Expanding Exports withFood Processing
Technology & Packaging Systems
Thomas DunnFlexpacknology LLC
July, 2012Central Philippine
University
Food Technology: Gearing Up for Exports
What is Success?
• WHAT: Increased exports• WHY: Increased national capital↑ Jobs↑ Wealth↑ Economic demand
• How long: Long term SustainabilityEconomicSocialEnvironmental
HOW: Food Technology!
What is that?
First: Food Science is
The study of foods’ Makeup Chemical Physical Biological/
Microbial
Decline Chemical Physical Biological/
Microbial
Processing Chemical Physical Biological/
Microbial
Food technology is the application of the following to Food Science
For the Safe Use of Food!Se
lecti
on
Pres
erva
tion
Proc
essi
ng
Pack
agin
g
Dis
trib
ution
Source: Institute of Food technologists
Beginning—Middle—End
END: Distribution
MIDDLE: PreservationProcessingPackaging
BEGINNING: Selection
Gearing up for Exports
Begin with the End in MindCovey’s Successful Habit
#2…
Literally:The distribution
system• Product Destination • Product Quality @ Destination• Product Safety @ Destination • Product Demand @
Destination • Product Itinerary to
Destination
Gives Specification to:
PreservationProcessingPackaging
Gives direction for:
Selection
Distribution: Destination
From Distribution comes Direction For Selection
US, Western Europe, Japan
• The demand for Consumer packaged goods (CPGs) is well established.
• Cultural pressures influence priorities– Convenience– Healthy Life Style– Perpetual snacking– Mix up Global cuisine
Ready for imports
Western Pacific• The growth of Middle
Class drives demand for CPGs.
• Area is the source of “exotic fare”.
Opportunity: Global exports Internal/Regional
growth Economic dynamics*Slow
growthFast
growth
* Economic opportunity:Developing Countries#
Top52% with >$8/day
Middle39% with $2-8/day
Bottom9% with <$2/day
2.7 billion people in developing countries:
• Concerned about safe & healthy food (children)
• Live in remote areas,
• Shop traditional stores
• Buy for one day
Wor
ld P
opul
ation
#TetraPak(2012) ref. Prahalad(2004)
From Selection comes Direction For others
Selection
Preservation
Distribution
Processing
Packaging
Value Addition Opportunity
Processed in the PhilippinesSelection Preservation
/Processing Packaging
Tropical Fruits
Healthy Snack
Thermally Stabilized
(Value-added)Product of the Philippines
Processing Research
• Center for Advanced Processing and Packaging Studies (CAPPs): http://fst.osu.edu/capps/index.htm
• Institute of Food Technologists– Food Technology Industrial Achievement Award
• Processing/Packaging Processing Systems (2009 and 2010)
• USDA National Institute of Food and Agriculture (NIFA)– $25Million study to strengthen food safety
• Studying human noro-viruses across the food supply chain• Design effective control measures • Reduce the number of virus-caused foodborne illnesses
Advances in Processing
• Thermal Processing– Microwave Assisted Thermal Sterilization
• Continuous Flow (North Carolina State University)*
• Prepackaged (Washington State University)*
– Pressure Assisted thermal Sterilization• Ohio State University• National Center for Food Science and Technology
• Non-Thermal Processing– High Pressure Processing (Commercial)– Pulsed Electric Field (Commercial)*IFT: Food Technology Industrial
Achievement Award
“ Fresh Prepared” Food
• Minimally processed food– Healthy life styles– Convenience– Sustainable sourcing and product life
cycle
Packaging & Sanitation Enable “Fresh Prepared” Food
• Sanitation– Good manufacturing practices– HACCP– Global Standards
• Packaging– Contain– Protect & Preserve– Distribute– Inform/Sell
Taken to new levels of excellence
Case Study: I
• Stand up pouches with fitmentsSolutions in search of a problemAvailable for decades
Gualapack CheerPack
Same food: new opportunity
• Convenience for time-poor mothers of toddlers
Traditional No glass chardsLess messProcess - Challenging
Reclosable optimized process
Same Food: Distinctive Package
Jar Cup Pouch
Material Glass jar/metal cap
Foil laminate lid/ barrier plastic
cup
Foil laminate/ plastic
fitment & capReclosable Yes Additional cap YES
Processing Thermal Thermal/Aseptic Hot fill/Thermal
Dispensing Assisted Assisted Self
Distinctive Package: Enhanced Experience
Remaining Possibilities
• Expand high acid-hot fill/low acid-thermal– Continuous Flow Microwave
– High Pressure Processing
– Pulsed Electric Field
• Develop aseptic form/fill/seal
• Tropical fruit purees
• Low price point/traditional distribution
Case Study: II
• Global Fresh Foods (US pat No. 8,187,653 )
Smart Packaging:Multi-tasking
Component FunctionGFF Service Module Sum of these parts/temperature
controlPallet Basic transport unit/Cube shipping
container Product Stored in rigid totes
SAF-D Sealed Enclosure Flexible controlled atmosphere packaging
GFF Blue Box Convert residual O2 to H2OSmart Packaging:Team Player
Impressive Results
• 30+ days shipping/storage– 14 Day ocean transport– 14 day retail shelf life
• Green Supply Chain– CO2 emissions/lb: 99%
– Recycled content corrugated– Reusable packaging components– Natural gases/no preservatives
In Summary
• Packaging is a critical part of food technology
• Food technology involves other disciplines
• Packaging must work with these other parts
• There are always new jobs for packaging to do!
• Preservation & processing drive packaging.
• Begin with Food Science
• End with food safety