Packaging

1. 1. Introduction to Food Packaging
Foodpackagingis packagingforfood.A package providesprotection, tampering resistance, and special
physical,chemical, or biological needs. It may bear a nutrition facts label and other information about
food being offered for sale.
Food packaging development started with humankindís earliest beginnings. Early forms of packaging
ranged from gourds to sea shells to animal skin. Later came pottery, cloth and wooden containers.
These packages were created to facilitate transportation and trade.
Utilizing modern technology, todayís society has created an overwhelming number of new packages
containingamultitude of foodproducts.A modern food package has many functions, its main purpose
being to physically protect the product during transport. The package also acts as a barrier against
potential spoilage agents, which vary with the food product. For example, milk is sensitive to light;
therefore, a package that provides a light barrier is necessary. The milk carton is ideal for that. Other
foods like potato chips are sensitive to air because the oxygen in the air causes rancidity. The bags
containing potato chips are made of materials with oxygen-barrier properties. Practically all foods
should be protected from filth, microorganisms, moisture and objectionable odors. We rely on the
package to offer that protection.
Aside from protecting the food, the package serves as a vehicle through which the manufacturer can
communicate withthe consumer.Nutritionalinformation ingredients and often recipes are found on a
food label. The package is also utilized as a marketing tool designed to attract your attention at the
store. This makes printability an important property of a package.
The food industry utilizes four basic packaging materials: metal, plant matter (paper and wood), glass
and plastic.A number of basic packaging materials are often combined to give a suitable package. The
fruitdrinkbox isan example where plastic,paperandmetal are combinedina laminate to give an ideal
package. This concept can be easily seen in your peanut butter jar. The main package containing the
food(primarypackage) ismade of glass (or plastic), the lid is made of metal lined with plastic, and the
label is made of paper.
Each basic packaging material has advantages and disadvantages. Metal is strong and a good overall
barrier, but heavy and prone to corrosion. Paper is economical and has good printing properties;
however, it is not strong and it absorbs water. Glass is transparent, which allows the consumer to see
the product, but breakable. Plastics are versatile but often expensive. Therefore, combining the basic
materialsworkswell inmostcases.So,fora product like milk,whichisanessential foodforchildrenand
youngadultsand therefore cannotbe veryexpensive, paper makes a good economical material. It also
provides a good printing surface. However, since paper absorbs water, it will gain moisture from the
milk,getweakerandfail,therebyexposingthe milktospoilage factors.Itmayevenbreakandwaste the
product.Whena thinlayerof a plasticcalledpolyethyleneisutilizedtoline the insideof the milkcarton,
it serves as a barrier to moisture and makes an economical, functional package.
After making a food product and placing it in the appropriate package, a number of these individual
packages must be placed in a large container to facilitate shipment. These larger containers are called
secondary packages. The paperboard box is a very common secondary package. Plastics also can serve
as secondary packages. The milk case in which a number of milk cartons are delivered to the
supermarket is a good example.
We cannot discuss food packaging without discussing the effects of packaging waste on the
environment. Clearly, recycling is a sound approach. However, the problem often lies in feasibility of
collection,separationandpurificationof the consumerísdisposedfoodpackages.Thismode of recycling
iscalledpost-consumerrecycling.While it offers a logistic challenge, recycling is gaining in popularity,
and the packagingindustryiscooperatinginthateffort.Aluminumcansare the most recycled container
at this time. Plastic recycling is increasing, yet most plastic is recycled during manufacturing of the

2. containers; not as post-consumer recycling. For example, trimmings from plastic bottles are reground
and reprocessed into new ones.
The plastics industry is helping to facilitate consumer recycling by identifying the type of plastic from
whichthe containerismade.A numberfrom1 to 7 isplacedwithinthe recyclinglogoonthe containerís
bottom.For example,1refersto PET (Polyethylene Terephthalate), the plastic used for the large 2 liter
softdrinkbottles.Plasticshave the advantage of beinglight.Thishelpsto conserve fuel duringtransport
and also reduces the amount of package waste.
There are many interesting packaging concepts being explored by the industry to keep up with the
changinglife style of the consumerandnew technologies.Manyprofessionalsare involved in designing
and manufacturing the modern package. Today's package is designed with the consumer's safety and
convenienceinmind.Examplesare microwaveable popcorn packages, squeezable ketchup bottles and
the tamper-proof milk bottle cap.
Packaging and package labeling have several objectives.
1. Physical protection - The food enclosed in the package may require protection from, among other
things, shock, vibration, compression, temperature, bacteria, etc.
2. Barrierprotection - A barrierfromoxygen, watervapor,dust,etc.,isoftenrequired.Permeation is a
critical factor indesign.Some packagescontaindesiccantsoroxygenabsorberstohelp extend shelf
life.Modifiedatmospheresorcontrolledatmospheres are also maintained in some food packages.
Keeping the contents clean, fresh, and safe for the intended shelf life is a primary function.
3. Containmentoragglomeration - Small itemsare typicallygroupedtogether in one package to allow
efficient handling. Liquids, powders, and granular materials need containment.
4. Information transmission - Packages and labels communicate how to use, transport, recycle, or
dispose of the package or product. Some types of information are required by governments.
5. Marketing - The packaging and labels can be used by marketers to encourage potential buyers to
purchase the product.Package designhasbeenanimportantand constantlyevolving phenomenon
for several decades.Marketingcommunicationsandgraphicdesignare appliedtothe surface of the
package and (in many cases) the point of sale display.
6. Security - Packagingcan playan importantrole in reducing the security risks of shipment. Packages
can be made withimprovedtamperresistance todetertamperingandalsocan have tamper-evident
featurestohelpindicate tampering.Packagescanbe engineeredtohelpreduce the risksof package
pilferage; some package constructions are more resistant to pilferage and some have pilfer-
indicating seals. Packages may include authentication seals to help indicate that the package and
contents are not counterfeit. Packages also can include anti-theft devices, such as dye packs, RFID
tags, or electronic article surveillance tags, that can be activated or detected by devices at exit
points and require specialized tools to deactivate. Using packaging in this way is a means of retail
loss prevention.
7. Convenience - Packagescanhave featureswhichaddconvenience indistribution,handling,stacking,
display, sale, opening, reclosing, use, and reuse.
8. Portion control - Single-serving packaging has a precise amount of contents to control usage. Bulk
commodities(suchassalt) canbe divided into packages that are a more suitable size for individual
households.Italsoaidsthe control of inventory:sellingsealedone-liter bottles of milk, rather than
having people bring their own bottles to fill themselves.
1.1. Definition of Food Packaging
Food packaging is the process of wrapping food with a suitable package. The package may be made of
one or more materialsthatprovide properfunctionalities andproperties for holding and protecting the

3. food from the point of production to the consumer, while the quality and safety of the food are
maintained. Holding and protecting the food are two major functions for packaging of food.
Food is generally sensitive and susceptible to environmental abuse, and deteriorates by chemical,
biochemical,and/ormicrobiological changesthatare usuallyacceleratedby environmental factors such
as oxygen,water,light, and temperature. With a suitable package, these changes can be prevented or
delayed.A suitablepackage canalsoprevent contaminationbyfoodborne pathogens, which render the
foodhazardousand unwholesomeforconsumption.Food packagingprovideswholesome, high-quality,
and nutritious food products.
1.2. Importance of Food Packaging
Foodpackagingis the mostreliable method of food containment. This is the best way to safely control
and protectthe foodagainstphysical,chemical,biological andenvironmental factors. Food packaging is
vital for safe delivery of hygenic food in market.
1. Protection against damage or contamination by micro-organisms, air, moisture and toxins –
Products must be safeguarded against rough transport and possible tampering as well as ensuring
they meet any physical, chemical or biological needs.
2. Prevention of product spilling or leaking – Packages must be tightly sealed and made resilient to
ensure the product remains uncompromising at all stages of distribution until opened by the
consumer.
3. ProductIdentificationandLabeling –Nutrition,ingredientsandsell-bydates are important not only
to the consumer, but to grocery stores as well. Bar codes help stores to track inventory and sales.
4. Marketing of Product to Consumers – The integrity of the product is extremely important, but
marketingisequallyessential.Inadditiontocontainingandprotectingthe item,the packaging must
speakto a buyerand ultimatelyleadtoa sale. Containers that achieve the ‘wow’ factor can set any
product apart from its competitors.
Because packaging plays such an important role in the preservation and marketability of a product,
many companies seek a contract packaging service to help them obtain the best quality packaging
available. Benefits to a co-manufacturer include cost, speed, quality and innovation.
• Cost: Capital costs of equipment and facilities can be enormous. Through the utilization of a
contract packagingservice,startupcostsare significantly reduced while energy and labor costs
are kept low.
• Speed:Co-packingservicescansignificantlyreduce leadtime ingetting a product to market and
can ensure enough time is allowed for quality assurance and validation. State-of-the-art
equipment like continuous motion machinery produces consistent and high speed assembly,
enacting multiple processes simultaneously without interruption.
• Quality and Innovation: Today’s market presents countless options in packaging and labeling
needs. Co-manufacturers guarantee meeting all food specifications and requirements. More
value is added by assisting in product development. Suggestions can be made in regards to
alternative ingredients, raw materials, processes and packaging. As product lines continue to
broaden, many manufacturers are faced with the constant need to evolve their products.
Relyingoncontract packagers allowsthemtoremainflexible andrespondquicker to changes in
the market.
1.3. Scope of Food Packaging
Packagingtechnologyisdynamicasa resultof the new challenges and new technologies developed to
accommodate newneedsinthe changingsociety.Discoveryof new packagingmaterials,new processes,

4. and new techniques have shaped the way we package, deliver, and consume products. The
thermoplastics developed in the 1950s have revolutionized the packaging industry. Although many
foodsare still packagedintraditional glassbottlesandtin cans,newerplastic,multilayer,andcomposite
packagingmaterialsare creatingopportunitiesforimprovedproduct convenience,presentation,quality,
and safety, as well as innovative food product development.
An ideal food package is designed to meet many requirements of the food itself, the processing or
preservation methods, distributor and retailer needs, and consumer expectations and acceptance.
Modern packaging is driven toward more intensive marketing and globalization. Packaging plays a
significantrole inmotivatingpurchase.Among competing products that are similar in performance and
quality,theirpackagesare different. Package design is then critical in competition, and a new package
often helps create uniqueness for its brand.
An increase in market globalization requires a product with an extended shelf life. Better barrier
packaging materials and techniques are needed to achieve a desirable shelf life for export. There are
twofactors influencing the development of food packaging with increased barrier properties. First are
the regulatoryinitiativesthatare intendedto limitwaste generation.Source reductionviadowngauging
of flexible packagingisone wayof reducingplastics’content insolid waste.Secondisthe improvedfood
preservation that barrier flexible packaging can offer in preventing food losses and spoilage during
storage.
Food packaging market is by far the largest application segment of the packaging industry, accounting
for more than one-thirdof the global packaging market. From a global perspective, the food packaging
market is at a very interesting situation, where the market has almost reached a plateau in terms of
technologyinthe more developednationsinNorth America and Europe, while the emerging countries
of Asia Pacific region are playing catch up to the packaging technologies and food supply chain
management. Different types of food products require varied packaging types according to their
individual usage and perishability.

5. 2. Packaging Materials
Packagingfor foodstuffs comes in many different forms, based on technical requirements throughout
the supply chain, as well as marketing needs (like brand identity or consumer information) and other
criteria. The layer that is in direct contact with the food or beverage is called “food contact material”.
For some types of food packaging the food contact material determines the name: a plastic bottle is
made of plastic and has this material type in direct contact with the foodstuff. For glass jars the
materials in contact with the foodstuff are glass and coated metal from the closure. In the case of
beverage cartonsthe directfoodcontact layerisnotcarton, but laminatedplastic.Foraluminium cans a
coatingis indirectcontact withthe beverage.Some typesof papercanalsobe coated(for example with
a grease-proof coating).
The term food contact material applies to food (and beverage) packaging, but also to any other
materialsthatcome intocontact withfood,eitherduringstorage,processingandfilling,orconsumption
(like cooking utensils).
2.1. Roles of Food Packaging
The principal rolesof foodpackagingare to protectfoodproductsfrom outside influences and damage,
to containthe food,and to provide consumerswithingredientandnutritionalinformation (Coles 2003).
Traceability,convenience,andtamperindicationare secondaryfunctionsof increasing importance. The
goal of foodpackagingisto containfoodina cost-effectivewaythatsatisfiesindustryrequirements and
consumer desires, maintains food safety, and minimizes environmental impact.
Protection/preservation
Food packaging can retard product deterioration, retain the beneficial effects of processing, extend
shelf-life, and maintain or increase the quality and safety of food. In doing so, packaging provides
protection from 3 major classes of external influences: chemical, biological, and physical.
Chemical protection minimizes compositional changes triggered by environmental influences such as
exposure to gases (typically oxygen), moisture (gain or loss), or light (visible, infrared, or ultraviolet).
Many different packaging materials can provide a chemical barrier. Glass and metals provide a nearly
absolute barriertochemical andotherenvironmental agents, butfew packagesare purelyglassormetal
since closure devices are added to facilitate both filling and emptying. Closure devices may contain
materialsthatallowminimal levelsof permeability.Forexample,plasticcapshave some permeability to
gases and vapors, as do the gasket materials used in caps to facilitate closure and in metal can lids to
allow sealing after filling. Plastic packaging offers a large range of barrier properties but is generally
more permeable than glass or metal.
Biological protection provides a barrier to microorganisms (pathogens and spoiling agents), insects,
rodents, and other animals, thereby preventing disease and spoilage. In addition, biological barriers
maintainconditionstocontrol senescence (ripeningandaging). Such barriers function via a multiplicity
of mechanisms, including preventing access to the product, preventing odor transmission, and
maintaining the internal environment of the package.
Physical protectionshieldsfoodfrommechanical damage andincludescushioningagainstthe shock and
vibration encountered during distribution. Typically developed from paperboard and corrugated
materials,physical barriers resist impacts, abrasions, and crushing damage, so they are widely used as
shipping containers and as packaging for delicate foods such as eggs and fresh fruits. Appropriate
physical packagingalsoprotectsconsumersfromvarioushazards. For example, child-resistant closures

6. hinder access to potentially dangerous products. In addition, the substitution of plastic packaging for
products ranging from shampoo to soda bottles has reduced the danger from broken glass containers.
Containment and food waste reduction
Anyassessmentof foodpackaging'simpacton the environment must consider the positive benefits of
reducedfoodwaste throughout the supply chain. Significant food wastage has been reported in many
countries, ranging from 25% for food grain to 50% for fruits and vegetables. Inadequate
preservation/protection,storage,andtransportationhave beencitedascausesof foodwaste.Packaging
reduces total waste by extending the shelf-life of foods, thereby prolonging their usability.
Marketing and information
A package isthe face of a productand oftenisthe onlyproductexposure consumersexperience prior to
purchase. Consequently, distinctive or innovative packaging can boost sales in a competitive
environment.The package may be designed to enhance the product image and/or to differentiate the
product from the competition. For example, larger labels may be used to accommodate recipes.
Packaging also provides information to the consumer. For example, package labeling satisfies legal
requirements for product identification, nutritional value, ingredient declaration, net weight, and
manufacturerinformation.Additionally,the package conveys important information about the product
such as cooking instructions, brand identification, and pricing. All of these enhancements may impact
waste disposal.
Traceability
The Codex Alimentarius Commission defines traceability as "the ability to follow the movement of a
foodthroughspecifiedstage(s)of production,processinganddistribution".Traceabilityhas3 objectives:
to improve supply management, to facilitate trace-back for food safety and quality purposes, and to
differentiate and market foods with subtle or undetectable quality attributes. Food manufacturing
companiesincorporate unique codesontothe package labelsof theirproducts;thisallowsthemtotrack
theirproductsthroughoutthe distributionprocess.Codesare availableinvariousformats (for example,
printedbarcodesorelectronicradiofrequencyidentification[RFID]) andcanbe readmanuallyand/orby
machine.
Convenience
Convenience featuressuchasease of access,handling,anddisposal;productvisibility;resealability; and
microwavabilitygreatlyinfluence package innovation. As a consequence, packaging plays a vital role in
minimizing the effort necessary to prepare and serve foods. Oven-safe trays, boil-in bags, and
microwavable packaging enable consumers to cook an entire meal with virtually no preparation. New
closure designs supply ease of opening, resealability, and special dispensing features. For example, a
cookie manufacturerrecentlyintroducedaflexiblebagwithascored section thatprovides access to the
cookies. A membrane with a peelable seal covers the opening before sale and allows reclosure after
opening. Advances in food packaging have facilitated the development of modern retail formats that
offerconsumersthe convenienceof 1-stopshoppingandthe availabilityof foodfromaround the world.
These convenience featuresaddvalue and competitive advantages to products but may also influence
the amount and type of packaging waste requiring disposal.

7. Tamper indication
Willful tampering with food and pharmaceutical products has resulted in special packaging features
designed to reduce or eliminate the risk of tampering and adulteration. Although any package can be
breeched,tamper-evidentfeaturescannoteasilybe replaced.Tamper-evidentfeaturesinclude banding,
special membranes,breakawayclosures,andspecialprintingon bottle liners or composite cans such as
graphics or text that irreversibly change upon opening. Special printing also includes holograms that
cannot be easilyduplicated.Tamper-evidentpackagingusuallyrequires additional packaging materials,
whichexacerbatesdisposal issues,butthe benefits generally outweigh any drawback. An example of a
tamper-evident feature that requires no additional packaging materials is a heat seal used on medical
packaging that is chemically formulated to change color when opened.
Other functions
Packaging may serve other functions, such as a carrier for premiums (for example, inclusion of a gift,
additional product,orcoupon) or containers for household use. The potential for packaging use/reuse
eliminates or delays entry to the waste stream.