Download - Packaging Innovations
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Fres-co System USA, Inc. Confidential Reproductions Prohibited
NCA
2008
Packaging Innovations
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Agenda
Coffee Packaging Quiz
Packaging Trends
Market Developments
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Coffee Packaging Trivia
How does O2 the barrier of foil compare tometalized film?
A. 2 x better barrier
B. 10 x better barrier
C. 100 x better barrier
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Coffee Packaging Trivia
What O2 % is desired level off the a coffeevertical, form, fill and seal machine?
A. Less then 10%
B. Less then 2%
C. Less then .2%
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Coffee Packaging Trivia
How many time does a Fres-co degassingvalve open and close during the degassing
period of freshly packaged coffee?
A. 5-10
B. 50-100
C. 100s
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Fresco System USA Valve Results
Fresco
0.00
0.05
0.10
2/9/05 0:00 2/9/05 2:24 2/9/05 4:48 2/9/05 7:12 2/9/05 9:36 2/9/05 12:00
Reliable, reproducible opening characteristics throughout the
lifetime of the coffee's degassing period. Reproducible opening
characteristics under radically different environmental conditions.
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Flexible Packaging Trends
Sustainable Packaging
Convenience
Senior FriendlyPortioning
Quality and Safety
Active Packaging
Customization
SensoryPackaging Regulation and Specifications
Increasing Shelf Life
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Sustainable Packaging: Is beneficial, safe & healthy for individuals and communities throughout its
life cycle.
Meets market criteria for performance and cost.
Is sourced, manufactured, transported, and recycled using renewable energy.
Maximizes the use of renewable or recycled source materials.
Is manufactured using clean production technologies and best practices
Is made from materials healthy in all probable end-of-life scenarios.
Is physically designed to optimize materials and energy .
Is effectively recovered and used in biological and/or industrial cradle-to-
cradle cycles.
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Wal-Marts Packaging Scorecard Wal-Marts packaging scorecard is a measurement tool
that allows suppliers to evaluate themselves relative to
other suppliers, based on specific metrics. The metrics in the scorecard evolved from a list of
favorable attributes, known as the 7 Rs of Packaging: Remove Packaging
Reduce Packaging
Reuse Packaging
Recycle (able) Packaging
Renew (able) Packaging
Revenue (Economic Benefits)
Read (Education)
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Wal-Marts Packaging Scorecard 15% will be based on GHG / CO2 per ton of Production
15% will be based on Material Value
15% will be based on Product / Package Ratio
15% will be based on Cube Utilization
10% will be based on Transportation
10% will be based on Recycled Content 10% will be based on Recovery Value
5% will be based on Renewable Energy
5% will be based on Innovation
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Fres-co System USA, Inc. Confidential Reproductions Prohibited
BI-AXINTERNATIONAL INC.
DEVELOPMENTAL DATASHEET
EVLON EV (Co-Extruded Plain
Polylactide Film)
Description: EVLON is a crystal clear filmmanufactured form NatureWorks PLA (Polylactide).
PLA is derived from corn, a widely accessible,renewable, natural resource. EVLON film can beused in many packaging applications either plain or
printed and laminated. After use, EVLON productscan be composted, and the material will breakdown
and revert to carbon dioxide and water.
Evlon PLA Film
Sustainable Materials
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NatureWorks PLA Resin
NatureWorks LLC, a division of Cargill
Derived from plant based materials
Plant material is fermented creating dextrose, a sugar
The sugar is transformed into lactide monomer
The lactide monomer is transformed into Polylactidepolymer
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Stackability and Stability:
The package needs tobe easy to stack and beattractive and stable onthe retail shelf
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Stackability and Stability:
Minimize air space inthe package to prevent
deformation fromhandling
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Stackability and Stability:
Package needs to bestable after opening to
minimize spillingduring use
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Convenience:
Opening convenience
such as peel seal no
scissors required
Dispensing Features
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Fres-co System USA, Inc.
Slider Reclosure
Fitment Reclosure
Fres Close
Reclosure
Tin Tie
Lift & Lock
Convenience:
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Senior friendly: Easy to read and
understand
Easy to open (includingchild resistant packaging)
Light and easy to handle
BIG BOLD PRINT
Smaller portionswith easy grip
space or handle
The package must be easy to
open but retain a hermetic
seal throughout shipping and
distribution.
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Portioning:
Single serve
Diet control
100-calorie portion
Dispensing measured
portion
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Quality and Safety: Non-glass structure
No sharp edges
Quality indicator such as
oxygen sensor or
temperature recorder
Tamper-evident
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Active Packaging: Scavengers for
Moisture
Oxygen
Carbon Dioxide
Moisture
Odor
Anti-static
Antimicrobial
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Customization:
Regional sizes and graphics
Seasonal or other promotional items
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Sensory: Beyond visual
appearances: audio
touch
taste scent
Shaped packages
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Packaging Regulation &
Specification:
Carbon dioxideemissions
10/01/2007- The European Food SafetyAuthority (EFSA) has issuedpositive scientific opinions onanother batch of 10 packagingsubstances, part of an EU-wideeffort to prevent the chemicalsfrom contaminating foods.
Residuals in material
Source of raw materials
GMO free
BSE free
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Increasing Shelf Life:
Higher barrier
Oxygen removal
Gas scavengers
CAP
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Market Developments
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Organic coffee adds PLA layer to 12-ounce bagIn a first for coffee, Jims Organic Coffee, Wareham, MA, replaces inner layer of
polyester in its 12-ounce foldover top stand-up bag with modified film made frompolylactide (PLA) resin from Natureworks LLC, Minnetonka, MN. Lamination from
Fres-co System USA, Inc., Telford, PA, results in structure with 19% renewable content,reflects green positioning of firms more than 35 varieties of hand roasted, certifiedorganically grown coffees.According to Chris Burger, coffee product manager for Fres-co, four layer adhesivelamination consists of 48-gauge rotogravure printed polyester/28-gauge aluminumfoil/80-gauge PLA/2.5 mil coextruded polyethylene (PE). PLA layer replaces 48-gauge
polyester, which had been adhesive-laminated to 3-mil coextruded PE. Foil providesoxygen barrier, coextruded PE serves as sealant layer. Copy on bag bottom providessubtle indication of PLA content: This bag is the first generation of sealed, stay freshcoffee bags to include renewable resources in its design. Jims Organic Coffees EmilySheehan, marketing, explains, We dont really like to be over the top and preachyabout the good things that we do, they are just the way we conduct business. However,
she notes, all elements work together to entice senses. These bags now feature a greatone-way valve for de-gassing the fresh roasted coffeestrategically placed inside theartwork on the coffee cups steam to add the stimulant of aroma to the packaging. Bagsalso feature sticker with new detailed descriptions about coffee, information aboutcountry of origin. Color-coding identifies coffee roast. Tin ties that allow for resealingnow feature botanical and company information on them, Sheehan reports. Forexample, In Guatemala, we have built and supplied a childrens library or In CostaRica, our supplier is part of a 40,000 acre eco-preserve. Follow-up: At Fres-co Chris
Burger, +1 215-721-4600, ext. 2129, [email protected]; at Natureworks, +1 877-423-7659; Link: www.natureworksllc.com. Packexpo.com, Sept 10, 2007
Sustainability
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Social Responsibility Leads the Way at Green Mountain Coffee Roasters
GMCR packages its ground and whole beancoffee in multilayer flexible packaging.The company is working with itssupplierFres-co System USA, Inc to research the feasibility of replacing asmany as 2 of the 4 nonrenewable polymerlayers in the flexible packaging withPLA. The key will be to maintain vaporand moisture barrier specifications.
GMCR recently introduced newpackaging for its Newman's OwnOrganics line of coffees that incorporatesa single layer of PLA into the overall
packaging.Sustainable Packaging newsletter, Sept 07
Sustainability
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Current standard12 Retail Items
4-ply easy open = 48PET/Ink/adh/28Alu/adh/48PET/adh/3.0PE
0.5 mil Easy Open 11Ax3 (provides hot tack and easy peel )
2.5 mil Polyethylene (provides structure bulk & feel, abuse resistance, sealant layer)
Adhesive
0.48 mil Polyester Film (provides oil barrier, improves seal performance, protects foil from cracking)
Adhesive
0.28 mil Aluminum Foil (provides oxygen, moisture & light barrier, stiffness & dead fold)
Adhesive
0.48 mil Polyester Film (provides heat & abrasion resistance)
Sustainability
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Revised 12 Retail Items
4-ply easy open = 48PET/Ink/adh/28Alu/adh/80PLA/adh/2.5PE
0.5 mil Easy Open 11Ax3 (provides hot tack and easy peel )
2.0 mil Polyethylene (provides structure bulk & feel, abuse resistance, sealant layer)
Adhesive
0.80 mil PLA (provides oil barrier, improves seal performance, protects foil from cracking)
Adhesive
0.28 mil Aluminum Foil (provides oxygen, moisture & light barrier, stiffness & dead fold)
Adhesive
0.48 mil Polyester Film (provides heat & abrasion resistance)
Sustainability
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NatureFlex
Packaging referenced as
biodegradable and
compostable.
www.SuperfoodSnacks.com
Sustainability
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NatureFlex
100% renewable and compostable Frac-pack?
Coffee
FracPack
CoffeeFracPack
Sustainability
Significant Cost Upcharge
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Current standard12 Retail Items
4-ply easy open = 48PET/Ink/adh/28Alu/adh/48PET/adh/3.0PE
0.5 mil Easy Open 11Ax3 (provides hot tack and easy peel )
2.5 mil Polyethylene (provides structure bulk & feel, abuse resistance, sealant layer)
Adhesive
0.48 mil Polyester Film (provides oil barrier, improves seal performance, protects foil from cracking)
Adhesive
0.28 mil Aluminum Foil (provides oxygen, moisture & light barrier, stiffness & dead fold)
Adhesive
0.48 mil Polyester Film (provides heat & abrasion resistance)
Reduce
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Revised standard 12 oz. Retail Items
4-ply easy open = 40PET/Ink/adh/26Alu/adh/40PET/adh/2.0STF
0.5 mil Easy Open 11Ax3 (provides hot tack and easy peel )
1.5 mil STF
Adhesive
0.40 mil Polyester Film (provides oil barrier, improves seal performance, protects foil from cracking)
Adhesive
0.26 mil Aluminum Foil (provides oxygen, moisture & light barrier, stiffness & dead fold)
Adhesive
0.40 mil Polyester Film (provides heat & abrasion resistance)
Reduce
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Standard 2 oz. Frac Pack2-ply easy open = OL/Ink/48METPET/adh/2.0PE
Reduce
2.0 mil Polyethylene
48 Gage Met PET
Adhesive
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Revised 2 oz. Frac Pack2-ply easy open = OL/Ink/40METPET/adh/1.0 STF
Reduce
1.0 mil STF
40 Gage Met PET
Adhesive
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Fres-co System USA, Inc. Confidential Reproductions Prohibited
Graphics
Holographic
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Fres-co System USA, Inc. Confidential Reproductions Prohibited
High Pressure Packaging
A study has been conducted at a university inItaly which shows that coffee under pressure ofCO2 maintains its organoleptic properties longer.
High PressureValve
ShapedPouch
Zip LockReclosure
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Fres-co System USA, Inc. Confidential Reproductions Prohibited
Valves
Frac Pack
CoffeeFracPack
Coffee
FracPack
Direct pack from Grinder
No need for storage
degassing bins
Extreme FRESH coffee
No Degas time
Reduce Secondary Packaging
(Box Size)
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Fres-co System USA, Inc. Confidential Reproductions Prohibited
ValvesLid Stock
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Fres-co System USA, Inc. Confidential Reproductions Prohibited
Questions
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