Packaging Engineering Library
Rigid packaging can become technical quickly. The Empire EMCO Packaging Engineering Library explains the design principles, tooling terminology, manufacturing processes and common production issues involved in developing bottles, jars, closures and other rigid packaging.
Whether you are trying to understand a neck finish, determine why a bottle is paneling, learn what mold cavitation means or prepare a custom package for tooling, this library is designed to make packaging engineering easier to understand.
The library will continue to grow as Empire EMCO adds technical explanations, engineering resources, troubleshooting guides and custom mold development information.
Explore the Packaging Engineering Library
Start with the technical category that best matches the packaging question or problem you are trying to understand.
Package Design Fundamentals
Neck finishes, wall thickness, draft angles, parting lines, package geometry and other structural design concepts.
Molds & Tooling Engineering
Cavitation, mold venting, family molds, inserts, tooling materials, mold finishes and tooling strategy.
Packaging Problems & Troubleshooting
Paneling, warpage, flash, sink marks, gate marks and other common package or molding issues.
Engineering Drawings & CAD
Understand 2D drawings, 3D CAD, STEP files, IGES files and Final Revision Drawings.
Manufacturing Processes
Learn about extrusion blow molding, injection molding, injection blow molding and injection stretch blow molding.
Materials & Sustainability Engineering
Explore material selection, PCR considerations, lightweighting and package-performance requirements.
What Packaging Problem Are You Seeing?
You do not need to know the engineering term before you start. Packaging problems are often easier to identify by what the container is actually doing.
“My bottle is collapsing inward.”
Topics to investigate: Bottle Paneling, Vacuum Distortion, Wall Strength and Package Geometry.
“There is extra plastic along the seam.”
Topics to investigate: Flash, Parting Lines, Mold Condition and Processing.
“The bottle is warped or does not sit correctly.”
Topics to investigate: Warpage, Cooling, Base Geometry and Material Distribution.
“There is a visible mark where plastic enters the part.”
Topics to investigate: Gate Marks, Gate Location and Mold Design.
“The closure does not fit or seal correctly.”
Topics to investigate: Neck Finish, Closure Compatibility, Tolerances and Component Fit.
“The bottle walls do not appear consistent.”
Topics to investigate: Wall Thickness Distribution, Package Geometry, Material Distribution and Processing.
Understanding Container Geometry & Design
These concepts help define how a rigid package is shaped, manufactured and integrated with its components.
Neck Finish
The dimensional and thread configuration at the opening of a container that helps determine closure compatibility.
Wall Thickness
The thickness and distribution of material throughout a package, which can influence structure, performance and material use.
Draft Angle
A design angle used on certain molded features to support manufacturing and removal of the part from tooling.
Parting Line
The location where mold sections meet, which may create a visible line on the molded package.
Package Geometry
The overall shape, dimensions, shoulders, panels, base and structural features that define a rigid package.
Closure Interface
The relationship between the container finish and the closure, pump, sprayer or dispensing component.
Understanding Custom Packaging Tooling
Mold configuration can affect how a package is produced, scaled and managed throughout the life of the program.
Mold Cavitation
Cavitation refers to the number of cavities within a mold that produce parts during a manufacturing cycle.
Mold Venting
Venting provides pathways for displaced air and gases to escape during the molding process.
Family Mold
A common mold platform with interchangeable inserts can support multiple related package sizes when technically appropriate.
Interchangeable Inserts
Package-specific tooling components that may allow a common tooling platform to produce related package variations.
Tooling Materials
Mold construction materials are selected according to the package, manufacturing process, production requirements and tooling strategy.
Mold Finish & Texture
Mold-surface treatment can influence the visual appearance and surface characteristics of a molded package.
Common Rigid Packaging Issues
Packaging appearance or performance issues can have multiple potential causes. Proper troubleshooting considers the package, material, tooling, manufacturing process and product together.
Bottle Paneling
Inward deformation or distortion of container panels that may relate to pressure, vacuum, package structure or other application conditions.
Vacuum Distortion
Structural deformation that can occur when internal and external pressure conditions affect the package.
Flash
Excess material that may appear along mold seams or other areas of a molded part.
Sink Marks
Localized surface depressions that can be associated with material cooling, geometry or molded-part design.
Warpage
Unintended distortion that causes a molded package or component to deviate from its intended geometry.
Gate Marks
Visible evidence of the location where material entered the mold during certain molding processes.
Understanding Packaging Design Files
Drawings and digital engineering files help communicate package geometry and technical requirements throughout the development process.
2D Engineering Drawings
Technical drawings used to communicate package dimensions, geometry and other design information.
3D CAD Models
Digital three-dimensional models used to visualize and technically define package geometry.
STEP Files
A commonly used neutral CAD file format for transferring three-dimensional engineering geometry between systems.
IGES Files
A neutral engineering file format that can be used to exchange CAD geometry between design systems.
Final Revision Drawings
The approved technical drawings used to confirm the package design before custom mold manufacturing proceeds.
Drawing Revisions
Controlled design changes made during development before the package progresses to tooling and production.
How Rigid Packaging Is Manufactured
Different rigid packages require different manufacturing processes. The package geometry, material and application help determine which process is appropriate.
Extrusion Blow Molding
A blow-molding process commonly used to manufacture hollow rigid plastic containers in a range of shapes and materials.
Injection Blow Molding
A manufacturing process that combines injection molding and blow molding to produce certain hollow plastic packages.
Injection Stretch Blow Molding
A process used for certain oriented plastic containers where a preform is stretched and blown into final package geometry.
Injection Molding
A molding process widely used for closures and other rigid packaging components.
Material Selection Is Part of Package Engineering
Material decisions should consider package performance, manufacturing, product requirements and sustainability objectives together.
HDPE
High-density polyethylene is widely used in rigid packaging applications and can be manufactured in many package shapes.
PET
Polyethylene terephthalate is commonly used for rigid packaging where clarity, appearance and application requirements make it appropriate.
Polypropylene
Polypropylene is commonly used in closures and other rigid packaging components.
PCR Design Considerations
Post-consumer recycled content can introduce package, performance, aesthetic and manufacturing considerations that should be evaluated for the individual application.
Lightweighting
Lightweighting seeks to reduce package material while maintaining the performance required for the intended application.
Material Optimization
Packaging engineering can evaluate material use alongside geometry, performance and manufacturing requirements.
How to Use the Engineering Library
The library is designed to help whether you know the technical term already or are simply trying to understand a packaging problem.
Start With the Question
Look for the term, package feature or production issue you are trying to understand.
Understand the Engineering
Learn what the term means, why it matters and which packaging factors can influence it.
Apply It to Your Package
Use the information to ask better questions when evaluating package design, tooling, components or manufacturing.
Continue Your Packaging Engineering Research
Packaging Design & Engineering
Learn how concepts are developed into practical packaging solutions.
Design & Engineering →Custom Mold Development
Explore the complete custom tooling process from concept through commercialization.
Custom Mold Development →Development Process
Follow the stages of concept, drawings, tooling, sampling and production approval.
View the Process →Stock vs. Custom Packaging
Compare stock, hybrid and completely custom packaging strategies.
Compare Options →Family Mold Design
Learn how a common mold platform may support multiple related package sizes.
Family Mold Design →Custom Mold Cost
Understand the project-specific factors that influence tooling requirements and cost.
Mold Cost Guide →Custom Mold FAQs
Get answers to common questions about custom mold development and tooling.
Custom Mold FAQs →Custom Mold Library
Explore Empire EMCO's growing collection of existing custom packaging molds.
Browse Custom Molds →Frequently Asked Questions
What is packaging engineering?
Packaging engineering applies design, material, tooling, manufacturing and performance requirements to the development of a package that can be produced consistently and function as intended.
What does a packaging engineer evaluate?
Depending on the project, packaging engineering may evaluate package geometry, materials, wall thickness, neck finish, closures, dispensing components, tooling, manufacturing requirements, samples and production considerations.
What is a neck finish?
A neck finish is the dimensional and thread configuration at the opening of a bottle or container. It is an important part of determining compatibility with closures, pumps, sprayers and other dispensing components.
What is mold cavitation?
Mold cavitation refers to the number of cavities within a mold that produce parts during a manufacturing cycle. Cavitation requirements are determined as part of the tooling and production strategy.
Why does a plastic bottle panel or collapse inward?
Bottle paneling or inward distortion can have several potential causes involving pressure conditions, package geometry, material distribution, product conditions or application requirements. The complete package and use environment should be evaluated when troubleshooting the issue.
What are Final Revision Drawings?
Final Revision Drawings are the approved technical drawings used to confirm the package design before custom mold manufacturing proceeds.
What is the difference between a STEP file and a drawing?
A STEP file contains transferable three-dimensional CAD geometry, while an engineering drawing presents dimensional and technical information in a drawing format. Both may play different roles during package development.
Can packaging engineering help determine whether I need a custom mold?
Yes. Reviewing package geometry, functional requirements, available stock components, existing tooling and manufacturing requirements can help determine whether an existing package, hybrid solution, family mold or completely new custom tooling should be evaluated.
Can packaging engineering support sustainability goals?
Depending on the project, engineering can evaluate material selection, PCR objectives, lightweighting, package geometry and material optimization alongside performance and manufacturing requirements.
Will the Packaging Engineering Library continue to grow?
Yes. Empire EMCO is building the Packaging Engineering Library as an expanding educational resource covering rigid packaging design, tooling, manufacturing, troubleshooting, materials and custom mold development.
Have a Packaging Engineering Question?
You do not need to know the technical term before starting. Tell Empire EMCO what your package is doing, what it needs to accomplish or what you are trying to develop, and we can help evaluate the packaging path.