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JurusanJurusan TeknologiTeknologi IndustriIndustri PanganPangan
FTIP FTIP –– UnivesitasUnivesitas PadjadjaranPadjadjaran
Souvia Rahimah
2 Maret 2011
Paper for FoodKira-kira 10 % kertas digunakan untuk bahan pengemas dan 50 %-nya digunakan untuk industri makanan.
Paten pertama untuk kertas sbg pengemas makanan : Charles Hildeyerd on 16th February 1665 for ‘The way and art of making blew paper used by sugar-bakers and others’
Uses can be found in packaging all the main categories of food such as:
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such as:
dry food products – cereals, biscuits, bread and baked products, tea, coffee,
sugar, flour, dry food mixes etc.
frozen foods, chilled foods and ice cream
liquid foods and beverages – juice drinks, milk and milk derived products
chocolate and sugar confectionery
fast foods
fresh produce – fruit, vegetables, meat and fish.
Latar Belakang
Bahasa Yunani : Papyrus 3000 SM
Tahun 105 : pembuatan kertas
pertama di Cina (Dinasti Han)
Tahun 1799 : pembuatan mesin
kertas pertama secara modern
Abad 19 : kertas sebagai
pengemas (kertas dan kardus), pengemas (kertas dan kardus),
penemuan karton
beralur/bergelombang
Abad 20 : penggunaan karton
secara masal
Bahan baku :
- kayu lunak (pohon berdaun jarum)
- kayu keras
Proses Pembuatan Pulp
Paper Recycling
Kelebihan Pengemas Kertas
range of surfaces, in terms of colour and finish,
available
range of strength properties, in terms of fibre type,
thickness and method of manufacture, available
choice of functional coating, lamination, decoration,
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choice of functional coating, lamination, decoration,
printing etc.
ease of conversion into packages in terms of cutting,
creasing, folding, gluing, locking, heat sealing etc.
innovative machinery for conversion and packing.
Karakteristik Umum Kertas
Dibuat dari selulosa kayu atau merang padi
Diberi perlakuan kimia, dihancurkan, dipucatkan, dibentuk lapisan dan akhirnya dikeringkandikeringkan
Dua jenis kertas yang utama digunakan sekarang yaitu kertas kasar dan halus
Jenis KertasWet strength paper
Microcreping
Greaseproof
Glassine
Vegetable parchment
Tissues
Paper labels
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Paper labels
Bag papers
Sack kraft
Impregnated papers
Laminating papers
Solid bleached board (SBB)
Solid unbleached board (SUB)
Folding boxboard (FBB)
White lined chipboard (WLC)
Wet strength paper
Paper sacks used in wet conditions need to retain at least 30% of their dry strength when saturated with water. To achieve wet strength, urea formaldehyde and melamine formaldehyde are added to the stock. These chemicals cross link during drying and are deposited on the surface of the cellulose fibresmakingthem resistant to water absorption.
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makingthem resistant to water absorption.
Microcreping
Microcreping, e.g. as achieved by the Clupak process, builds an almost invisible crimp into paper during drying enabling paper to stretch up to 7% in the MD compared to a more normal 2%. When used in paper sacks this feature improves the ability of the paper to withstand dynamic stresses, such as occur when sacksare dropped.
GreaseproofThe hydration (refining) of fibres at the stock preparation stage, already described, is taken much further than normal. It is carried out as a batch process and is known as beating. The fibres are treated (hydrated) so that they become almost gelatinous.
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become almost gelatinous.
GlassineThis is a supercalendered (SC) greaseproof paper. The calendering produces a very dense sheet with a high (smooth and glossy) finish. It is non-porous, greaseproof, can be laminated to board and can be silicone coated to facilitateproduct release. Glassine is also available in several colours.
Vegetable parchment
Bleached chemical pulp is made into paper conventionally and then passed through a bath of sulphuric acid. Some of the surface cellulose is gelatinised on passing into water and redeposited between the surface fibres forming an impervious layer. This paper has high grease resistance and wet strength.
Tissues
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Tissues
Neutral pH grades with low chloride and sulphate residues are laminated to aluminium foil. The grammages range from 17–30 g/m2. Tea and coffee bag tissue is a special light weight tissue available either as a heat sealable product (containing a proportion of Polypropylene fibres), or as a non-heat sealable product, in grammages from 12–17 g/m2. It incorporates long fibres, such as those derived from manilla hemp which give a strong permeable sheet at the low grammages used.
Paper labels
These may be MG (machine glazed), MF (machine finished) or calendered kraft papers (100% sulphate chemical pulp) in the grammage range 70–90g/m2. The paper may be coated on-machine or cast coated for the highest gloss in an off-machine or secondary process.
Bag papers
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Bag papers
For sugar or flour, coated or uncoated bleached kraft in the range 90–100 g/m2 is used. Imitation kraft is a term on which there is no universally agreed definition, it can be either a blend of kraft with recycled fibre or it can be 100% recycled. It is usually dyed brown. It has many uses for wrapping and for bags where it may have an MG and a ribbed finish. Thinner grades may be used for lamination with aluminium foil and PE for use on form/fill/seal machines.
Sack kraft
Usually this is unbleached kraft (100% sulphate chemical) pulp, though there is some use of bleached kraft. The grammage range is 70–100 g/m2.
Impregnated papers
Wax impregnated paper and fluorocarbon treatment for grease/fat resistance is produced on-machine.
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Wax impregnated paper and fluorocarbon treatment for grease/fat resistance is produced on-machine.
Laminating papers
These are coated and uncoated papers (40–80 g/m2) based on both kraft (sulphate) and sulphite pulps. These papers can be laminated to aluminium foil and extrusion coated with PE. The heavier weights can be PE laminated to plastic films and wax or glue laminated to unlined chipboard.
Solid bleached board (SBB)
Solid bleached board is made exclusively from bleached chemical pulp. It usually has a mineral pigment coated top surface and some grades are also coated on the back. The term SBS (solid bleached sulphate), derived from the method of pulp production, is sometimes used to describe this product.
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product.
Solid unbleached board (SUB)
Solid unbleached board is made exclusively from unbleached chemical pulp The base board is brown in colour. This product is also known as solid unbleached sulphate. To achieve a white surface it can be coated with a white mineral pigment coating, sometimes in combination with a layer of bleached white fibres under the coating.
Jenis-jenis Kertas
Kertas Kraft
Kertas Glasin dan Kertas Tahan Minyak
Kertas Perkamen
Daluang (Containerboard)
Kertas berlapis (laminated)
Kertas tissue
Karton (paperboard)
Kertas KraftSangat kuat
Warna kecoklatan
Harga relatif murah
Diproduksi sebagai lembaran satulapis, berlapis-lapis danbergelombang (corrugated)
Ketebalan kertas 10 – 180 gr/m2Ketebalan kertas 10 – 180 gr/m
Dibuat melalui proses sulfat danpemucatan (bleaching)
Bentuk kemasan sak, kantung, pembungkus, tabung, kalengkomposit.
Untuk mengemas bahan-bahandengan BJ yang besar
Kraft Paper
Kertas Tahan Minyak (waxed Paper)
dan Glassin (Glassine Paper)
Berbagai warna dan sedikit tembus pandang
Dibuat dengan proses sulfat dan calendering sehingga permukaannya licin
Ketebalan 20 – 40 g/m2Ketebalan 20 – 40 g/m2
Tahan terhadap minyak dan lemak.
Untuk kemasan yang mengandung minyak dan lemak : mentega, keju, dll
Kertas perkamen (parchment)/baking paper
Dibuat dengan proses sulfat
Tahan terhadap lemak dan
cukup kuat dalam keadaan
basah
Lebih keras dan kasar
dibandingkan kertas minyakdibandingkan kertas minyak
Digunakan untuk mengemas
mentega, keju.
Sering digunakan sebagai kertas
label.
Karton (paperboard)Kertas yang paling tebal (lebih dari 0.3 mm)
BJ 150 – 200 kg/m2
Menggunakan filler tanah liat
Untuk box dalam berbagai bentuk
Tipe :CCN (Clay Coated News)
CKB (Coated Kraft Back)
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CKB (Coated Kraft Back)
CNB (Coated News Back)
CWTK (Coated White Top Kraft)
FBB (Folding Boxboard)
SBB (Solid Bleached Board)
SBS (Solid Bleached Sulphate)
SUB (Solid Unbleached Board)
SUS (Solid Unbleached Sulphate)
WLC (White Lined Chipboard)
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Kertas berlapis
(laminated paper)
Dilaminasi bahan lain
seperti plastik,
alumunium foil.
Dibuat dalam berbagaiDibuat dalam berbagai
bentuk
Contoh Tetrapack yang
terdiri dari lilin, karton
alufo dan polietilen
Bahan Laminasi
Polyethylene (PE) heat sealable moisture barrier. Low density
polyethylene (LDPE) Easier heat sealing results when PE is
modified with EVA (Ethylene vinyl acetate). Medium and high
density PE has a higher temperature limit, better abrasion
resistance and higher barrier properties than LDPE.
Polypropylene (PP) heat sealable, moisture and fat barrier. It can
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Polypropylene (PP) heat sealable, moisture and fat barrier. It can
withstand temperatures up to 140°C and is used for packing foods
to be reheated in ovens up to this temperature. One and two side
coatings are available.
Polyethylene terephthalate (PET) heat sealable, moisture and fat
barrier. It can withstand temperatures up to 200°C and is dual
ovenable (microwave and conventional ovens). It is coated only
on the non-printing side.
Polymethylpentene (PMP) moisture and fat barrier and not heat sealable. It is therefore used as flat sheets, deep drawn trays and trays with mechanically locked corners. It is coated only on the non-printing side.
Ethylene vinyl alcohol (EVOH) and polyamide (PA)
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Ethylene vinyl alcohol (EVOH) and polyamide (PA) heat sealable, fat, oxygen and light barrier.
Ionomer resin (Surlyn™), a polyolefin with high resistance to fat, including essential oils in citrus fruit, and moisture with very good sealing properties, is used as a tie layer on aluminium foil when applying PE to foil.
Proses Laminasi
Corrugated boardTerdiri dari bagianbergelombang yang di keduasisinya ditutup denganlembaran karton yang direkatkan (linier)
Konstruksi kelombangbertujuan untuk meredambertujuan untuk meredamgetaran
transport
Kotak Karton Bergelombang (KKG)
Harga per unit yang rendahBobot yang ringan dengan kekuatan yang tinggiMenghemat ruanganMudah diangkutMudah diangkutMelindungi benda-benda yang dikemas dengan amanMemiliki nilai promosiDapat didaur ulang (recycle)Proses pembuatan cepat
Tipe Ukuran Karton Bergelombang
Flute shape Flute pitch Flute heightFlute shape Flute pitch Flute height
Coarse flute (A flute) 8.0 - 9.5 mm 4.0 - 4.9 mm
Medium flute (C flute) 6.8 - 8.0 mm 3.2 - 4.0 mm
Fine flute (B flute) 5.5 - 6.5 mm 2.2 - 3.0 mm
Microflute (E flute) 3.0 - 3.5 mm 1.0 - 1.8 mm
DIAGRAM PROSES PEMBUATAN KERTAS
PENGECILAN
UKURAN
PEMBUBURAN DALAM DIGESTER
Proses : soda/sulfit/sulfat
P = 5 kg/cm2 t = 1400C
BAHAN DASAR
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PENCAMPURANBUBUR KERTAS
Air : 96 %
Padat : 4 %
• PENCETAKAN
• PENGERINGAN
• CALENDERING
BAHAN TAMBAHAN
Paper
Making
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Making
Step 1: Forestry
Typically, trees used for papermaking are specifically grown
and harvested like a crop for that purpose. To meet
tomorrow's demand, forest products companies and private
landowners in Wisconsin plant millions of new seedlings every
year.
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Step 2: Debarking, Chipping and/or Recycling
To begin the process, logs are passed through a debarker,
where the bark is removed, and through chippers, where
spinning blades cut the wood into 1" pieces. Those wood
chips are then pressure-cooked with a mixture of water and
chemicals in a digester.
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Step 3: Pulp PreparationThe pulp is washed, refined, cleaned and sometimes
bleached, then turned to slush in the beater. Color dyes,
coatings and other additives are mixed in, and the pulp slush
is pumped onto a moving wire screen.
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Step 4: Paper FormationAs the pulp travels down the screen, water is drained away and recycled. The resulting crude paper sheet, or web, is squeezed between large rollers to remove most of the remaining water and ensure smoothness and uniform thickness. The semidry web is then run through heated dryer rollers to remove the remaining water.
Waste water is carefully cleaned and purified before its release or reuse. Fiber particles and chemicals are filtered out and burned to provide additional power for the mill.
Papermakers carefully test for such things as uniformity of color and surface, water resistance, and ink holding ability.
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Tea and coffee bags
Paper bags and wrapping paper
Sachets/pouches/overwraps
Multiwall paper sacks
Jenis Kemasan Kertas
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Multiwall paper sacks
Folding cartons
iquid packaging cartons
Rigid cartons or boxes
Paper based tubes, tubs and composite containersTubes
Tubs
Composite containers
Fibre drums
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Corrugated fibreboard packaging
Moulded pulp containers
Labels
Sealing tapes
Cushioning materials
Cap liners (wads) and diaphragms
Contoh Jenis Kertas
A B C
A. Kertas Glasin
B. Kertas Perkamen
C. Daluang (Container Board
Bentuk kemasan
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Bentuk kemasan
Bentuk dan Jenis Kemasan
Amplop dan Kantung
Karton Lipat dan Kardus :- Lipatan terbalik (reverse tuck)
- Dasar menutup sendiri (auto-lock bottom)
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bottom)
- Model pesawat terbang (airplane style)
- Lipatan lurus
- Model perekat ujung (seal end)
- Model perkakas dasar (hardware bottom).
Standar Karton
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A. Pola Dasar B. Lipatan Terbalik
C. Model Pesawat Terbang D. Lipatan Putus
E. Model Perekatan Ujung F. Model Perkakas Dasar
PolaPolaPolaPola----pola dasar untuk membuat kemasan daluang lipatpola dasar untuk membuat kemasan daluang lipatpola dasar untuk membuat kemasan daluang lipatpola dasar untuk membuat kemasan daluang lipat
Berbagai model kotak karton lipat
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