John Fagan    fagan@bim.iejohn.fagan@teagasc.ie
Tech-transfer
Researching Innovative technologies for industry
Kinds of queries we deal with…     “I have the raw material – what will I make”?   “I found this French product, can I mak...
We deal with numerous Irish and         International packaging companiesEquipment suppliersTraysFilmBottlesCansPouc...
We deal with numerous National and International packaging suppliers
We deal with numerous National and International              equipment suppliers
Numerous ingredients companies..
Numerous other processing equipment             suppliers
To date….Over 300 company NPD projectsRanging from small to largeRaw, chill, frozen, pasteurised, freeze-chill etc.Con...
Every company is differentSize of operationStages of growthBudget available for CapexRequired shelf-lifeTarget market...
However one common factor…The most successful NPD ideas are market-led.  Packaging represents most queries to date.
Important to have a starting point for NPD                processVaried nature of queriesNot all complete A-Z projects (...
Develop our own model building on tried-        and-tested methodologies1. Marketing Input                       9.    She...
Client comes in to   discuss numerous            Launch and    ideas with team              monitor      Companycapabiliti...
All NPD should be market-led          “one-in-ten products are successful”       “”a new product can take 18-months to get...
Importance of market researchFirst step on the NPD processIs there a gap / demand for your product?Market research is e...
Store checks- quick and convenient
Store checks allow you to buy and reverse-engineer                successful productsGastropub: Main For   Count on us: Lo...
Additional sources of data e.g. Mintel/Kantar                   Bord Bia
Recipe formulation/reverse engineering(Mintel)  Tesco Thai Crab Fish Cakes  Company: Subcategory:  Date Published: ID:1...
E.g. Mintel data
Market-data can help you decide which strategy to go with                  Branded v’s own brand ?
(Does the retailer have room for another fish chowder?!)
Packaging has important role to playIn getting your product and brand noticedCan be retailer-push towards packaging form...
Remember we are still in the initial stages of  the project and are defining how market               requirements 1. Mark...
Initial first product make-up….     From the food scientific perspective….Try to identify packaging materials/technologies...
Physical functions of packaging                 Colour      OxidationMicrobialTexture                            Odour    ...
Spoilage organisms – Fresh meat    E.g. Pseudomonas, Acinetobacter,Moraxella,Shewanella, Alcaligenes, Aeromonas,      Esc...
Bacterial spoilage beer For brewing industry, beer spoilage bacteria have been  problematic for centuries. They include s...
Yeasts and mouldsYeasts and Moulds are major spoilage organisms predominately in low water activity foods (e.g. jams, syr...
Packaging….Is only one Hurdle used in conjunction with others.Temperature (heat and/or cold- chain)pH/AwAir/Modified A...
Packaging has numerous functionsPhysical protectionBarrier protection – air/water etcAvoid Cross contamination/security...
When developing a new productImportant to use commercially-available packaging equipment and materials early-on in trials...
Many packaging suppliersUnderstand incremental growthNumerous entry-level solutions to help you to get up and runningEn...
IngredientsTrend towards clean-label ingredientsRetailers have list of preferred suppliersRetailers have list of ingred...
IngredientsTrend towards clean-label ingredientsRetailers have list of preferred suppliersRetailers have list of ingred...
Raw Pre-pack + IngredientsSauces/spices/ glazes etcSavoury crumbButters/toppingsIncreased convenienceBacteriological...
Ingredients work well with raw seafood      Chilled shelf-life (+ gas) <10 days        Frozen raw shelf-life < 1 year
Raw Pre-pack +Ingredients… Add flavour Mask odours Increase convenience Rosemary can reduce  microbiological growth L...
Develop our own model building on tried-        and-tested methodologies1. Marketing Input         9.    Shelf life and   ...
Product sign-off with customerProject so far has identified correct look and feel of productInitial shelf-life determina...
Photography and pack design
Both commodity and own-brand can make                money
Develop our own model building on tried-and-tested methodologies  1. Marketing Input         9.    Shelf life and         ...
Case study 1.Artisan seafood producer who wanted to produce ready meal products with min 21              days shelf-life ...
Product LimitationsHe tried Gas flushing but not effective due to physical nature of productCompany using combi-oven to ...
Choice of tray
Competitor offerings identified during            store check                M&S  Foil +         C-pet           Foilwaxed...
Early screening suggested Foil oven tray (12c) 40-60mm deep tray D2/group 6 footprint (200x155) Dual oven/microwavable...
Ingredients considerationsStore-checks suggested mixture of clean-label and not-so-clean on marketAs chowder product, fi...
Equipment trialledIlpraMultivacPromensHired for 1         €27-30k month each€750- 1200/monthD2 footprint8-12 trays/...
Practical considerationsCold-fill delivered 8 days shelf-lifeTo achieve 8+ days, necessary topasteurise in-tray (e.g. 85...
Deciding factors…MAP not suitable for this application as cooking step (process)Polypropylene tray chosen as with-stands...
Other product produced with similar      packaging technologies
Case study 2   Smoked meats manufacturer   considering upgrading packaging    €30k spend on equipment.
Artisan salami and cooked meats
Issues with current packaging range  Competitor offerings more visually appealing  Manual filling/vacuum packing  Handl...
Competitor PackagingEquipment - Thermoforming                  ILPRA                  Multivac                  Ulma      ...
Solutions tested Printed pouch – Alert Packaging and Fosters  Packaging Multivac T250 – Tray and skinpack Mecapack S100...
Printed PouchBetter visual impact / brandingStill issue of manual fillingOption to develop similar style pack on flow-w...
Multivac T250 Dual tray sealing and skin-pack (in tray) D2 x 4 trays (200x155) (PP) 20mm deep tray skin-pack (in-tray)...
Mecapack S1000Polypropylene 20mm traySkin-pack top-film4-6 trays per minS1000 heads fit large machines (trade-up possi...
Deciding factorsOne stop shop for machine + film (Mecapack)Possibility to trade-up and save money on sealing heads/die s...
These packaging technologies can also be               used for
Case Study 3    Nut and cereal based snack bar. 6 bars per               box (printed carton).
Competitor offerings
Packaging used by competitors         Large Flow wrappers               €75-200k
In terms of packaging materials…Important when dealing with film manufacturers   •   The size and weight of the bar   •   ...
Paddy’s O’ Granola Range                        75% common colours                       throughout with distinct         ...
Trialled during this projecthttp://www.youtube.com/watch?feature=endscreen&NR=1&v=bvwHBlMxUlE                             ...
Machine & material sourcingFlow-wrapBasic Packaging Ltd. (£9995 entry)(Also supply VFFS for Crisps)(£7995 entry)Print R...
Final product important factsWater activity (Aw) control crucialProduct discoloured with lightFoil layer used to omit l...
ANSER U2 PRINTERS          •   300 DPI Printing          •   Dates, times, counters and logos          •   Handy remote co...
Want to know moreabout flow-wrapping??Good site re Flow wrapping and material;http://www.boschpackaging.com/doboy/eng/pd...
Flow wrapping has application for
Case Study 4Chowder producer looking for longer shelf-life             (currently 14 days).     Monies available – €20k...
Current processBrat panBrought to boil and fish added for last 20 minLadled and hot-filled into tamper- evident tubsBl...
Competitor technology     Limitech mixer/heating     Automatic dosing into tubs     Mondini tray sealer with de-nester ...
First of all…..REALITY CHECK !!!High volume competitor productNot main product (ready meals)Major supplier to Tesco (U...
Benchmark against similar products  Range of product with 3 months max shelf-   life  Small volumes  Artisan values, pr...
Packaging trialledHand sealer with profile cut (4 up die                  €12k set – circular tubs) x 2 HDPE tubs (150ml...
Value for money??Pro’s16 trays per minSemi-automated dosing into HDPE tubsOption to use printed top-film and eliminate...
However…. This client needed to produce min 3000 units per week to supply  retailer Capex would have been too small Dec...
Outsourcing production Outsourced to ready meals company Did not want to fillet/skin/bone Additional costs for outsourc...
Important when outsourcing…   Pre-meeting     Confidentiality agreement     Bring prototypes/competitor products     G...
Case Study 5   Large seafood processor wanted to test       Thermoforming/skin-packagingEquipment trials & costs analysi...
Skin-pack/Thermoform Equipment – RawPre-pack (Trialled 4 machines)      €28k              €120k++
Focus group and buyer feedback re skin-pack Increased visual spec Less plastic/packaging More in box/pallet Increased ...
Client gathered quotes for      equipment Multivac R095 Flex R105 Semi rigid (MAP+ skin) R125/145 Cooked meats R175 D...
We carried out trials re materials/usage/costs withfilm manufacturers       Topweb TC201 650m       long = 2400 trays/roll...
Calculating costs  Throughput per hour  Dictated by machine size  E.g. 420mm carousel  E.g. 3 x 127 x 270mm packs (381...
Shelf-life analysisDarfresh material versus barrierGas flush = 6 daysVaccum = 6 daysDarfresh = 8 daysSensory/odour/ch...
Thermoforming has applicationfor
So when developing new products Identify markets and competitor offerings Identify RTM strategy and buyer requirements ...
Thank youJohn Fagan087 9045047
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BIM Presentation J Fagan Food Product Development

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Presentation by John Fagan of BIM as part of Enterprising Donegal Business Week 2013

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BIM Presentation J Fagan Food Product Development

  1. 1. John Fagan fagan@bim.iejohn.fagan@teagasc.ie
  2. 2. Tech-transfer
  3. 3. Researching Innovative technologies for industry
  4. 4. Kinds of queries we deal with… “I have the raw material – what will I make”? “I found this French product, can I make something similar”? “Where can I source these trays/film”? “How do I package it”? “I’m only getting 6 days shelf-life, I want 12…21...”“What kind of packaging equipment will I buy”? “Ive already bought a packaging machine – do you think its suitable”?!
  5. 5. We deal with numerous Irish and International packaging companiesEquipment suppliersTraysFilmBottlesCansPouchBag etc
  6. 6. We deal with numerous National and International packaging suppliers
  7. 7. We deal with numerous National and International equipment suppliers
  8. 8. Numerous ingredients companies..
  9. 9. Numerous other processing equipment suppliers
  10. 10. To date….Over 300 company NPD projectsRanging from small to largeRaw, chill, frozen, pasteurised, freeze-chill etc.Consumer foods, baby foods, pet-foodsDairy, beverage, meat/muscle foods, cereals etc.No “One-fits-all approach”Each situation is different
  11. 11. Every company is differentSize of operationStages of growthBudget available for CapexRequired shelf-lifeTarget marketMarket size/volumeLevel of automation requiredExpertise/skillsProvenanceUse of ancillary equipment/processesEtc
  12. 12. However one common factor…The most successful NPD ideas are market-led. Packaging represents most queries to date.
  13. 13. Important to have a starting point for NPD processVaried nature of queriesNot all complete A-Z projects (farm to fork / boat to throatDifferent competencies of companies/individualsDifferent requirementsNeed to have a formal approach to dealing with client queries
  14. 14. Develop our own model building on tried- and-tested methodologies1. Marketing Input 9. Shelf life and nutritional testing2. Concept Research 10. Customer Presentation3. Proposed ingredients and 11. Product sign off with raw material source customer4. Initial first product make up 12. Photography and pack5. Recipe Formulation design6. Sensory Evaluation 13. Confirm packaging7. Process technology 14. Pre production trials8. Work up costings 15. Launch Exhaustive process – stage gates at each stage to allow project to proceed/kill to next step Ref: Leatherhead UK
  15. 15. Client comes in to discuss numerous Launch and ideas with team monitor Companycapabilities/strengths/equipment etc. versus Capex/equipment/ competitor outsourcing etc Tweak/adjust prototype based Market-specific on buyers spot check to look requirements at opportunity Working prototype If business-case Project proceed to project design/timelines/respo design (if not nsibilities/stage kill/adjust) gates/deliverables
  16. 16. All NPD should be market-led “one-in-ten products are successful” “”a new product can take 18-months to get to market”
  17. 17. Importance of market researchFirst step on the NPD processIs there a gap / demand for your product?Market research is essential & time well spent.Benchmark your concept against competitor offeringsSee what multiples require in terms of pack size/price-point etcOpportunity to determine what your competitors are using and try to improve upon this
  18. 18. Store checks- quick and convenient
  19. 19. Store checks allow you to buy and reverse-engineer successful productsGastropub: Main For Count on us: Low Fat Range Haddock CumberlandTwo€10.49 per 720g €5.99 per 400g Pie€3.39 per 300g Ensuring competitor USP’s are improved upon
  20. 20. Additional sources of data e.g. Mintel/Kantar Bord Bia
  21. 21. Recipe formulation/reverse engineering(Mintel) Tesco Thai Crab Fish Cakes Company: Subcategory: Date Published: ID:1592970 Tesco Fish Products 12 Jul 2011 Tesco Thai Crab Fish Cakes contain Alaska pollack and sweet chilli melt in the middle. The fish cakes are free from artificial preservatives, flavours and colours. This product retails in a 290g recyclable pack containing two pieces. Country: Ireland Storage Type:Frozen Ingredients: Crab meat (21%) (white crab meat (70%), brown crab meat (30%)), Alaska pollack (15%), wheat flour, sweet chilli sauce (12%) (water, red pepper, sugar, fructose, tomato, vinegar, cornflour, fish Nutrition: Per 100g: Energy 770kJ/185kcal, Protein 10.2g, Carbohydrate 18.1g (of which Sugars 4.7g), Fat 7.8g
  22. 22. E.g. Mintel data
  23. 23. Market-data can help you decide which strategy to go with Branded v’s own brand ?
  24. 24. (Does the retailer have room for another fish chowder?!)
  25. 25. Packaging has important role to playIn getting your product and brand noticedCan be retailer-push towards packaging formats e.g. MAP versus Skin-packAlso importantly, packaging must deliver optimal product quality over duration of shelf-life (food contact packaging)Important to screen competitor offerings
  26. 26. Remember we are still in the initial stages of the project and are defining how market requirements 1. Marketing Input 9. Shelf life and 2. Concept Research nutritional testing 3. Proposed ingredients 10. Customer and raw material Presentation source 11. Product sign off with customer 12. Photography and 4. Initial first product pack design make up 13. Confirm packaging 5. Recipe Formulation 14. Pre production trials 6. Sensory Evaluation 15. Launch 7. Process technology 8. Work up costings
  27. 27. Initial first product make-up…. From the food scientific perspective….Try to identify packaging materials/technologies early-onPackaging materials and equipment must deliver maximum quality throughout the shelf-lifePrototype development must ensure commercial scalability
  28. 28. Physical functions of packaging Colour OxidationMicrobialTexture Odour SPOILAGE Moisture/Aw Chemical Sensory
  29. 29. Spoilage organisms – Fresh meat E.g. Pseudomonas, Acinetobacter,Moraxella,Shewanella, Alcaligenes, Aeromonas, Escherichia, Enterobacter, Serratia, Hafnia,Proteus, Brochothrix, Micrococcus, Enterococcus, Lactobacillus, Leuconostoc, Carnobacterium and Clostridium.The predominant spoilage flora in a meat is determined by nutrient availability, oxygenavailability, storage temperature, pH, storagetime of the product, and generation time of themicro organisms present in a given environment
  30. 30. Bacterial spoilage beer For brewing industry, beer spoilage bacteria have been problematic for centuries. They include some lactic acid bacteria such as Lactobacillus brevis, Lactobacillus lindneri and Pediococcus damnosus, and some Gram- negative bacteria such as Pectinatus cerevisiiphilus, Pectinatus frisingensis and Megasphaera cerevisiae. They can spoil beer by turbidity, acidity and the production of unfavorable smell such as diacetyl or hydrogen sulfide
  31. 31. Yeasts and mouldsYeasts and Moulds are major spoilage organisms predominately in low water activity foods (e.g. jams, syrups, dried foods) and foods with low pH (e.g. 3.8 pickles/marinades). In general, Yeasts will grow in the presence or absence or oxygen while moulds are generallyinhibited by oxygen-free environments. However “oxygen-Free” status isdependent on effectiveness and integrity of packaging medium
  32. 32. Packaging….Is only one Hurdle used in conjunction with others.Temperature (heat and/or cold- chain)pH/AwAir/Modified AtmosphereHeat treatmentsIngredients/additivesPackaging maintains inhospitable environment to spoilage bacteria
  33. 33. Packaging has numerous functionsPhysical protectionBarrier protection – air/water etcAvoid Cross contamination/securityFacilitate TransportRetard spoilage (NB ***)As a processing step e.g. can/jarMarketing toolConvenience e.g. microwave/oven
  34. 34. When developing a new productImportant to use commercially-available packaging equipment and materials early-on in trialsEnsures commercial simulation of the cold-chainTest seal integrity and associated properties of productAllows natural spoilage to occur as per commercial cold- chain/logisticsGenerates usable microbiological data for development of HACCP/FSMSUse accredited micro-testing when possible
  35. 35. Many packaging suppliersUnderstand incremental growthNumerous entry-level solutions to help you to get up and runningEntry-level equipmentHire of larger equipmentSmall print runsAllows you to test concept at prototype stage before large investment
  36. 36. IngredientsTrend towards clean-label ingredientsRetailers have list of preferred suppliersRetailers have list of ingredients they do not want in productsChoice of ingredients may be dictated by price-points and target marketE.g. M&S UK v’s ChinaImportant to screen ingredients suppliers in terms of BRC, quality systems etc
  37. 37. IngredientsTrend towards clean-label ingredientsRetailers have list of preferred suppliersRetailers have list of ingredients they do not want in productsChoice of ingredients may be dictated by price-points and target marketE.g. M&S UK v’s ChinaImportant to screen ingredients suppliers in terms of BRC, quality systems etc“fresh ingredients” may require more expensive processing technologies to deliver shelf-lifeDried ingredients can often make more financial sense
  38. 38. Raw Pre-pack + IngredientsSauces/spices/ glazes etcSavoury crumbButters/toppingsIncreased convenienceBacteriologicalAnti-oxidant affect
  39. 39. Ingredients work well with raw seafood Chilled shelf-life (+ gas) <10 days Frozen raw shelf-life < 1 year
  40. 40. Raw Pre-pack +Ingredients… Add flavour Mask odours Increase convenience Rosemary can reduce microbiological growth Lemon/lime/citric can reduce oxidation However must source from reputable supplier Spices can be loaded with bugs!!! Wash vegetables well!! Early identification of ingredients will ensure usable results e.g. shelf- life trials/nutritional
  41. 41. Develop our own model building on tried- and-tested methodologies1. Marketing Input 9. Shelf life and nutritional testing2. Concept Research 10. Customer3. Proposed ingredients Presentation and raw material 11. Product sign off with source customer4. Initial first product 12. Photography and make up pack design5. Recipe Formulation 13. Confirm packaging6. Sensory Evaluation 14. Pre production trials7. Process technology 15. Launch8. Work up costings
  42. 42. Product sign-off with customerProject so far has identified correct look and feel of productInitial shelf-life determinationCalculation of associated costs (materials, equipment, labour, over heads etc)Sensory trials to identify consumer feedback and adjust/incorporate as suggestedProduct specs maximised before approaching buyerUnderstanding of all associated costsFinalise branding/pack design/labelling etc
  43. 43. Photography and pack design
  44. 44. Both commodity and own-brand can make money
  45. 45. Develop our own model building on tried-and-tested methodologies 1. Marketing Input 9. Shelf life and nutritional testing 2. Concept Research 10. Customer 3. Proposed ingredients Presentation and raw material 11. Product sign off with source customer 4. Initial first product 12. Photography and make up pack design 5. Recipe Formulation 13. Confirm packaging 6. Sensory Evaluation 14. Pre production trials 7. Process technology 15. Launch 8. Work up costings
  46. 46. Case study 1.Artisan seafood producer who wanted to produce ready meal products with min 21 days shelf-life Small company with €30k to spend on equipment (combi-ovens)
  47. 47. Product LimitationsHe tried Gas flushing but not effective due to physical nature of productCompany using combi-oven to cook fish, sauce, potato etcFollowed by cold assemblyMicro Log 7 after 8 days.Too short to access UK market (and beyond)Plans to distribute throughout EU and needs 21+ days
  48. 48. Choice of tray
  49. 49. Competitor offerings identified during store check M&S Foil + C-pet Foilwaxed card D2/Topfilm D2/Topfilm
  50. 50. Early screening suggested Foil oven tray (12c) 40-60mm deep tray D2/group 6 footprint (200x155) Dual oven/microwavable Recyclable 200-350g portion size (adult serving) Cardboard sleeve (22c – 5 colours)
  51. 51. Ingredients considerationsStore-checks suggested mixture of clean-label and not-so-clean on marketAs chowder product, fish stock crucial componentCompany did not want to make own stockChose foodservice (dry) product with reasonably clean ingredients deckDecided to use frozen fish cubes and par-cooked veg
  52. 52. Equipment trialledIlpraMultivacPromensHired for 1 €27-30k month each€750- 1200/monthD2 footprint8-12 trays/min
  53. 53. Practical considerationsCold-fill delivered 8 days shelf-lifeTo achieve 8+ days, necessary topasteurise in-tray (e.g. 85 deg C for 30 minchamber temp)Therefore Polypropylene (PP) or HighDensity Polyethylene (HDPE) materialrequired (C-pet/foil misshapen after cook)Possible suppliers e.g. Promens orMecapackRH Packaging V511 machine
  54. 54. Deciding factors…MAP not suitable for this application as cooking step (process)Polypropylene tray chosen as with-stands high temperaturesAntifog top film to increase visibilityThroughput (Promens 511) 6-8 trays per minCost 12-15c each + 5 c top web + 12c cardboard sleeve (volume dependant)Machine - €27kFinal product microwavable but not oven-able (but working on this)
  55. 55. Other product produced with similar packaging technologies
  56. 56. Case study 2 Smoked meats manufacturer considering upgrading packaging €30k spend on equipment.
  57. 57. Artisan salami and cooked meats
  58. 58. Issues with current packaging range Competitor offerings more visually appealing Manual filling/vacuum packing Handling time and cross contamination Manual packaging bottleneck Inconsistent look to product range No shelf-ready packaging therefore poor product placement on shelves (Plan-o-gram) Difficult to Brand current pack
  59. 59. Competitor PackagingEquipment - Thermoforming ILPRA Multivac Ulma Optional gas- flush application Forms its own trays High volume throughputCosts €75k-220K
  60. 60. Solutions tested Printed pouch – Alert Packaging and Fosters Packaging Multivac T250 – Tray and skinpack Mecapack S1000 Skin packer Trays and film supplied by Versatile packaging, Monaghan Group 4 PP with skin-pack top film
  61. 61. Printed PouchBetter visual impact / brandingStill issue of manual fillingOption to develop similar style pack on flow-wrapperBut flow-wrap = 75k (“not a runner”)Buyer liked the new packaging but manual packaging too expensive
  62. 62. Multivac T250 Dual tray sealing and skin-pack (in tray) D2 x 4 trays (200x155) (PP) 20mm deep tray skin-pack (in-tray) Option to gas flush salamis/smoked chorizo in tray (50mm deep) on same machine Cost per tray 12c + 5c top-film Tray material – optional as reheat/oven/microwave not required (PP chosen) Optional printed top-film Machine €35k Throughput – 4 up die set (4 trays per cycle) – 12 trays per min skinpack/8 per min gas flush (product dependent)
  63. 63. Mecapack S1000Polypropylene 20mm traySkin-pack top-film4-6 trays per minS1000 heads fit large machines (trade-up possibility)Same supplier manufacturers PP traysCost trays 18-25c (per 5000)/topfilm 6-8c)
  64. 64. Deciding factorsOne stop shop for machine + film (Mecapack)Possibility to trade-up and save money on sealing heads/die setClient also sourced wrap around cardboard sleeve from Dollard Packaging (12c each)Shelf-life extended by 1 week due to removal of cross contamination issue (manual packaging – Entero)Rent-to-buy option with this companyWill probably scale up to a Multivac Thermoformer in near future (greater efficiencies)
  65. 65. These packaging technologies can also be used for
  66. 66. Case Study 3 Nut and cereal based snack bar. 6 bars per box (printed carton).
  67. 67. Competitor offerings
  68. 68. Packaging used by competitors Large Flow wrappers €75-200k
  69. 69. In terms of packaging materials…Important when dealing with film manufacturers • The size and weight of the bar • Product, Positioning, Price (Premium vs “cheap-as-chips”) • Reverse engineer (copy!) competitor product packaging or bespoke • Shelf-life required (this will dictate barrier properties e.g. laminate of barrier Polypropylene) • Throughput per hour • Laminates trap ink and avoids scuffing • On what type of machine will you pack . (DIY vs. OUTSOURCE) • Packaging machine dimensions • What kind of work have they done before? • Min print runs (e.g. 5000 linear metres entry level) • Costs per additional colour (gold & metallic ink expensive) • Can they do artwork or bring myself? • Finalise material specs and document (important is unexpected change in product down the line) • Check supplier ISO, BRC, Repack accreditations (important for selling to multiples) www.alertpackaging.com
  70. 70. Paddy’s O’ Granola Range 75% common colours throughout with distinct colouring to indicate variations in rangeWhite background and“Paddy O’s” common
  71. 71. Trialled during this projecthttp://www.youtube.com/watch?feature=endscreen&NR=1&v=bvwHBlMxUlE + Flowrap one (Basic packaging Ltd, UK)
  72. 72. Machine & material sourcingFlow-wrapBasic Packaging Ltd. (£9995 entry)(Also supply VFFS for Crisps)(£7995 entry)Print Registration Unit (PRU)Acrylic coated outer layerPolypropylene inner layerBarrier film inner layerGas-flushed with nitrogen (to eliminate air)Rental option – rented for 3 months with rentalcost deducted from final priceThroughout 20 packs per minOptional extension on carousel line
  73. 73. Final product important factsWater activity (Aw) control crucialProduct discoloured with lightFoil layer used to omit lightClient had 3 products5000 linear metres film best utilised with common coloursourceSpot colouring to show variations in product/ingredientsClient explored Paper : PP material for artisan feel.Client also needed to source a printer for BB date etc.
  74. 74. ANSER U2 PRINTERS • 300 DPI Printing • Dates, times, counters and logos • Handy remote control • Available as network version • Clean, no mess • Up to 5 lines of text • Prices from €1,650.00 • Also see CODICO (Ire)
  75. 75. Want to know moreabout flow-wrapping??Good site re Flow wrapping and material;http://www.boschpackaging.com/doboy/eng/pdf/BoBut always consult your materials supplierwho will discuss cost and shelf-lifeimplications and different materials
  76. 76. Flow wrapping has application for
  77. 77. Case Study 4Chowder producer looking for longer shelf-life (currently 14 days). Monies available – €20k “at a push”!! “But I’m not buying new”
  78. 78. Current processBrat panBrought to boil and fish added for last 20 minLadled and hot-filled into tamper- evident tubsBlast chilledSticker/label applied by handPlaced into outer cardboard box12 in outer cardboard box (2 x 6 per layer)
  79. 79. Competitor technology  Limitech mixer/heating  Automatic dosing into tubs  Mondini tray sealer with de-nester  Pasteurised in steriflow retort  Shelf-life 1year (ambient) (minimum)  Printed tubs  Traceability system  Already paid for factory & equipment  Large workforce
  80. 80. First of all…..REALITY CHECK !!!High volume competitor productNot main product (ready meals)Major supplier to Tesco (UK)Use of additives and thickenersContrary to brand values of our clientCapex investment €2million ++Go back and start your market check againCompare yourself to more realistic competitor
  81. 81. Benchmark against similar products Range of product with 3 months max shelf- life Small volumes Artisan values, provenance, freshness etc Start small e.g. local Supervalu Focus on freshness, quality and “local” Improve upon competitor products Allow for growth
  82. 82. Packaging trialledHand sealer with profile cut (4 up die €12k set – circular tubs) x 2 HDPE tubs (150ml)Wrap around cardboard sleeve (Dollard packaging) €1100Second-hand Semi- automated depositor (Riggs autopack, UK) Riggs autopack
  83. 83. Value for money??Pro’s16 trays per minSemi-automated dosing into HDPE tubsOption to use printed top-film and eliminate cardboard sleeveDosing machine reduced handling/cross contaminationCon’sStill a manual operationAdditional investment required for scale-upLonger shelf-life requires further heat-treatment in- pack
  84. 84. However…. This client needed to produce min 3000 units per week to supply retailer Capex would have been too small Decided to OUTSOURCE (in short-term) Pros Large-volume possible Can focus on sales You know your capacity Slightly more expensive €1.12/pack) HACCP/FSMS/BRC etc responsibility of another company Cons Different factory number (FR) Tied in to 6-12 month contract Eventually outsourcer might take business
  85. 85. Outsourcing production Outsourced to ready meals company Did not want to fillet/skin/bone Additional costs for outsourcing filleting etc Outsourcing company wanted to use commercially-available ingredients E.g. dried spices, UHT cream, Kibbled onions etc Balance had to be struck between original product and outsourced Outsourced more realistic in terms of price-points However fresh herbs, cream etc were not allowed in factory Work in progress…
  86. 86. Important when outsourcing…  Pre-meeting  Confidentiality agreement  Bring prototypes/competitor products  Go armed with market data re price-points  Research outsourcing company product portfolio  ID positive and negative attributes  Meeting  Taste your prototype  Discuss ingredients/shelf-life “Remember your brand can  Understand their capabilities/capacity be affected by quality  Discuss packaging requirements issues related to  Especially min runs (product, process, packaging)  outsourcing” Ask for contact point on factory floor re product spec/prototype dev  Agree project plan (Slide 11)  Follow-up  Finalise product spec/ingredients  Check/review regularly
  87. 87. Case Study 5 Large seafood processor wanted to test Thermoforming/skin-packagingEquipment trials & costs analysis/throughput
  88. 88. Skin-pack/Thermoform Equipment – RawPre-pack (Trialled 4 machines) €28k €120k++
  89. 89. Focus group and buyer feedback re skin-pack Increased visual spec Less plastic/packaging More in box/pallet Increased logistics (cheaper transport) Tactile – can see underneath of product Retailer wanted this in fish section Company had to be prepared to do 2 for 1’s three times a year
  90. 90. Client gathered quotes for equipment Multivac R095 Flex R105 Semi rigid (MAP+ skin) R125/145 Cooked meats R175 DARFRESH R275 Darfresh MAP + SKIN DARFRESH 45mm above tray + 50mm deep ULMA TFS 300 TFS 500 TFS 700 Mondini TRAVE 590 E340 Client also visited All MAP and skin-pack other machine demo 100-200k facilities
  91. 91. We carried out trials re materials/usage/costs withfilm manufacturers Topweb TC201 650m long = 2400 trays/roll Cryovac, alert packaging etc Bottom web EGEV supplying materials to Irish 200m long = 740 companies trays/roll
  92. 92. Calculating costs Throughput per hour Dictated by machine size E.g. 420mm carousel E.g. 3 x 127 x 270mm packs (381mm) Rest of film excess/waste Approx cost 11-15c per pack Plus cardboard sleeve 22c/pack Printed top-web – 18-22c per pack Potential savings
  93. 93. Shelf-life analysisDarfresh material versus barrierGas flush = 6 daysVaccum = 6 daysDarfresh = 8 daysSensory/odour/chemcial/microbiological analysisSet up sampling plansLabelling requirementsIn-factory prototype developmentActing in neutral capacity for SME’s
  94. 94. Thermoforming has applicationfor
  95. 95. So when developing new products Identify markets and competitor offerings Identify RTM strategy and buyer requirements Narrow down packaging formats based on competitor offerings/new technologies Link with agencies to define how product is produced (upstream and downstream) Hire/trial equipment on site/incubation unit Preliminary sensory trials before expensive micro trials Ensure micro carried out using commercial conditions (simulate cold-chain) Teagasc/BIM/Bord Bia/EI/Universities etc can give neutral advice re equipment suitability/selection Work on developing innovative culture in your company and don’t be afraid to try new technologies
  96. 96. Thank youJohn Fagan087 9045047
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