SUSTAINABILITY & FUNCTIONALITY AT THE HEART OF

PACKAGING INNOVATION

Islem Yezza

Palais des Académies, Bruxelles

It has to be said, packaging gets a lot of bad press (People love to hate packaging):

Packaging was seen as nothing but waste, a nuisance to be avoided

Chemical contamination through packaging materials

PACKAGING PERCEPTION THE PARADOX OF PACKAGING: SAINT OR SINNER?

1. 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. Would we be better off without it?

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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

AGENDA

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FOOD PACKAGING DRIVING FORCES

SUSTAINABLE PACKAGING

CONCEPTS, TRENDS & INNOVATIONS

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THE FUNCTIONS OF PACKAGING TECHNICAL & MARKETING

Preserve Protect

Inform Transport

Extend Interact

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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.

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Source: Innventia

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

FINDING THE BALANCE IS THE AIM FOR ALL OF OUR BUSINESSES

UNDER-PACKAGING AND OVER-PACKAGING

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Packaging

Cost

Sustainability

Convenience Marketing

Functionality

PACKAGING DESIGN: 5 PILLARS

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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.

ECO-DESIGN RECONCILING THE ENVIRONMENT WITH PACKAGING

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ECO-FRIENDLY PACKAGING DESIGNING BETTER WITH LESS

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Win-Win-Win for the environment, for manufacturers and suppliers, and for consumers

BAG-IN-BOX

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BAG-IN-BOTTLE

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BOX-IN-BOX

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BOX-IN-BAG

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AN INNOVATIVE FRUIT BASKET

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CONVENIENCE SALAD BOWL

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SUGARCANE-BASED PET BOTTLE

FLEXIBLE PACKAGING

CONCEPTS, TRENDS & INNOVATIONS

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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.

FLEXIBLE PACKAGING: GLOBAL MARKET

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Source: PCI Films Consulting

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.

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STAND-UP POUCHES: FLEXIBILITY, SUSTAINABILITY &CONVENIENCE

Stand-Up Pouches are growing rapidly: Standing for

protection, Standing for communication, Standing for

convenience, Standing for sustainability

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

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

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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.

Offer tamper-evident capabilities by protecting lids and tops and

add shelf-life to the product through UV protection.

SHRINK SLEEVES : AESTHETIC AND FUNCTIONAL LABELING

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Shrink sleeves provide many aesthetic and functional labeling and packaging advantages:

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SMART PACKAGING

CONCEPTS, TRENDS & INNOVATIONS

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FOOD SAFETY: FOODBORNE, OUTBREAK & RECALL

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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 food-

supply 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

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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

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How Smart Packaging could protect the environment and ensure food security & safety?

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.

ACTIVE PACKAGING

CONCEPTS & INNOVATIONS

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ACTIVE PACKAGING SHELF-LIFE EXTENSION

Microbial contamination and subsequent growth reduces the shelf life

of foods and increases the risk of food borne illness

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

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

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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…

ACTIVE PACKAGING SYSTEMS

Some of the more commonly-used types of active packaging include :

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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!

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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.

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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.

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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.

SELECTIVE PERMEABILITY: SIRANE’S SIRA-FLEX™ AND EVAP FILM

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.

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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%.

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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

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.

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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

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.

SLB™ (SHELF LIFE BOOSTER): HEFESTUS

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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.

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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.

INTELLIGENT PACKAGING

CONCEPTS & INNOVATIONS

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INTELLIGENT PACKAGING TRACK, SENSE & COMMUNICATE

1. Track the product

2. Sense the environment inside or outside the package

3. Inform the manufacturer, retailer and consumer

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.

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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

INTELLIGENT PACKAGING TIME TEMPERATURE INDICATORS

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

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INTELLIGENT PACKAGING APPLICATIONS

1. Tamper evidence: Breach of pack containment

2. Quality and safety indicators: (TTIs) - microbial growth -

gas sensing devices - pathogen detection

3. Traceability devices: Radio frequency identification (RFID)

chips/tags

4. Product authenticity: RFID - holographic images, logos

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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.

FRESHNESS DETECTOR: THE FRESH LABEL

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

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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

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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.

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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).

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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 membrane-

forming 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

BIOSENSOR: THE FOOD SENTINEL SYSTEM™

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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.

PAKSENSE: TEMPERATURE MONOTORING LABEL

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• 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: TRACK AND TRACE

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

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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

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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

RFID TAG: MEAT AUTHENTICITY AND TRACEABILITY

“ 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”

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WRAP-UP . . .

SMART, FLEXIBLE & ECO-FRIENDLY

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1) Packaging only exists because products exist: Packaging protects what

it sells and sells what it protects

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) Modern Society couldn’t function without it!!

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PACKAGING A PART OF THE SOLUTION

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.

PACKAGING FUTURE…

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Islem Yezza

islemyezza@gmail.com

THANK YOU !!!

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