The Packaging Designer's Book of Patterns - Softcover

Roth, Lįszlo; Wybenga, George L.

Softcover

ISBN 10: 0471385042 ISBN 13: 9780471385042

Publisher: John Wiley & Sons, 2000

Synopsis

Now the best thing to happen to package design since paper is even better!

This new edition of The Packaging Designer′s Book of Patterns does what may seem impossible to many devoted users of the first edition–it makes a unique and indispensable resource even better! With more than 100 completely new patterns, as well as significant revisions and improvements to more than 250 existing patterns, this unparalleled practical resource gives you the tools you need to meet virtually any packaging challenge.

Every pattern has been test–constructed to verify dimensional accuracy and is ready to be traced, scanned, or photocopied for immediate use. The patterns can be scaled to suit particular specifi–cations, and many are easily converted to alternate uses. Details–such as tabs, locks, and closures–are often interchangeable and may be adapted to specific requirements or personal preference. Other outstanding features of this new edition include:
∗ More than 500 ready–to–use patterns and structural designs
∗ A broad array of patterns for folding cartons, trays, tubes, sleeves, wraps, folders, corrugated cartons, point–of–purchase displays, and more
∗ All patterns are based on the use of 100% recyclable paper materials and many packaging configurations lend themselves to after–use
∗ All glue areas are clearly indicated with black dots
∗ Saves hours–even weeks–of research or trial–and–error design

For packaging and industrial design professionals, packaging manufacturers, graphic designers, and structural designers, the new edition of The Packaging Designer′s Book of Patterns does what no other industry resource can: it gives you the power and ingenuity of hundreds of structural designers–all in a single volume.

About this title

About the Author:

The late LĮSZLO ROTH was chairperson of the Packaging Design Program at the Fashion Institute of Technology in New York. Now retired, GEORGE L. WYBENGA was professor in the Packaging Design Program at the Fashion Institute of Technology and succeeded Lįszlo Roth as chairperson. He remains active as a consultant to the packaging industry.

Excerpt. © Reprinted by permission. All rights reserved.:

Introduction

Paper is among the noblest of human inventions. It is worthwhile, therefore, to begin with a short history of papermaking.

Before books could be written and preserved, a writing surface had to be developed that was light, not too bulky, and was easily stored. The first great advance was the Egyptians' use of papyrus in the third millennium B. C. Sheets of beaten papyrus stems were fastened together into scrolls, some more than 120 feet long, that could be rolled up for storage. After papyrus came parchment, which was perfected in Asia Minor in the city of Pergamum (from which its name is derived) in the second century B. C. Animal skins had long been used as a writing surface in Greece and Rome, but it was in Pergamum that methods were evolved for the production of a durable, velvet-smooth parchment that could be written on on both sides.

For hundreds of years all paper was made by hand from rag pulp. The use of wood fibers to make paper was discovered in the mid 1800s. In 1840 Friedrich G. Keller in Germany invented a way to grind logs into a fibrous pulp; this method produced a rather poor quality of paper, as all parts of the wood--not just the fibers--were used.

Paper as we know it today was first made in China in 105 A. D. Ts'ai Lun, a member of the court of Emperor Ho Ti, succeeded in turning husks of cotton fibers into paper pulp. This method spread throughout China, Korea, and Japan and as far west as Persia. In 751 A. D. Moslems captured a Chinese paper mill in Samarkand and learned the method of papermaking. They brought the method to Spain around 950 A. D., and by the thirteenth century paper mills had been established throughout western Europe, first in Italy and then in France, Germany, England, and Scandinavia.

The first paper mill in America was built in 1690 by William Rittenhouse near Philadelphia. Sheets of paper were produced one at a time until 1799, when Nicholas Louis Robert developed a continuous process. (This method was patented in England by the Fourdrinier brothers and is known by that name.) In 1817 the first cylinder-type papermaking machine, which can produce a better quality of paper in a continuous process, was invented by John Dickenson.

MODERN PAPERMAKING Today almost all paper is manufactured from wood. Cellulose fibers (which account for 50 percent of the content of wood) are the primary ingredient, followed by lignin (about 30 percent), which acts as a fiber binder or glue.

Water plays an important role in modern papermaking. The manufacture of 1 ton of paper requires about 55,000 gallons of water, most of which is recycled. The papermaking process also uses sulfur, magnesium, hydroxide, lime, salt, alkali, starch, alum, clay, and plastics (for coating). There are two basic types of paper: fine paper for writing and paper for printing and industrial use (packaging).

The first step in manufacturing paper from wood is to remove the bark. The cheapest way to separate the fibers is to grind up the wood by forcing the logs against grindstones submerged in water. The water carries off the wood fibers. In this process everything is used, and the paper produced is of low quality. Another, more frequently used process is chemical pulping, in which the wood is chipped into small pieces, the fibers are extracted through a chemical process, and the unusable material is eliminated. Chemical pulping is more expensive, but it produces better-quality paper.

Chemical pulping creates a pulp, which is then refined by washing and separating the fibers. Refinement, a time-controlled process during which the manufacturer can add various chemicals to increase bonding, texture, and water resistance, increases the quality and strength of the paper. Pigments (for coloring) and coatings (plastics) can also be added at this stage.

Once the pulp is prepared, it goes to one of two types of machines: The Fourdrinier, or the cylinder machine. Modern papermaking machines are huge. They can be as long as a city block and several stories high. They produce paper up to 30 feet wide at a speed of 3,000 feet per minute, resulting in 800 miles of paper a day! The primary papermaking machine is the Fourdrinier. Most Fourdrinier machines make only one layer of material, although they can be equipped to make several layers.

Paper produced by a Fourdrinier machine is smoothed by a stack of highly polished steel rolls, a process known as calendering. The finished paper is then cut, coated, and laminated.

Another frequently used papermaking machine is the cylinder machine. This machine makes heavy grades of paperboard, generally using recycled paper pulp. The pulp is built up in layers. Since paperboard is much thicker than paper, the drying operation is far more extensive. Large steam-heated cylinders drive the excess moisture out of the paper. A coating is then added to create a smooth surface.

The great advantage of the cylinder machine is that it uses large amounts of recycled paper in thick layers to provide strength.

Paper is bought on the basis of the weight (or basis weight), in pounds, of a ream of paper. (A ream is equal to 3,000 square feet of surface.) The thickness of paperboard is expressed in caliper points, which are stated in thousandths of an inch (usually written in decimals). Since most papers are laminated or coated with other materials, caliper points are rarely used today to specify weight. The paperboard used in folding cartons is specified according to the size of the carton or, more often, the weight of the item that goes into it. A glass bottle for 3.5 fluid ounces of fragrance, for example, would require a folding carton with a thickness of approximately 18-24 points.

The thickness of paper can be controlled by means of calendering, pressing, and laminating. High-quality paper is up to 12 points thick; paperboard varies in thickness from 12 to 70 points.

About this edition

• Publisher: John Wiley & Sons
• Publication date: 2000
• ISBN 10: 0471385042
• ISBN 13: 9780471385042
• Binding: Paperback
• Edition number: 2
• Number of pages: 608