Sustainability & Functionality at the Heart of Packaging Innovation


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- In the near future the role of packaging will change, we will see packaging as a resource rather than a resource waster

- Keeping the molecule in play will gain momentum (recyclability)

- Bio-based packaging materials will grow, but not necessarily biodegradable.

- Bright Future for Stand-Up Pouches: Standing for protection, Standing for communication, Standing for convenience, Standing for sustainability

- Increasing health and environmental awareness, rising food prices and food safety concerns and improved purchasing power will drive growth in the smart packaging market.

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Sustainability & Functionality at the Heart of Packaging Innovation

  2. 2. PACKAGING PERCEPTION THE PARADOX OF PACKAGING: SAINT OR SINNER? It has to be said, packaging gets a lot of bad press (People love to hate packaging):   1. Packaging was seen as nothing but waste, a nuisance to be avoided Chemical contamination through packaging materials Is packaging as big an issue as consumers, the media and politicians seem to think? 2. Is packaging really the scourge of our society? 3. 2 Would we be better off without it?
  3. 3. AGENDA 1. Food Packaging: Driving Forces 2. Packaging’s Vital Role 3. Packaging Trends and Innovations: 1. Sustainable packaging 2. Flexible Packaging 3. Smart Packaging 4. Take-Home 3
  6. 6. THE FUNCTIONS OF PACKAGING TECHNICAL & MARKETING Preserve Inform Transport Extend 6 Protect Interact
  7. 7. PACKAGING AND OVER-PACKAGING THE CONFUSION When we think of the environment and packaging, we inevitably think of waste. The problem often arises from over packaging, rather than the packaging itself. This problem is costly for manufacturers and is very annoying for consumers. 7
  8. 8. UNDER-PACKAGING AND OVER-PACKAGING FINDING THE BALANCE IS THE AIM FOR ALL OF OUR BUSINESSES Source: Innventia 8 It is even more important than ever before to find the so-called innovation sweet spot where consumer needs, environmental impact, technical & business capabilities converge
  9. 9. PACKAGING DESIGN: 5 PILLARS Cost Sustainability Functionality Packaging Marketing 9 Convenience
  10. 10. ECO-DESIGN RECONCILING THE ENVIRONMENT WITH PACKAGING An innovative approach that focuses on prevention as a means of minimizing the impact of packaging on the environment throughout its life cycle. It involves Reducing at the source, Reusing and Recycling, and promoting the use of Renewable materials in the designing process. 10
  11. 11. ECO-FRIENDLY PACKAGING DESIGNING BETTER WITH LESS Win-Win-Win for the environment, for manufacturers and suppliers, and for consumers 11
  12. 12. BAG-IN-BOX 12
  13. 13. BAG-IN-BOTTLE 13 13
  14. 14. BOX-IN-BOX 14
  15. 15. BOX-IN-BAG 15
  20. 20. FLEXIBLE PACKAGING: GLOBAL MARKET  The global flexible packaging market (at $71 billion in 2011) will grow by around 5 % a year, reaching $90 billion in 2016.  North America and Central/East Asia will be the top two regional markets with 25% and 24% shares, respectively  One of the key factors contributing to this market growth is the increase in demand for convenience in packaging. Source: PCI Films Consulting 20
  21. 21. STAND-UP POUCHES: FLEXIBILITY, SUSTAINABILITY &CONVENIENCE  Stand-Up Pouches are growing rapidly: Standing for protection, Standing for communication, Standing for convenience, Standing for sustainability   21 US demand for stand-up pouches is forecast to grow by 42% over the next five years to reach almost 24 billion units in 2018 Beverages and pet food are the largest end use categories, closely followed by human food applications with around 30% share.
  22. 22. DOW 100% PE RECYCLABLE STAND UP POUCH 100% Polyethylene Stand Up Pouch is manufactured with only one raw material, PE, making it easier to recycle, and it can be used in a variety of markets including beverages, dry and frozen foods... 22
  23. 23. STAND-UP POUCH IMITATES A CANNING JAR Faux canning jar shape, uses a three-layer laminated structure, formulated to minimize oxygen transfer and maximize product freshness and shelf life 23
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  25. 25. SHRINK SLEEVES : AESTHETIC AND FUNCTIONAL LABELING Shrink sleeves provide many aesthetic and functional labeling and packaging advantages:  High quality, 360 degree head-to-toe graphics on a series of complex packaging shapes and container geometries  maximizes on-shelf impact and appeal and contributes to differentiation in the marketplace.  25 Offer tamper-evident capabilities by protecting lids and tops and add shelf-life to the product through UV protection.
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  30. 30. FOOD WASTE: THE ENVIRONMENTAL SLEEPING GIANT FOOD LOSS occurs mostly at the production stages harvesting, processing and distribution, while FOOD WASTE typically takes place at the retailer and consumer end of the foodsupply chain. In a world of 7 billion people, set to grow to 9 billion by 2050, wasting food makes no sense Economically, Ethically and Environmentally 30 30
  31. 31. SMART PACKAGING ACTIVE & INTELLIGENT : MARKET & FORECAST  Packaging system that is capable of carrying out intelligent functions: 1) Extend: Prolong the shelf life of food products and 2) Interact: Give consumers more product quality information  US Demand for AP and IP is forecast to climb 8% annually to $2.3 billion in 2015  Demand for IP is expected to expand at 20% annually to $370 million in 2015  Demand for AP is projected to increase 6.5% per year to $1.9 billion in 2015  Some of the world's largest markets : US, Japan, UK, Germany and Australia. How Smart Packaging could protect the environment and ensure food security & safety? 31
  33. 33. ACTIVE PACKAGING SHELF-LIFE EXTENSION   AP: Packaging that changes the condition of the packed food to extend the shelf-life or/and to improve safety or sensory properties, while maintaining the quality of the food  33 Microbial contamination and subsequent growth reduces the shelf life of foods and increases the risk of food borne illness All AP technologies involve some physical, chemical, or biological action for altering the interactions between the package, the product, and the package headspace to achieve certain desired outcome
  34. 34. ACTIVE PACKAGING SYSTEMS Some of the more commonly-used types of active packaging include :  Modified atmosphere packaging (MAP) - first developed in the 1970s, MAP substitutes the air inside a package with a correct gas mix for optimum quality and shelf life  Gas Absorbers (sachets/pads/film) - capture residual gases such as O2 and ethylene from inside the package  Gas Generators (sachets/pads/film) - ethanol and CO2 emitters can be used as active features in order to address the weak points in the shelf life of packed goods  Antimicrobial compounds: Spices & essential oils, organic acids, organic & inorganic salts, nano-compounds, enzymes, bacteriocins… 34
  35. 35. ETHYLENE ABSORBER: IT’S FRESH  Small plaster-style strip containing a patented mixture of clay and other minerals that absorb ethylene, the ripening hormone which causes fruit to ripen and then turn mouldy  The strip does not affect the recyclability and do not add extra cost to the consumer If all UK supermarkets used It’s Fresh!, they could avoid wasting over 13 500 000 packs of tomatoes and almost 19 500 000 punnets of strawberries! 35
  36. 36. ETHYLENE ABSORBER: SCA PACKAGING  The fruit crate “fruit fresh”, made of corrugated cardboard, uses the hollow spaces between the corrugations to apply active materials (Kaolin & Zeolithe), in this case an ethylene absorber.  The ethylene absorbing corrugated cardboard crate can help to slow down the ripening process and reduce losses due to more rapid ripening. 36
  37. 37. SELECTIVE PERMEABILITY: SIRANE’S SIRA-FLEX™ AND EVAP FILM  Fully compostable film which has been developed to have the optimum balance between humidity control and gases (O2 and CO2) permeability.  Allowing the moisture and gases that are normally released by ripening produce to escape, preventing the development of mould.     37 Cauliflower & broccoli: 5 days extension 2 days shelf-life for cabbages, leeks and carrots. Green beans shelf life extension of more than 20 days Asparagus shelf life extension by an extra 2 days.
  38. 38. ACTIVE SHEET: FENUGREEN FRESHPAPER  An innovative and active “dryer sheet of paper” made from edible organic extracts (Impregnated with organic spices) that can be placed under the produce where it’s stored.  Inhibit the growth of bacteria, fungi and the like, making the food last longer : keep produce fresh for 2-4 times longer than normal  It’s biodegradable and can be composted or recycled.  As long as the sheet emits a maple-like odor that means it’s active. After about two or three weeks, the smell will fade and the sheet should be replaced. 38
  39. 39. FRESH THINKING STRATEGY: LINPAC PACKAGING  Biomaster Antimicrobial Technology is a silver-based additive that can be introduced into any plastic, paper, textile, paint or coating product.  Treated products have been proven to reduce the growth of Campylobacter on their surface by up to 99.99%.  New range of bakery containers that keep pastry-based products spongier and fresher for longer: reduced the amount of moisture lost and thereby increasing the shelf-life without using additional food preservatives 39
  40. 40. CO2 EMITTERS: ULTRAZAPXTENDAPAK  An active absorbent pad designed to extend freshness of meat, poultry and fish by maintaining the product's sensory features: color, texture and smell.  Includes additives that produce CO2, an inert gas known to have bacteriostatic properties. Moisture from the packaged protein is absorbed by the cellulose pad, which then produces a steady stream of CO2  CO2 gas "wraps" itself around the protein creating an envelope that helps retard the growth of spoilage bacteria present on the surface of the food. 40
  41. 41. SLB™ (SHELF LIFE BOOSTER): HEFESTUS SLB™ - Unlike all other MAP sealers – Hefestus’ modified atmosphere is achieved within one fully automatic vacuum free SLB™ sealing head. SLB™ extends product’s shelf life without need of preservatives or freezing, enabling storage & delivery of goods at room temp or chilled.  Enables manufacturers to pack fresh fish and seafood and keep its freshness, good flavor and high quality for up to 21 days  Doubling poultry product shelf life to 8 days  Double salads shelf life, but also maintain the delicate texture and freshness of vegetables 41
  42. 42. VACUUM SKIN PACKAGING: FRESHCASE®  The hermetic packaging offers a shelf life of more than 30 days for whole muscle beef and extends typical retail display life up to 28 days compared to 3-5 days for tray overwraps-an advancement that offers cost savings from reduced markdowns, spoilage, waste and labor costs for repackaging.  Significantly decreases packaging and logistic costs—as well as material waste (up to 75 per cent less ) and energy usage— compared to MAP (modified atmosphere packaging) packaging. 42
  44. 44. INTELLIGENT PACKAGING TRACK, SENSE & COMMUNICATE  Intelligent packaging (IP): systems that monitor the condition of the packaged food to give information about the quality during transport and distribution  Enhance food safety and biosecurity  The uniqueness of IP is in its ability to communicate: the package is the food’s best companion and is in the best position to communicate the conditions of the food. 1. Track the product 2. Sense the environment inside or outside the package 3. Inform the manufacturer, retailer and consumer 44
  45. 45. INTELLIGENT PACKAGING TIME TEMPERATURE INDICATORS  Temperature variations can lead to changes in product safety and quality. An important indicator for monitoring the quality of packaged food is temperature.  TTIs are used as cost-effective and user-friendly devices to monitor, record, and translate the overall effect of temperature history on food quality in the supply chain  Principle of TTI operation: mechanical, chemical, enzymatic or microbiological irreversible change, usually expressed as a visible response in the form of a mechanical deformation, colour development or colour movement IP demand will be fueled by greater use of TTI labels and tags due to new regulations calling for increased track and trace capabilities with perishable foods 45
  46. 46. INTELLIGENT PACKAGING APPLICATIONS 1. 2. Quality and safety indicators: (TTIs) - microbial growth gas sensing devices - pathogen detection 3. Traceability devices: Radio frequency identification (RFID) chips/tags 4. 46 Tamper evidence: Breach of pack containment Product authenticity: RFID - holographic images, logos
  47. 47. FRESHNESS DETECTOR: THE FRESH LABEL  Made to test the different levels of ammonia that the meat contains.  Different types of meats emit a source of ammonia that can determine the expiration or spoilage.  The sticker changes its color as more ammonia releases the meat.  When the meat is completely expired, the bar-code on the package label would completely disappear and the cashier would not be able to ring up the item 47
  48. 48. CHECKPOINT®: ENZYMATIC TTIS  Warn of any time-temperature conditions which could potentially represent abusive conditions that might lead to growth of pathogens like E. coli within the product  Based on a colour change induced by a drop in pH resulting from the controlled enzymatic hydrolysis of a lipid substrate  Hydrolysis of the substrate causes a drop in pH and a subsequent colour change in the pH indicator from dark green to bright yellow 48
  49. 49. FRESH-CHECK®: FRESHNESS YOU CAN SEE  A self-adhesive device that is specifically formulated to match the shelf life of the food products to which it is affixed  As the active center is exposed to temperature over time it gradually changes color to show the freshness of the food product  Fresh-Check is based on a solid state polymerization reaction, resulting in a highly coloured polymer. 49
  50. 50. 3M MONITORMARK™: TEMPERATURE EXPOSURE  Monitor product temperature exposure through the entire supply chain  Provide a non-reversible record of temperature exposure that is accurate and easy to interpret  Utilize a chemically activated, irreversible dye color change that occurs when the monitored environment reaches a specified threshold temperature (+/-1°C). 50
  51. 51. BIOSENSOR: THE FOOD SENTINEL SYSTEM™  Biosensors are compact analytical devices that detect, record and transmit information pertaining to biological reactions  FSS is a biosensor system capable of continuous detection of pathogens in food packages  A specific-pathogen antibody is attached to a membraneforming part of the barcode.  The presence of contaminating bacteria such as Salmonella sp., E. coli 0157:H7 and L. monocytogenes will cause the formation of a localized dark bar, rendering the barcode unreadable upon scanning 51
  52. 52. PAKSENSE: TEMPERATURE MONOTORING LABEL  Monitor time and temperature of perishable products during distribution and storage.  Visual indicators will flash if temperature excursions occur and all time and temperature data can be downloaded at the receiving point. 52
  53. 53. RFID: TRACK AND TRACE • RFID (Radio frequency identification) uses tags affixed to assets (food product, containers, pallets, etc.) to transmit accurate, real-time information to a user’s information system. • RFID benefits to the food industry: traceability, inventory management, labour saving costs, security and promotion of quality and safety  RFID tag may also be integrated with a TTI or a biosensor to carry time-temperature history and microbiological data  RFID tags can be printed on packaging like bar codes. Nanotech could eliminate the need for silicon chips entirely with ink-based RFID circuits 53
  54. 54. ACTIVE RFID: FIX TEMPERATURE TROUBLES  Up to 50% of food products are wasted in the food supply chain.  Strawberries and other ‘soft fruits’ that are highly sensitive to temperature conditions experience the greatest amount of loss, hence the need for a real-time temperature monitoring system (The optimum T for strawberries is between 37-39 deg F)  Bionest, the largest Spanish organic strawberry producer, deployed active RFID tag that supplies information on the remaining shelf-life of strawberries  Lead to significant reductions in strawberries loss 54
  55. 55. RFID TAG: MEAT AUTHENTICITY AND TRACEABILITY  Track the entire production process, from the time pigs arrive at the slaughterhouse until the prosciutto is sent to warehouses and retail stores  Verify ham's authenticity “ We want to protect the consumer so that each person knows the story of each ham through RFID, including when the pig was born and details about its life and death” 55
  57. 57. PACKAGING A PART OF THE SOLUTION 1) 2) The environmental impact of over-packaging is widely debated, and rightly condemned 3) It’s very visible but little understood by consumers: Packaging comprises approx. 5% of the environmental impact 4) Packaging serves to protect more resources than it consumes, thus bringing economic, environmental and social benefits. 5) 57 Packaging only exists because products exist: Packaging protects what it sells and sells what it protects Modern Society couldn’t function without it!!
  58. 58. PACKAGING FUTURE…  In the near future the role of packaging will change, we will see packaging as a resource rather than a resource waster  Keeping the molecule in play will gain momentum (recyclability)  Bio-based packaging materials will grow, but not necessarily biodegradable.  Bright Future for Stand-Up Pouches: Standing for protection, Standing for communication, Standing for convenience, Standing for sustainability  Increasing health and environmental awareness, rising food prices and food safety concerns and improved purchasing power will drive growth in the smart packaging market. 58
  59. 59. THANK YOU !!! Islem Yezza 59