Please enable JavaScript.
Coggle requires JavaScript to display documents.
Week 11: Current Food Packaging Trend III - Coggle Diagram
Week 11: Current Food Packaging Trend III
With Cryovac
6 Functions of Packaging, related to the 4 Functions discussed before Week 11
Shares information of product
Hold the content
Protect
Move from one point to another in the container
Preserve, especially perishable products
Display in retail markets
Issue: food Waste
Food wastage due to unsuitable packaging used
Landfill has about 21% of food waste (largest). Includes half-eaten, expired, spoiled food...
Flexible plastic, used in food industry, is only 3%
The management of food wastage releases methane that is 25% more harmful than carbon dioxide as a greenhouse gas.
4 % of carbon print to produce a product is by packaging
Packing options and Their Effects on Shelf Life
CRYOVAC® SIMPLE STEPS® (suitable for ready meals, used as packaging and can be chilled or pasteurised) Smaller proportion of Nylon than Oven Ease
Properties
Specific skin top webs
Vertical display: Prevent product from falling
Exceptional appearance
Easy-opening
No need to cut or rupture the lidding material
Ready to cook, heat or pasteurise in the pack
Steam-assisted cooking with even heat distribution
Lid expands to capture steam, retaining moisture and heat
Suitable for post pack cooking and treatments including sous vide pasteurising and High Pressure processing (HPP)
Heat treatable and microwaveable materials.
Microwaveable,
self venting
to prevent overcooking without perforation
Variety of premade tray sizes and shapes to fit the application
Semi-rigid and rigid PP bottom webs
Total pack integrity
Vacuum sealed
: To preserves freshness and sensory quality
Can be directly eaten from the tray
NO Headspace t
hat allows water to migrate out of food, forming ice-crystals under low temperature. When moisture is lost, flavour is lost too
Suitable for freezing
Extended chilled shelf life
Chilled and frozen ready meals, marinated proteins (meat, poultry and fish). Added-value fish and meat, snacks and tapas, side-dishes.
No irritating microwave structure
CRYOVAC OVEN EASE
BENEFITS FOR PROCESSORS
Enables
seasonal and/or regional offerings
, Kosher foods, and special occasion meals (eg Ribs whch consumers usually cook them in
summer grilling
)
Offer value-cuts of meat
such as chuck roast (tough) that consumers are not comfort cooking
Reduces shrink for cuts of meat today's consumers are unsure of how to cook
Provides the opportunity to
offer value-added product
s such as seasoned meats without capital cost
Uses existing equipment
Materials are heat-sealable
Little/No equipment modification
Open new markets
(including the ability to target store brands) with minimal captial costs
Benefits for consumers & food preparers
Increase cooking yield
with moisture retained in packaging
Juicier
and
more consistent
product
Delivers tender, consistent results no matter who is cooking
Eliminates pre-cook preparation
- just place the product in the oven and cook while doing other things
Meets consumers' needs for
hassle-free meal
prep and the convenience of unattended cooking.
Consumers do not need to clean the tray used to hold the product. Just need to dispose the film after heating in oven
Consumers need to pierce some holes onto the film and put the product in oven
Increase product offerings
when the product can remain hot and moist for hours after being removed from oven. Packaging traps heat and moisture.
Improved food safety
when the packaging is not in contact with food and food stays in packaging during handling and cooking (No cross contamination)
Properties
Endure dry heat at high temperature and long duration
Flexible plastic film
: Mainly 'special' nylon with other plastics. Generally, plastics such as PP and most commercial nylon melts and do not expand above 200 Cel at dry heat.
Vacuum Packaging
CRYOVAC® DARFRESH® (Thicker film for more presentable product)
Properties
Assist with meal planning for consumer
Inhibit oxygen from entering
Easy-open features available
Can be semi-rigid and flexible
Longer shelf life (21+ days)
Product stay fresher longer with oxygen removed.
Oxygen binds with hemoglobin to form oxyhemoglobin, the bright red pigment.
Takes at least 20 minutes for the colour to formed on meat stored in vacuum skin packaging
Prevent oxidation of fats
Inhibit growth of aerobic microbes
For Optimal aging and better eating experience
Product differentiation
with better presentation than competitive products
3D presentation with 2nd skin of product to present product better
Freezer-ready
package, no issues such as freeze burn
Leak resistant
with the seal all the way besides the product, ensuring food safety
Very reliable seal integrity
Decrease drip loss or purge
with pressure from the film
Reduce product crushing and improve shape
Vertical display capability
, reduced packaging allows better utilization of case space (purge is contained)
Comparing to Polyethylene film with 14 days of shelf life
Cryovac BDF with Modified Atmosphere
SES Film
No leaks
Lid film
Vacuum skin packaging: A process that utilizes two films to form a vacuum package with second skin appearance.
Packaging options
(in meat) SCS
Glass and metal are unsuitable for HPP due to rigidity
With Tetra Pak
Materials used in Example: Carton
Structure
Aluminium: Protects against oxygen and light to maintain the nutritional value and flavours of the food in the package in ambient temperatures. Allows Induction sealing
2 layers as Food contact surfaces: Protects package from product inside
Outermost layer: PE as Moisture barrier
Paperboard: Strength & rigidity
2nd in aseptic packaging: LDPE with low melting point Glues paper to the foil to enhance protection.
Process
Printing design on paper board
5 various printing methods with printing ink
Flexo process enhanced
Tetra Pak Sharp
Offset palette
Flexo line
Tetra Pak Select
Create crease lines to fold packaging
Lamination
Slitting huge rolls into desired smaller sizes for filling machines
Goes to customers
Possible Changes in next 10 years
Now 2020
Emerging online grocery shopping
Litter & Waste
Industry 4.0
10 years later 2030
Food waste & scarcity
Demand for food increases as population is prohected to increase further.
Hyper customized consumption & products
Autonomous drone deliveries
without human interaction
Technology as an enabler of food formulation
Real time data driven decisions
Climate change
Product example: Tetra Recart (retortable cartons, mimicking tin cans)
Overcome problems regarding use of tin cans
User-friendly:
needs no tools but your hands. Laser perforated tear opening and simple re-closure make the package very easy to handle. Even little hands can open the package without risk of being hurt.
Environment-friendly
: mainly made of renewable materials i.e. wood fibers from Forest Stewardship Council™ (FSC™) certified forests and other controlled sources. FSC™ is a global not-for-profit organization dedicated to the promotion of responsible forest management worldwide. FSC™ is supported by major non-governmental organizations like WWF and The Nature Conservancy.
Can be converted into products such as paper when recycled
Extremely efficient to transport.
You can fit 6 to 10 times more empty Tetra Recart cartons on a single truck compared to cans
Very
lightweight
with ̴ 60% less weight than a can
. This helps you save 10-20% in outbound distribution compared to cans. (Occupies less space on shelf, hence can
stock more on shelf
) Moreover, it
cut costs on transportation
and l
owers your carbon emissions.*
Can
handle both liquids and solid food
(Eg Beans, sauce)
Distribution
Ambient
Chilled (less than 7 Cel)
Focuses on 3 components
Filing machines
3 functions done aseptically
Seal the pack
Form the pack
Fill the pack
Downstream equipment
Packs in any amounts are put into secondary packaging that carries the packs
Packaging & Additional materials (Eg bottle caps)
3 Key Changes
E-commerce
Visual
Community discussion & opinions
Stimulate impulse shopping/ Attract customers' attention
Picture quality & 3D vision
Good picture quality, bright colours
Offer different attractive angles of product
Contains basic information
Physical
Strong
Light
Easy to transport
Avoid leakages during collection & transportation
Sustainability
Consumers are becoming more aware of the environment and are willing to help it while consuming
2 ways Tetra Pak secure environmentally preferred port filo
Sustainable openings
2011 Biobased caps
Non-detachable alternatives: Attached to the packaging, you cannot remove it. Europe will ban singe-use plastics in the future. This plastic is reusable.
2019 paper straws
Tethered caps
2019 Bio-based paper straws
Biodegradable straws
Renewable Packaging
Develop Bio-based further & deploy it
Fully renewable Aseptic packaging
Connected Packages
At each stage (eg sourcing, manufacturing, consumer), data is collected digitally & processed
Qr code holds unique digital identity
2 uses
Consumer Engagement
Treasure Hunt
Consumer Transparency: Builds trust & verify the authenticity of product
Scan & Win/ Loyalty
Track & Trace
Channel management
Claims management
Supply chain optimization: Use data from connected supply chain to understand demand vs supply challenges better
Recall management: Identify packages and recall those affected.
Batch code/Production code for traceability
Modified Atmosphere Packaging: Atmosphere is changed to provide optimum environment to extend shelf life and maintain food quality
2 types
Passive: Effect of food's respiration or microbial respiration in food
Active: Air displacement with controlled desired gas mixture
Affected by permeability of film used in packaging which can be affected by the environment such as storage temperature
Used in chill temperatures. The preservative effect from chilling can be improved when combined with MAP
Many deteriorative reactions such as aerobic respiration of microbes uses oxygen and releases carbon dioxide and water
Increasing carbon dioxide inhibits aerobic microbial growth
Reducing oxygen inhibits aerobic respiration
Gas mixtures used depends on the food nature and the possible spoilage mechanisms
Microbial spoilage -> High carbon dioxide
In some food, May cause package collapse with high CO2 concentration
Use 30-60% CO2 and 40-70% N2
Oxidative rancidity in products prone to oxidation --> 100% N2 or N2 and CO2
Respiring products --> NO excess CO2 or lack of O2
Aim to inhibit anaerobic respiration
Characteristics to be considered
Heat sealability
Transparency
Mechanical properties
Package permeability to gases and water vapour
In products without respiration, packaging must be
Low permeability to gases
Laminates and coextruded films
EVOH
PAs
PVdC copolymer
Has
good heat seal
and
low water vapour permeability
LDPE
In products with respiration such as fruits and vegetables
Low oxygen level in headspace
NO high carbon dioxide concentration
Unsuitable polymers: EVOH, PVdC, PAs and LDPE
