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“NEW AGE TRENDS & INNOVATIONS
IN PACKAGING SOLUTIONS
FOR THE FUTURE”
PROF.( DR) N. C. SAHA,
DIRECTOR
INDIAN INSTITUTE OF PACKAGING,
16th Petrochemical Conclave Gandhinagar, Gujarat,29th July, 2017
Scope of Presentation
Packaging Industry Scenario.
Consumer”s Perception.
Packaging Trends and Innovations.
- Passive Packaging.
- Active Packaging.
- Intelligent Packaging.
- Smart Packaging.
- Aseptic Packaging.
- Retort Packaging.
- Nanotechnology & Food Packaging.
- Bio derived Packaging Materials.
Trends in Tomorrow's packaging.
2
ONE OF THE MOST IMPORTANT INDUSTRY GLOBALLY
• ONE OF THE WORLD’S LARGEST &
DIVERSE MANUFACTURING SECTORS
• VALUED AT ~US$ 771 BLN
• EMPLOYING > 5 MILLION PEOPLE
• ~ 100, 000 COMPANIES WORLDWIDE
• ASIA-PACIFIC – WORLD’S 3RD
LARGEST PACKAGING MARKET
• GROWING @ OVER 5-6%
• RANKED 9/10 IN DEVELOPED NATIONS
WORLD PACKAGING INDUSTRY:
FEATURES
ERNST & YOUNG, GK Townsend, UK as stated in Packaging India
GLOBAL PACKAGING INDUSTRY –
Sector break down
Food
38%
USD 161 bn
Beverage
18%
USD 76 bn
Cosmetic
3%
USD 13 bn
Pharma
5%
USD 21 bn
Others
36%
USD 153 bn
With growth getting tapered off in developed economies like EU, US & Japan, the
developing economies like India, China, Brazil etc hold the key for future growth
drivers.
56%
Total Size in 2017 US $ 771 Bn.
Expected to reach US $ 875 in 2020
ASIAN PACKAGING INDUSTRY –
Geographical break down
Japan32%
USD 93 bn
China48%
USD 140 bn
India12%
USD 35 bn
Others8%
USD 23 bn
Total Size- US $ 291 Billion
ASIAN PACKAGING INDUSTRY –
Packaging Material break down
Paper34%
Plastic40%
Metal14%
Glass12%
Total Size US $ 291 Billion
ASIAN PACKAGING INDUSTRY –
Sector break down
Food & Beverage
85%USD 247 bn
Pharma10%
USD 29 bn
Other5%
USD 15 bn
Total Size US $ 291 Billion
INDIAN PACKAGING INDUSTRY –
Packaging Material break down
Others
14%
Caps &
Closures
6%
Labels
3%
Glass
10%
Printed Cartons
17% Metal
10%
Rigid
18%
Flexible
22%
NO. OF PLAYERS
LARGE - 40
MEDIUM - 7,000
ORGANISED- 4,50,000
SMALL SCALE
THE POWER OF 4:
New Economic Order
Robust Regional Demand – Adding the 5th Dimension
• North East Asia
• South East Asia
• India
• China
Consumer’s Perception
Changing perceptions of packaging & plastics.
New Concepts in Packaging.
Relevance of new packaging systems.
10
Market Status
Food and Beverages are the two largest
markets for adopting innovations in
packaging technologies including active
and intelligent packaging
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Fundamental
Goal of Packaging Protection of contents from Light,
Microbes, Oxygen and Water vapor.
Preservation to enhance Shelf life.
Presentation to increase sales value.
Communication through labelling.
Compliance to statutory regulation.
Branding to increase market share.
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Emerging Concepts in
Packaging
Packaging Innovations are mainly into
the following categories:
Passive
Active
Intelligent
Smart
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Passive Packaging
Passive Packaging refers to the traditional packaging that involves the use of a covering material characterized by some inherent insulating, protective or ease-of-handling qualities.
Example : Simple plastic carry bag.
14
Active Packaging Active Packaging entails the concept of the
package reacting to various stimuli to keep the
internal environment favourable for the
products.
Example : A packaging system with oxygen
scavenger ( An oxygen scavenger can absorb oxygen
inside a package to increase the shelf-life of the
item.)
15
Salient Features of Active
Packaging
Active packaging does more than simply
provide a barrier to outside influence.
It can control and even react to events taking
place inside the package.
Active packaging senses environmental
changes and responds by changing the
properties.
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Salient Features of Active
Packaging
The reasons for the increased interest in “active” packaging stems from the known limitations of barrier packaging in controlling the internal environments of food (and other) packages.
Barrier structures can only keep out (or in) elements that are already present. But to enhance the value of the packaging to the contents, active agents are incorporated to act on behalf of something that is missing.
Removal of oxygen, both residual and that entering through the plastic package walls or seals, may be achieved by affixing an oxygen-scavenger sachet to the interior of the package wall to extend the quality of the product and suppress aerobic micro-organisms.
17
Salient Features of Active
Packaging
Active Packaging employs a Packaging material that
interacts with the internal gas environment to
extend the shelf-life of a food.
Such Technologies “continuously” modify the gas
environment (and may interact with the surface of
the food) by removing gases from or adding gases to
the headspace inside a Package.
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Oxygen Scavenging
Technology
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Figure: Oxygen Scavenging Label.
Source: Paper presented at 40th AIFST Convention, Melbourne,
and 25 June 2007 by Brian P. F. Day
Ethylene Scavenger
Technology
20
Photosource: EverFresh
Sachets Based on Ethylene Scavengers
Antimicrobial
Technology
21
Figure: Oxygen absorbers and anti-microbial
agents.
The ion exchange mechanism of silver antimicrobials from AgION Technologies Inc. The silver ions in
the Zeolite carrier exchange with the sodium ions in the environment/moisture, causing a controlled
release of silver on demand.
Enhancement of
Fragrances in Plastic
Packaging
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Scent Sational technology is also being used to add fragrance to the closures of shampoo, laundry
detergents, and other cleaning, health and beauty products to allow consumers to sample a product's
scent, without disturbing the product seal.
Intelligent Packaging
Intelligent Packaging refers to the concept of making innovations in the design of the package that renders it more useful to consumers.
Intelligent packaging increases the functionality of the package by simply changing the structure of the package without the addition of any technology.
Example :
Packaging of automobile oil , where the packaging structure makes it convenient for the user to pour oil without his hands getting dirty.
23
Smart PackagingSmartness in Packaging is a broad term that covers a number of functionalities, depending on the product being packaged, including food, beverage, pharmaceuticals, house-hold products etc.
Example of current & future “smartness” would be in packages that:
◦ Retain integrity& actively prevent food spoilage ( shelf-life)
◦ Enhance product attributes ( look, taste, flavor, aroma)
◦ Respond actively to changes in product or package environment
◦ Communicate product information & history or condition to user.
◦ Assist with opening & indicate seal integrity.
◦ Confirm product authenticity and act to counter theft.
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Evolution of Smart
Packaging
“ Exploring Synergy of Organic &
Polymer Chemistry To Create
Responsive Packaging Materials”
25
Responsive Materials
Polymers ,originally perceived to be electrical insulators.
Today, the role is “ organic electronics” used in mobile phones & solar cells.
Polymer molecular architecture can be tailor-made.
Advances in molecular level is reflected in macro-scale effects.
Color changes, fluorescent tags enable to view changes inside a package.
Changes such as fruit ripening, fragrance release, security marker can be achieved with smart polymers.
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Need For Smart
Packaging
Why would a packaging technologist be interested in Smart Materials ?
“ Dumb materials” ( cardboard, metals, paper & simple plastics ) seem to be doing an adequate job.
These materials have performed well.
However, expectations from packaging are growing with time.
With this, need for new materials & effects are emerging.
New packaging with exciting & novel properties are imperative.
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Need For Smart
Packaging
Next generation packaging materials are not just for covering & storage, protection, tracking & safety.
They must fulfill needs such as excitement, surprise, luxury appeal, branding & improved communication.
Smart packaging materials open up new opportunities, adding diversity, & functionality to fast-moving consumer goods packaging.
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Comparison between
Active & Smart Packaging
Active Packaging
Oxygen scavenging.
Antimicrobial.
Ethylene scavenging.
Odor absorbing/ flavor release.
Moisture removers.
Ethanol release.
Carbon dioxide emitters.
Smart Packaging
Time-temperature history.
Microbial growth indicators.
Light protection
( photochromic).
Physical shock indicators.
Leakage indicators.
Spoilage indicators.
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Polymer/Inorganic Nanocomposites:
Opportunities in Food Packaging
Applications
•Nanotechnology is the characterization and manipulation of materials with dimensions in the nanometer range, typically 1 to 100 nanometers.
•Nanotechnology has great potential application in food packaging to improve properties of existing materials (for example increasing barrier properties for plastics)
•Develop new materials with unique properties.
Nanotechnology &
Packaging: High
Barrier Clear Films
31
Nanotechnology & Packaging:
High Barrier Clear Films &
Bottles
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Figure : Imperm Oxygen Permeability
(Source: Mitsubishi Gas Chemical)
Figure : Imperm Core (L),
Multilayer Bottle (R)
(Source: Mitsubishi Gas Chemical)
FreshExtend
Packaging Technology(Source: GardIn Fresh LLC)
33
GardIn Fresh's FreshExtend nanotechnology uses a silver coated
nanoparticle additive to retard food spoilage
Bio Degradable Packaging
Concepts
34
Compostable Cellophane Disposable Barrier Film
Figure : NatureFlex NK
Film Construction
(Source: Innovia Films)
Figure : NatureFlex NK Film
Wrapped Chocolate Bars
(Source: Innovia Films
Bio Degradable Packaging
concepts
35
Sustainable Whey Based Protein Packaging
Figure : Whey-based Composite Film Layers
(Source: Wheylayer Consortium)
Aseptic Packaging Concepts
36
Aseptic packaging is defined as the filling of a commercially sterile
product into a sterile container under aseptic conditions and
hermetically sealing the containers so that reinfection is
prevented.
A great variety of packages may be
aseptically filled
•Carton Boxes
•Bags and Pouches
•Cups and Trays
•Bottles and Jars
•Metal Cans
•Plastic Cans
•Composite Cans
Retort Packaging Concepts
37
A retort pouch is a type of
food packaging made from a
laminate of flexible plastic and
metal foils.
It allows the sterile
packaging of a wide variety of
food and drink handled by
aseptic processing, and is used
as an alternative to traditional
industrial canning methods.
Tomorrow's Packaging
Tomorrow’s packaging will have to be designed to
meet many requirements- than those of food itself.
Changes in Distributor & retailer practices.
New trends like internet shopping.
Unexpected consumer expectations like for mildly
preserved foods that have fresh-like qualities
Internationalization of markets, resulting in increased
distribution distances & longer storage times
( shelf –life) of a set of different products.
38
Key Trends in Tomorrow's
Packaging
Demand for active and intelligent packaging in the USA is forecast to grow at an annual rate of 8% reaching $3.5 billion by 2017, well above total packaging demand growth for the same period.
Active packaging demand is expected to increase 5.7 per cent annually to $2.2 billion by 2017.
However, cost and performance factors will tend to inhibit broad usage, says Freedonia.
Source: The Freedonia Group
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THANK YOU
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