Global Food & Drink TrendsGlobal Food & Drink TrendsFood & Drink Innovation Food & Drink Innovation

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Packaging InnovationPackaging Innovation

bybyRichard Roberts, Principal ConsultantRichard Roberts, Principal Consultant

Pira InternationalPira International

20 October 200420 October 2004

InnovationInnovation

WHY INNOVATE?

“The only sustainable competitive advantage comes from ‘out innovating’ the competition.”

James Moore

InnovationInnovation

• Need to understand:– Consumer perspectives– Customer perspectives– Supplier perspectives

InnovationInnovation

1995• Quality• Cost/price• Service• Customer focus• Investment• Delivery• Flexibility• Technology• Account Management• NPD

2001• Quality• Cost/price• Service• Innovation• Partnership• Supply chain• Flexibility• Technology• Account Management• NPD

Single serveSingle serve

Single serveSingle serve

Innovative shapesInnovative shapes

Innovative shapesInnovative shapes

Convenience - easy dispensingConvenience - easy dispensing

RumblersRumblers

• Twinpots sleeved together

Active & Intelligent Packaging

Oxygen scavengers - Oxygen scavengers - mechanismsmechanisms

• Iron powder oxidation• Polymer oxidation (metal catalyst)• Ascorbic acid oxidation• Photo-activated organic compound• Enzymatic oxidation• Complexation

Selected commercially available Selected commercially available oxygen scavenging systemsoxygen scavenging systems

• Sachets– Ageless® (MGC)– Freshilizer (Toppan)

• Labels– ATCO® (EMCO)– Freshmax® (Multisorb)

Selected commercially available Selected commercially available oxygen scavenging systemsoxygen scavenging systems

• Closure liners– DarExtend™ (Darex)– Pureseal™ (WR Grace)– Oxycap (Standa Industrie)

Oxygen scavenging plasticsOxygen scavenging plastics

• Films, bottles, trays, cupsShelf plus ™ O2 (Ciba S.C)

Oxyguard ® (Toyo Seikan)

BindOX ™ (Amcor)

Amosorb® DFC (BP Amoco)

OS1000/2000™ (Cryovac)

OSP (Chevron Phillips)

ZerO2™ (CSIRO)

Benefits of oxygen scavengersBenefits of oxygen scavengers

• Extend shelf-life– reduce distribution losses– reduce spoilage claims

• Meets consumer demand for natural foods– eliminate or reduce food additives– reduce use of sugar and/or salt– maintain nutritional value

• Reduce need for extremely low levels of O2 in MAP– accelerated line-speeds

Ethylene scavengers - Ethylene scavengers - mechanismsmechanisms

• Potassium permanganate– Ethysorb™ (StayFresh Ltd)

• Activated carbon/Pd catalyst– Sendo-mate (Mitsubishi Chemical Corp)

• Activated carbon/bromine-based chemical– Hato-fresh (Honshu paper)

• Disadvantages:– Toxicity/migration

– Non-specific

– Not suitable for packaging films

Ethylene removing filmsEthylene removing films

• Everfresh™, Orega™, Profresh™, Peakfresh™• PE based films containing activated clay

CSIRO’s ESP technologyCSIRO’s ESP technology

• The only ethylene scavenging technology developed for packaging films

• Specific• Colour change• Transparent colourless to pink

transparent• Overcomes drawbacks of ethylene

scavenging sachets

Thermochromic InksThermochromic Inks

• Reversible and irreversible• Various temperature ranges• Limited colours• Combination with conventional ink

can reveal messages

• Reversible ink for use on milk labels

TTI’sTTI’s• Provides irreversible evidence of a physical or

physicochemical change, typically a colour or shade change

• Function– Provide information on exceeding a temperature threshold or

exceeding a cumulative time-temp history– To inform the supply chain and consumer that correct storage

conditions have or have not been adhered to

• Benefit– Provides reassurance to consumers– Real environment information rather than implied fitness

(use/sell by date)– Highlights problems in supply chain– Can reduce shrinkage/wastage

Freshness indicatorsFreshness indicators

• Provides irreversible evidence of a chemical or enzymatic change, typically a colour or shade change

• Function– Provide information on actual degradation spoilage of

products– To inform the supply chain and consumer of product

freshness

• Benefit– Provides reassurance to consumers– Real product information rather than implied fitness

(use/sell by date)– Highlights problems in supply chain– Can reduce shrinkage/wastage

Current applicationsFindus

• Combined technology TTI and RF data tag• One product line monitored in Sweden from early

2003 using Bioett’s TTI• Device the size of a credit card• Cost 15 to 25 Euro Cents• Device records temperature change through supply

chain which can be read by hand held scanner• Enzyme based reaction provides data and power

source• Large Swedish dairy Skanemejerier are also using

these devices

Current ApplicationsLifelines (US)

• US retailer Trader Joe require suppliers to apply LifeLines TTI’s to any fresh produce supplied to the company

• Monoprix the low cost French retailer uses the labels on 175 of its private label chilled products

• LifeLines sold over 200 million TTI’s in 2002 and project 25% pa growth

SteamersSteamers• Steams food• Valve releases excess pressure

Self-Heating/CoolingSelf-Heating/Cooling

• Tempra– both heating and

chilling technologies

Self heating/Self cooling packaging

Barrier TechnologiesBarrier Technologies

• Improvements to O2/CO2 barrier– new resins or improved PET resins– coatings– multilayers - overmoulding or co-injection– inclusion of nanocomposites

New ResinsNew Resins

• Polyethylene naphthalate (PEN)– use on its own or as blend with PET– higher glass transition temperature– barrier improvements about 5x– cost increase

• Polyglycolic acid (PGA)– O2 barrier 10x better than MXD6

– similar melting point to PET– FDA approval 2004?

Transparent barrier coating Transparent barrier coating - films- films

• SiOx or AlOx

• barrier similar to metallised films

Transparent barrier Transparent barrier coatings - bottlescoatings - bottles

• External– no food contact issues– can be scratch resistant and friction of

bottle can be improved

• Internal– not easily damaged– protects drink from gases/chemicals in

bottle wall– easier to incorporate PCR PET

External coatingsExternal coatings

• Resin coatings from PPG/SIPA, Du Pont, Dow

• SiOx - plasma - Krones / Coca Cola / Leybold

Internal coatingsInternal coatings

• Diamond like coatings (carbon), plasma and acetylene– Nissei, Mitsubishi/Kirin, Sidel (ACTIS)– brownish colour

• Silicon oxide– plasma Tetra Pak (Glaskin), SIG Schott

HiCotec

MultilayerMultilayer

• Co-injection of EVOH or MXD6– Kortec, Owens Illinois, Pechiney

• Active– Oxbar - MXD6 + cobalt catalyst– SurShield (Owens Illionois)

– Dar Eval - O2 scavenger in EVOH layer

Multilayer - activeMultilayer - active

MultilayerMultilayer

• Active– Amosorb 3000 - transparent O2

scavenging copolyester– OSP (Chevron Phillips Chemical) -

oxidisable polymer resin cyclohexenyl methyl acrylate + photoinitiator and catalyst

NanocompositesNanocomposites

• Improved mechanical properties, eg strength to weight

• Improved thermal stability and heat distortion temperature

• Improved barrier properties• Better chemical resistance• Better transparency, appearance

NanocompositesNanocomposites

• Mitsubishi Gas Chemical Co + Nanocor– nanoclays combined with polymers– silicate clays, 100-1000 x 1nm, large surface area, high

aspect ratio– nanocomposites retain flexibility, transparency of unfilled

polymer– permeability greatly reduced 2-20x, filler levels 1-5%– improved barrier for film and PET bottles– first application ‘Imperm 105’ in films - still clear– second application ‘Imperm 107’ in bottles - currently

hazy– potential cost reduction - fewer layers