
wouldrequireonly 18
squaremeteresand oneperson.quality
ofthe
milk would notdeteriorate
before
it
couldbe
consumed.Currently,
onepercentof
the
consumptionof milkis
packedin
aseptic carton packages.Introducing
modernpackaging
solutionshas
therefore
been
identified
as an areaofstrategic
importance
by
the
national governmentsin Eastern Europe
and alsoby
investment
institutions
such asthe
European
Bank
for Reconstruction
andDevelopment
(EBRD). These
institutions
recognizethat
goodquality
packaging
willnotonly
reducefood
spoilage andimprove
living
standards withinthe
countries ofEastern
Europe,
but
willalso
facilitate
the
export ofgoods,
enabling manufacturing
companiesto
earnthe
hard currency
that
is
neededto
upgradethe
manufacturing base.
According
to
Marketpower,
the
value ofthe
packaging
industry
in Eastern
Europe
is
setto
growfrom
the
1990 level
ofEcu 37.8
million(about
30
millionUS
$)
to
Ecu 74
million(about 60
millionUS
$) by
1995,
withgrowth rates of14%
per yearpredicted
for
the
CIS,
Czechoslovakia
andPoland.5
In
Czechoslovakia,
the
introduction
of carton-based
packaging has helped
to
solvethe
problem ofleaking
packages,
offflavors,
andtheeffect oflight
thatliquid food
products,
in
particular milkin
plasticspouches,
have been
plaguedwithin
the
past.The introduction
of asepticpackaging
cartons
has
also meantthat
retailers can nowbe
surethat the
milk will nothave
spoiledby
the time that
it
has
reachedthe
consumer.Poor cooling
systems andlong
distances
ofdistribution
have
meantthat
in
the
past milk(except
for
the
50
yard oneither side ofoccasionalpolicestations)
and pitted withunexpectedpotholes.
In
the
West,
food-storage facilities
arelocated
mostly
in
the country-side,
closeto the
placeofproduction.In
Russia,
producegenerally
goesfrom
the
field
into
trucks
or
railway
carsthat
haul it
to
city
warehouses.The
result: shipments of spoiledproduce,
along
withrocks,
mud and other refuse.Although
the
Russian
governmenthas
issued
adecree
breaking
up
state and collectivefarms,
the
systemis simply
not adoptedto
smallproducers.
The
smallest shipmentthat
railway
authoritiesaccept,
for
example,
is
usually
one
full
freight
car.And
for
collectives,
only
the
statedistribution
system canabsorbtheir
huge
output.Many
oftoday's
problems are ahangover from 70
years ofcentralized planning.But
the
movetoward
afree
marketeconomy
is
alsowreaking
havoc,
especially
newpricing
mechanisms which arepushing many
staplefoodstuffs
out of reach.According
to
Professor
Pearce,
"We
must not runaway
withthe
idea
that
packaging
willsave allthe
food
that
is
lost,
but
it does have
a contributionto
make."
While
there
is
nodoubt
that
problemswillcontinue,
alot
of expertsbelieve
that
the
marketoffersincredible
opportunitiesfor both Russian
Packaging
andWestern
companies who are
willing
to
gamble and moveinto
the
Russian
market.Teresa
Presas,
ofTetra Pak
Europe,
said:"We believe
there
is
abright
future for
food
distribution
in
the
former Soviet Union
and withoutimporting
food
-but packaging
is
necessary
elementin
this
development."
Packaging
role and
importance
in
the
U.S. economy
Packaging
is
a majorcontributorofjobs
and revenueto the
U.S.
economy.Over
one-half millionpeopleearn
their
livelihood making
packagesandpackaging
materialsand
many
more areresponsiblefor
packaging
the
vastarray
of consumer andindustrial
goodsproduced
in
this
country.Virtually
nothing is
madethat
is
not packagedat somepoint
in
the
manufacturing
cycle.Packaging
is
a$70
billion
business
in
the
United
States,
the third
largest
in
terms
of sales.In
spite ofthe
size ofthe
packaging
business,
it
contributesless
than2
percentto
the
$4
trillionU.S.
gross national product.Packaging
also makesup
arelatively
smallpercentageof
the
cost ofgoodssold.On
average,
packaging
costs are about7%
ofthe
price consumers
pay for any
given product.Yet,
for
this
relatively
smallcost,
packaging'
s role
is
to
protect and market almost all ofthe
productsproducedby
othersectors of
the
economy.In
the
all-important area offood
production anddistribution,
in
underdevelopedcountries where
packaging is
minimalto non-existent,
losses
of30-50
percentbetween
the
producer and consumer arenot uncommon.In
the
U.S.
that
figure is less
than
3
percent
for
processedfoods
due
primarily
to
protectivepackaging.What
a packagedoes for
the
consumerThe primary
functions
ofa package arecontainment, protection,
information
andContainment
simply
meansthat the
package providesameansofcarrying
orholding
aproduct.
Most
productsin
amodernsociety
requiresometype
ofcontainment,
orthey
would
be
oflittle
use.Protection
andpreservation,
taken
together,
constitutethe
nextfunction.
Protection
andpreservation,
exemplifiedby
the
canning
process,
furnishes
high
quality,
uncontaminatedfoods
on a year-roundbasis.
Canning
has been
supplementedby
high quality
frozen
foods
and,
morerecently,
by
otherinnovative packaging
and preservationtechnologies.
These
include
asepticpackaging,
to
provide shelf-stable milk andjuices,
and controlledandmodified atmosphere
packaging
that
permitsfresh
entrees, pastas,
cooked meats andsimilar
foods
to
remainfresh in
the
coolerfor
weeks.Protection
extendsbeyond protecting
the
packaged productfrom
the
hazards
ofthe
environment andthe
distribution
system.Sanitation,
to
ensurethe
purity
of packagedfoods,
is
the
normin
modernfood
systems.
Food
is
packagedin
government-approvedprocessing
plants andis
protectedfrom
contaminationfrom
insects,
rodents,
orhumans
untilit
is
ready for
usein
the
home.
In
another area of productprotection, tamper
resistant andtamper
evidentpackaging
(common in
drug
packaging) is
nowbecoming
commonplacein
food packaging
to
help
assure consumers
that
the
foods
they
selectarefree
from
tampering.
Information
is
an often-overlookedpackaging
function.
In
its
simplestterms,
it
tells the
consumer whatis
in
the
package.The
can without alabel
is
a clearexampleof apackage without
information. Modern food
packagesconvey
far
moreinformation
than
simply
telling
the
consumer whatis
inside. Through
pictures ortransparent packages,
the
consumeris informed
aboutthe
appearance ofthe
packaged product.Through
printed
information
the
consumeris
informed
aboutthe
ingredients
and, often, the
nutritional value of apackaged
food. Through
print,
color and shape a package conveysimages
ofbrand
andquality
to the
consumer.Utility-of-use
(convenience)
is
the
fourth
packaging
function. Packages
makeit
easy
to
use
the
product.A
recent popularinnovation in food packaging
is
the
squeezebottle for
ketchup
which,
in
many
waysis
more convenient(has
greaterutility)
thanthe
glassbottle it
replaced.It
is
resistantto
breakage
andis lighter
and easierto
carry.It
is
alsosqueezable,
eliminating
the
struggleto
initially
getthe
ketchup
to
flow from
the
bottle
(and
to
getit
to
stop).The
choice of packagesizes,
ranging from "large
economy"
to
individual
portion,
is
an example of utility-of-useto
satisfy individual
needs, the
large
family
orthe
institutional
customer.Aerosol
dispensers,
microwavepackaging
andcook-in,
eat-inpackages are other examples ofhow packaging
makesproducts easierto
use.
Industrial/institutional
packaging
and retailpackaging
Packages
canbe
categorizedinto
those that
consumers see and use(retail
packages)
andthose
thatthe
consumergenerally does
not see or use(industrial/institutional)
.Improvements
in
industrial/institutional
packagesin
recent yearshave increased
efficiency
andlower
costsin many
serviceindustries. The
best
exampleis
the
delivery
ofamounts,
have
simplifiedandreducedthe
riskduring
many
hospital
and medical officeprocedures.
For
example,
surgicalkits
holding
allthe
equipmentand materials neededfor
aparticularsurgicalprocedurein
aprotected sterilecondition are usedin hospital
operating
rooms;
prepackaged sterilelaboratory
equipmentis
usedin
hospital
andresearch
laboratories
to
simplify
andspeedup
laboratory
analyses andto
assurequality
control;
and.flexiblebags
for
blood
andintravenous
solutions providefor sterility
andeasier
storage,
andgreatly
reducethe
risk ofbreakage
in
emergency
situations.Food
protection and preservationFood
andbeverage packaging
accountsfor,
by
far,
the
greatest proportion oftheindustry-approximately
two-thirds
ofthe
$70
billion
industry
in
the
U.S. New
technologies
andtrends
often appearfirst
in
the
food
sector andthen
find
their
way into
other
packaging branches.
In
a modernU.S.
supermarket,
where mostfood for home
consumptionis
purchased,
everything is generally
packaged,
eitherby
the manufacturer,
distributor
orretail outlet
(
and alot
offresh
produceis
pacakged-too,
e.g.lib
carrots etc.).Food
is
the
most perishablecommodity,
subject notonly
to
spoilagefrom
the
moment of
harvest,
slaughter,
ormanufacture,
but
also vulnerableto
attackfrom
a vastarray
ofliving
things
ranging from
microbesto
insects
to
rodents and other vermin.The 1960's
and70's
saw an acceleration ofthe trend to
single-personandtwo-income
families,
leading
to
ademand for
conveniencefoods,
carry-outs andsmaller,
individual
portions.The 1980's
weremarkedby
acontinuedtrend to convenience,
coupled with aconcern
for health
that
resultedin
ademand
for
naturalfoods,
andfresh
andfreshly
prepared
foods. These
trends
wereacceleratedandcomplementedby
advancesin
food
preparation
technologies,
especially
the
microwave.Microwave
technology
alonehas
been
responsiblefor
whole newfamilies
ofpackagesthat
are microwave compatible ormicrowave enhancing.
Today's
consumer can choosefrom
a vastarray
offood
productsin
serving
sizescompatiblewith
their
needs.Fresh, frozen,
canned, condensed,
anddried
foods
arereadily
available.All
ofthis
is
made possiblethrough the
combination of modernfood
processing
andfood packaging
technologies.
Packaging's
rolein distribution
The distribution
systemin
the
United
States is
animportant
elementin
the
standard of
living
enjoyedby
American
consumers.However,
American-style
distribution
systems existin only
a small portion ofthe
world.Developing
counties,
centrally
plannedeconomies,
and evenmany
other economic powersdo
notenjoy
the
advantages of
the
U.S. distribution
system.Packaging
is
an essentialingredient
in
moderndistribution
systemsthat
provideconsumers with
the
productsthey
want:1
.When
they
wantthem,
2.
At
convenientshopping
locations,
package/product combinations
have
been
developed
that
resultedin revolutionary
changes
in
the
way
goodsaredistributed.
Modern
packaging
as adirect
link between the
producer andthe
consumerOne
effectofpackaging
in
moderndistribution
systemshas
been
its
direct
linking
of
the
producer and consumer.Producers
retainresponsibility
for
theirproductsby
putting brand
namesonthe
package.Consumers quickly
learn
to
rely
on particularbrands
for
the
quality
they
want.The
intermediaries
between
the
producer andthe
consumer
the
wholesalers andretailersdo
notdetermine
the
quality
ofthe
product.Products
whicharepackaged,
but
unbranded,
aretaking
up
a smaller and smallerportion of supermarket shelf space.
Fresh poultry is
now almostuniversally
branded.
Branded
fresh
fruits
and vegetables arebecoming
the
norm.Other
products such asfresh
red meats andfish
are now alsoappearing
aspackaged,
branded
products.Packaging
andthe
1990s
quality
oflife
Today,
less
than
3
percent ofAmericans
live
and work onfarms. The fact
that
these
few Americans
canfeed
morethan
240
millionAmericans
and millions moreoverseas
is
the
result ofthe
successfuldevelopment
ofagriculturaltechnology
andthe
development
ofthe
distribution
systems andpackaging necessary
to
avoidspoilageandwaste.
At
presentin
the
United
States,
morethan
40
percent ofhouseholds
are notfamilies,
about25
percentarefamilies
withatleast
one child andboth
parents working.These
living
patternsindicate that, in many
households,
the
traditionalfamily
gathering
atmealtimes
is
athing
ofthe
past.With
this
pattern ofliving,
conveniently
packagedfoods
areessentials,
notluxuries.
Further, they
arecost effective.A study
atthe
University
ofMaryland
showedthat
"convenience
packagedfoods
areslightly less
expensivethat
prepared-from-scratchfresh
foods,
withoutaccounting
for
the
savingsin
food
preparationtime".
Customers
today
demand
more and more valuefrom
the
grocery
productsthey
purchase.
However,
what constitutes value often addsup
to
various combinations ofquality,
convenienceand price.Packaging
reinforcesthis
perception of valueby
preserving
food
quality,
securing
the
safety
ofpharmaceuticals,
andproviding
convenientreclosability,
opening
andremoval of personal care and
household
products.While
valuefor
money
rateshigh for
allproductcategories,
consumersbelieve
they
arepaying
morefor packaging
today
than
five
years ago.Resealability-one
ofseveralconvenient consumersexpect when
they
buy
packaged goods-is considered aslightly
moreimportant
packagetrait than
easy
opening
(
Fig.
2-1 ).
Reclosability
is
particularly
moreimportant for OTC drugs.
Packaging
offersthe
food
industry
amarketing
tool that
is
most usefulin
the
growth andpromotion ofsales.
In
principle, the
product andits
package are anintegrated
unit.A
moistureand
/or
oxygen-sensitivefood
product requires apackage withadequatebarrier
properties.
A
high-acid,
hot-filled food
productrequires asanitary
can withthe
properlining
material.Product
development
and packagedevelopment
shouldbe
conductedsimultaneously
andinteractively.
This
could eveninclude
the
changing
orreformulating
of a
food
productin
orderto
makeit
easieror
more economicalto
package.CoinisiuiinraersE_aeUnrajpasitainiSPackageTraits
I
1994 Value fortheMoney 1995
1994 ConvenienttoReseal 1995
Figure
2-1
Consumer
rateimportant
package traits6The
increase
ofthe
food
industry
to
meetthe
populationgrowth ofthe
country
was
naturally
followed
by
anexpansionin
the
field
of packaging.Of
course,
the
packaging
requirementsfor
drugs,
pharmaceuticals,
hardware,
personal careitems,
etc.,
also
increased
rapidly.The
growth rateofpackaging
closely followed
the
growth ofthe
45
40
2
a35
30
J
25
g
20
=Packaging
-?-GNP
15
*c
10
Z
c Z
5
O0
1960
1965
1970
1975
1980
1985
1990
Figure 2-2
GNP
and growth ofpackaging
in
USA7In
fact,
at yearend,
one ofthe
leading
nationalbusiness
magazines,
Forbes,
in
the
9
January
1989
issue;
treated
packaging
as anindustry
untoitself.
Packaging
wasincluded
whenit
reportedtrends
andforecasts
for
majorindustries
such asfood,
steelpharmaceuticals,
electronics,
and otherindustrial
segments.Aluminum
has become
avery
successfulpackaging
material usedfor
beverage
cans and
foil laminations. Technological breakthroughs in
metals, glass, paperboard,
composites,
laminations,
andespecially
plastics areproviding
a multitude ofopportunities
for improved food packaging
(
Fig.
2-3
).
In 1981 Total Units
= 161,190MM
In 1991 Total Units
= 175,869MM
40.0
35.0
mm
30.0
25.0
c
20.0
15.0
10.0
5.0
0.0
Glass
Steel
Aluminum
Plastics
Paper
Comp.
Bottl's
Cans
Packaging
Material
Figure 2-3
All
containersby
material7
The
major catalystfor
packaging
advancementhas
been
the
plastic materialsrapidly
being
developed.
The
plastics segment ofthe
packaging
industry
has
shownthe
most rapid growth
for
many
reasons(
Fig. 2-4 ).
Some
ofthe
mostimportant
arethat:
1
. plasticshave
a wide range of physical andbarrier
properties;
2.
plastics offerdesign
capabilities andfeatures
not available with otherpackaging
materials, and,
morerecently,
and3.
some plastics canbe
usedin
microwave ovens.4.
Plastics
can alsobe
usedin
combination withcoextrusions,
which offer economicadvantages.
1991
HDPE T-sets T-plastlcs PET PP LD/LLDPE
Figure 2-4
Plastics in
packaging
in
USA7The
opportunitiesfor food packaging
today
are astronomical.The development
of containers and packages
is
rapid anddiverse
to
allowthe
food
industry
to
meetthe
marketing demands
ofits
consumers.One
majorfood
company, the
Campbell
Soup
Company,
uses steelcans,
aluminumcans,
glassjars,
as well asbottles,
asepticcartons,
PET
(polyethylene
terephthalate)
bottles,
dual-ovenable
CPET
(
crystallizedpolyethylene
terephthalate) trays,
microwaveablepolypropylenetrays
andbowls,
paperboard and
fiber trays, just
to
nameafew. The company
seemsdetermined
to
give
its
consumersthe
packaging
optionsthey
want,
andtheir
wantsaremany
andvaried.
In
today's
intensly
competitivefood
marketplace,
a successfulfood
package mustfunction
in
away
that
enhances convenienceof usefor
the
consumer.The
challengefor food
processors andpackaging
suppliersis
to
find
waysto
adapt establishedconvenience
features
to
varioustypes
ofpackages.Thus,
consumer convenientpackaging
seemsto
be
one ofthe
majormarketing
considerationsin
today's
food
packaging
industry.
Another
conveniencefeature,
recloseability,
is
nowfinding
its
way
beyond
traditional
rigidcontainerssuch as metal coffee cans with plastic overcaps andinto
the
flexible
pouch/
bag
type
package.The
development
of"zipperpouches"and on-lineapplicationsystems
has
provided arecloseablefeature
for
such products ascereals,
lunch
meats,
snackitems,
candies, cheeses,
dry
pastas, rice,
andmany
otheritems.
Consumer
research showsthat
single portionpackaging
is
much moreimportant
to
consumersthan
it
wasafew
yearsago.Associated
with portionpackaging is
the
convenience
feature
ofportability
sothat
food
products canbe
taken to
school orto
work and
may
evenbe
microwavedin
the
package.The
portable portion package mustprovide adequate protection
during
storing
andhandling,
along
witha convenient shapeand
light
weight.Some
ofthe
conveniencefeatures,
such assingle-serving
portions, portability,
reclosability,
andtamper evidence,
arein
direct
conflict withthe
growing
problem ofsolid waste management.
Package design
andchoice of materials are nowstrongly
become
the
packaging quality
most selectedby
consumersin
the
1990s.
Even
now,
growing
number ofconsumersarewilling
to
pay
morefor
more-recyclable products.The data from U.S. Environmental Protection
Agency
(
E. P. A.
)
indicate
that
plasticsare
really
avery
small portion of municipal solid waste(
MSW
) (
Fig.
2-5
).
Currently,
only
1%
ofplasticsarerecycledversusaluminum's54%,
papers'
30%,
andglass'
25%.
However,
majoreffortsareunderway
by
plastics companies and usersto
develop
meansofsourcereduction andrecycling.
Besides
sourcereduction andrecycling, there
are othertwo
means ofdisposing
of solid wasteland
fills
andincineration.
All four
methodswillhave
to
be
consideredto
resolve
the
solid waste problemin
this
country.Thus,
it
appearsthat
in
the
future,
package
design
willbe
shaped atleast in
partby
solid waste considerations.As
paper andpaperboard, metal,
and glasspackaging
wasteincreases in
solidwaste,
food
wastedeclines. As
plastic wastesincreases in
the
U.S.,
theamount offood
waste
decreases
at an greaterrate.7It
is
sometimes claimedthat
municipal solid waste canbe substantially
reducedby
consumers
if
they
wouldbuy
only large
portions and "large economy
sizes "of
food,
but
lifestyles
anddemographic trends,
however,
pointtowardthe
needfor
smallerportionsand
individual
servingsfor many
consumers.By
volume
Other
paper11%
Diapers
1%
Paper packaging
16%
Other
(metal,
rubber,
wood)
29%Newspaper
14%
Magazines
2%
Cardboard
4%
Fast-food packaging
1%
By
weight
Yard
waste18%
Other
11%
Food
waste8%
Paper
37%
Figure
2-5
Contribution
ofpackaging
materialsto
solid-wastein
USA7In
1989,
the
Environmental
Protection
Agency
issued its
recommendationsconcerning
methodsto
solvethe
MSW
problem.For
the
packaging
position ofMSW,
1
. sourcereduction2.
recycling
3.
incineration
(waste-to-energy)
4.
landfill
Many
government actionsare pointedtoward
reducing
orcontrolling
solid wastecosts
through
reducing
some part ofthe
packaging
component of waste.It
is
popularto
givesolidwastecost
figures
for
amunicipality
or region andto
statethat
a costreduction can
be
achievedthat
is
directly
proportionalto the
weight or volume reductionthat
mightbe
achievedthrough
eliminating
certain packages.Since
allpackaging
makesup
about30%
ofMSW
by
weight orvolume,
eliminating
of whole categories ofpackaging
waste wouldnotlikely
be
transferred
into
meaningfulcost savings.The
main principles of
logistics in
the
USA
The
logistics
conceptembodiesthe
idea
that
materialsand productsflow
throughthe
organization,
from
a sourcethrough
productionto
distribution
to
customers or users.The
processinvolves many functions
and organizationalactivities,
andmay include
externaloperationsalso.
The
conceptis
orientedtoward the
objective ofmanaging
this
flow
as a singleintegrated
unit.The
conceptis important
today
because
ofthe
development
ofboth
technology
and a new management perspective.
Technology
includes
notonly transportation,
inventory,
and materialhandling,
but
information
andthe
ability
to
useit
to
direct
andcontrola complex system.
Products
consumers use arethe
result ofthe
processin
whichmaterials movefrom
raw materialsthroughproduction anddistribution
to
become
availableto
buyers
and consumers.
Logistics describes
this
movement of material and productsfrom
sourceto production,
andfrom
productionto the
market.Logistics
activities are socommonplace
that
they
aretakenfor
granted.The
purpose oflogistics
is
to
overcometime
and space.Management's
challengeis
to
direct,
plan,
andcontrolthe
materialand productflow
as oneintegral
unitby
coordinating
the
activities ofthe
firm,
and even external organizationsinvolved
in
the
product
flow.
Each
corporatesupply
anddistribution
systemcontributesto the
socialprocessharbors,
telecommunications,
and otherareasof common service.The
totalcoststo
society
in
both
publicandprivate expenditures arevery
great,
and also unavoidable.These
arecompelling
reasonsto
become
concernedwithlogistics
management.Logistics
management,
however,
would notbe feasible
withoutthe
logistics
concept.This
system-orientedform
ofmanagement permits managersto
group
separatebut
relatedactivities
together
in
acentrally
coordinated arrangementto
achievea commonend.
The
recognition ofthis
concepthas
been
relatively
recent.Only
in
the
last 25
years
has
managementbegun
to
use systemconceptsto
direct
the
flow
of productsthrough the
organization.It
treats
activities such astransportationandinventory
asboth
separate
functional
management areas and asinterrelated
elementsin
a common system.It
solves problemsby
using
the
complex methods ofsystems analysis and othercomputer-supported solutionprocedures.
More
importantly,
it
alterstraditionalmanagementperceptions of
the
nature andboundaries
ofthe
logistics
system.The
logistics
concept embracestwo
centralideas:
productflow
andthe
systemtrade-off.
The
roots ofthese
ideas
canbe
tracedto
writersin
the
nineteenth century.The
systemtrade-off
wasdescribed
by
aFrench
economist,
Jules
DuPuit,
in
the
early
nineteenth
century,
comparing
the
costs oftransportationby
carriage and canalbarge
to
differences in
transit
times
andinventories.
8Business itself developed
along functional
lines. Product flow decisions
were separatedinto
transportation,
inventory,
andproductionwith
little
considerationoftheircollectiveimpact.
In
the
1930's,
the
emergenceof motorcarriage andanincreasing
sophisticationin
business
encouragedafew
companiesto
investigate
the
problemsof physicaldistribution.
In
exceptionalcases, transportation
andwarehousing
were placed underthe
same control.
The
earliest applicationsofthe
computerto
business
included logistics
applications: vehicle
routing
andscheduling,
inventory
control,
location
analysis,
anddocumentation.
These
specializedtasks
areimportant
to
managementoflogistics
operations,
but
their
solutionsdid
notemphasizethe
integration
embodiedin
the
logistics
concept.The
computer nowservesthree
rolesin
the
organization:processing
transactions,
establishing
unifiedcontrol,
andpermitting
global analysis ofthe
system asa unit.
In
its
transaction role, the
computer givesthe
logistics
systemthe
ability
to
handle large
volumes ofrepetitive,
low-level
calculations, to
performoperations, to
record
them, issue
instructions,
and storethe
results on a scale otherwiseimpossible.
This
samedata
providesthe
basis
for
control over operations acrossthe
entire corporateorganizations.
The
challenge oflogistics
managementhas
attractedinterest in
the
development
of
integrated
mathematicaldecision
models ofincreasing
sophistication.The
resultextends
the
perspective of management over a widerdomain.
It
creates a new style ofmanagement,
onethat
relies on automation whereverpossibleto
process routineemphasis
is
onplanning;
operations,
the
previousfocus
of management'sattention,
becomes
the
result.The
logistics
conceptbegan
with amarketing
orientation,
during
a period ofexpanding demand
whichassumedunlimited resources.Events
during
the
1970's
however,
forced
an abrupt shiftin
this
perspective:periodic material shortages anduncertainties of
demand demonstrated
that the traditional
approach was one-sided.Interruptions
in
supply
and abrupt swingsin
priceforced
managersto secure, allocate,
and control
supply
in
orderto
maintaindistribution.8The
needto
managesupply
anddistribution
as a single unithas
resultedin
expanding logistics
managementto
include
supply,
in
orderto
coordinate production andprocurement with
marketing
anddistribution. Management
ofthis
extended systemrequires more
than
operationalcoordination;
planning
musttake
both
parts ofthe
systeminto
account atthe
sametime.
The logistics
environmenthas
been disturbed recently
by
severaldifferent
types
ofchanges.
Supply
uncertainty
is
only
one.Technological
changeis
occurring in
information
processing,
materialhandling,
andtransportation.
The
costs offuel
andcapital,
among
the
mostimportant inputs
to
logistics
decisions,
continueto
fluctuate
widely.
Management
mustdevelop
a comprehensive responseto these
changesthrough
strategies
that
embracethe
entirelogistics
system.Logistics
managementlies
in
the
heart
of organizationbecause
it
provides solutionsto
problems whichthreaten the
centralactivities of
the organization, the
productionofproducts andservices.Application
ofthe
logistics
concept presentsanopportunity
to
reducecosts and providethe
servicesthe
marketrequires.Defining
Logistics
The
term
business logistics
takes
its meaning from
two
ideas,
the
flow
of materialsthrough
an organizationtoward
the
market,
andthe
processofbalancing
activitiesto
achieve management objectivesof
efficiency
andeffectiveness.Logistics
is like
apipeline.
It
begins
withmaterialsand componentparts,
whichbecome
inputs
to
aproductionprocess.
Finished
productsemergefrom
the
end ofthe
processto
be
distributed
to
customers.Petroleum
is
perhapsthe
easiest productto
visualize.Crude
oilis
extractedfrom
wells,
collected,
and shipped via pipelineto
a refinery.Here it is
convertedinto
a set ofproducts:
gasoline,
jet
fuel, diesel,
petrochemicalfeedstocks,
and others.Each
movesfurther
toward
its
ownindividual
market.Gasoline
may
flow
througha product pipelineto
adistribution
point whereit
is
storedin
tanks
in
anticipation ofdemand. It
is
then
loaded into
tank trucks
for
transportationto
local
retailstations,
whereit is
again storeduntil
it is
purchasedby
consumers.Business Logistics
canthus
be defined
asthe
activitiesinvolved in
the
flow
of materialsand products
from
asource ofsupply
to
a point offinal
consumption.The
conceptincorporates
three
important
aspects:1. Logistics
spansthe
entire set of activitiesinvolving
materialflow from
sourceto
does
notinclude
productionoperations,
but
productiondecisions
areclosely
involved
in
logistics
decision
andoperations.2. Logistics involves
activitieswhichinteract
with eachother.The
output ofthe
logistics
systemdepends
onthe
effect of specificcombinationsofinputs. The
totalcost ofmoving
oilincludes
both
the
costsof storage andthe pipeline,
but
the
amount of storagecapacity
neededmay depend
onthe
pipeline's size and speed ofdelivery.
3.
Logistics
activitiesreachbeyond
the
boundaries
ofany
one organization.The
capacity
ofthe
oildistribution
systemdepends
onthe
rate ofdemand
for
products andthe
capacity
ofindividual
stations.The
premise ofthe
logistics
conceptis
that
all ofthese
activitiescanbe
managedas anintegrated
system.Scope
ofbusiness logistics
Logistics is
a collection of management activitiesthat
are repeatedmany
times
through the
channel which raw materials are convertedinto
finished
products.A
schematic representation of a product
flow
channelfor
automobilesis
shownin Fig.
3-1.
Elements
ofthe
logistics
system.The
activities presentedbelow
representa maximumlist
likely
to
be found
in
the
logistics
function. It
may be divided
into
key
and supportactivities,
along
with some ofthe
decisions
associated with each activity.A
singlefirm
is
notgenerally
ableto
control
its
entire productflow
channel.For
practicalpurposes,
business logistics for
the
individual
firm
takes
ona narrower scopethanthat
shownin Fig.
3-2.
Function Activity
Production Extraction
Logistics Movementand storage
Purchasing
Production Formation
Logistics Movementand storage Purchasing
Marketing Selling
Production Formation
Logistics Movementand storage
Production Formation
Logistics Movementand storage
Marketing
Selling Autobody stampingand finishing Steel making Final assembly Sourcesof raw materialsIronore mining Coal mining Limestone mining Dealers Autochassis preparation Finalconsumers Scrapcycle
Figure 3-1
A Product flow
channelfor
automobileBusiness logistics
Sources
ofsupply
Physical
supply-(Materials
management)" "txvoU x
Transportation
Inventory
maintenanceOrder processing
Acquisition
Protective packaging
*Warehousing
Materials
handling
Information
maintenancePlants
IJ
H'TT-ff
Transportation
Inventory
maintenance *Order
processingProduct
schedulingProtective
packagingWarehousing
Materials
handling
Information
maintenance CustomersFigure
3-2
Scope
ofbusiness logistics for
the
individual
firm8Key Activities
1.
Customer
servicestandardsCooperate
withmarketing
in
a.
Determining
customerneedsand wantsfor
logistics
serviceb.
Determining
customer responseto
servicec.
Setting
customerservicelevels
2.
Transportation
a.
Mode
andtransport
service selectionb.
Freight
consolidationc.
Carrier routing
d.
Vehicle scheduling
3.
Inventory
managementa.
Raw
materialsandfinished
goodsstocking
policiesb. Short-term
saleforecasting
c.
Product
mix atstocking
pointsd.
Number,
sizeandlocation
ofstocking
pointse.
"Push"
vs. "Pull"strategies
4.
Order
processing
a.
Sales order-inventory interface
proceduresb.
Order information
transmittal
methodsc.
Ordering
rulesSupport Activities;
1.
Warehousing
a.
Space determination
b. Stock layout
anddock design
c.
Warehouse
configurationd. Stock
placement2. Materials
handling
a.
Equipment
selectionb.
Equipment
replacement policiesc.
Order-picking
proceduresd.
Stock
storage andretrieval3.
Acquisition
b. Purchase
timing
c.
Purchase
quantities4. Protective packaging design for
a.
Handling
b. Storage
c.
Protection from
loss
anddamage
5. Product
scheduling
cooperatewithproductiona.
Specifying
aggregate quantitiesb.
Sequencing
andtiming
of production6. Information
maintenancea.
Information
collection, storage,
and manipulationb.
Data
analysisc.
Control
proceduresFig. 3-3
showsthe
majorfunctional
elements are considered part ofthe
logistics
systembecause
they
directly
influence
each other's performance.A
central core oflogistics functions
is
involved in supplying
products: orderprocessing,
inventory,
andtransportation.
They
areidentified
asprimary
activities.Channels
Environment
Markets
Secondary
Activities
Information
^^^Packaging
5
o o c __ 3 a o __ u CO u 3 a oPrimary
Activities
Transportation
Q CObjectives
Customer Service
Cost
Minimization
c 'Si n <_ u o (D Q> c '55 CD 3 Q.L
Materials
Handling
E o c o u 111 J_Warehousing
Resources
PublicPolicy
Figure 3-3
Logistics
activitiesandenvironment9
Primary
Activities.
Transportation
includes
both inbound
transportationfrom
suppliersto the
productionline
ordistribution
center,
andoutboundtransportation
from
the
productionline
ordistribution
centerto the
customer.Inventory
includes
both
finished
goods and processmaterials,
whereverthey
arelocated
within
the
productflow.
Order
processing involves
the
communicationfrom
the
customerto the
sellerto
initiate
the
activitiesthat
lead
to the
completion ofthe
order.Secondary
(
Supporting
)
Activities.
Distribution
centermanagement,
or warehousing.Refer
to the
storagefunction
whereinventory
is
maintained.The function
involves internal
operations andMaterial
handling
is
the
movementofinventory
within organizationalfacilities,
aswithin
the
distribution
center,
orbetween
receiving
inventory
andusing it in
the
production
line.
Packaging
involves decision
aboutthe type
anddegree
of protectionfor
products andmaterials
moving
withinthe
system.Specific
considerationsinclude
protectionin
storage,
ease of materialhandling, identification,
andthe
cost of movement.The
Logistics Environment.
The
performanceoflogistics
systemsis
alsoinfluenced
by
specific environmentfactors
andtrends.
They
influence
managementdecisions
which changethe
long-term
direction
ofthe
system.The
mostimportant
are:1
.Market
and customer.Patterns
ofdemands,
geographiclocations,
and servicerequirements.
2.
Distribution
channels.Determine
whichactivities mustbe
performedin-house
orby
external organizations.3.
Product
characteristics.Determine
the
channellogistics
requiredto
deliver
the
products
to market,
such as controlled environmentfor frozen
food,
and cost ofmovement,
storage,
andhandling.
4.
Technology.
Describes
avariety
oflogistics
processes:transportation,
materialhandling,
communication,
orderprocessing,
computer-basedinformation
systems,
packaging,
anddistribution
center operations.5.
Public
policies.General
policies,
suchas antitrustlaw,
and more specificpoliciesdirectly
relatedto
logistics.
6.
The
economy.Influences
demands
for
products andthe
intensity
of completionfor
markets.
7.
Resources.
Influences
logistics
decisions,
including
energy
costs whichdetermines
the
relativecost oftransportation.
Logistics Management
Logistics
managementcanbe defined
asthe
planning,
operation, coordinating,
and
controlling
ofthe
activitiesandresourcesinvolved
in
the
material(
product)
flow
from
sourceto the
final
c