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Retail Innovation Programme

Survey of packaging with potential to reduce food thrown away at home

A market survey of packaging formats and other retailer and in-home solutions to help consumers manage their food inventory better.

Project code: RWM005-002 Research date: October/December 2006 Date: July 2007

Front cover photograph: Representative images of several different types of packaging that could help to reduce food waste. WRAP and Paul Butler believe the content of this report to be correct as at the date of writing. However, factors such as prices, levels of recycled content and regulatory requirements are subject to change and users of the report should check with their suppliers to confirm the current situation. In addition, care should be taken in using any of the cost information provided as it is based upon numerous project-specific assumptions (such as scale, location, tender context, etc.). The report does not claim to be exhaustive, nor does it claim to cover all relevant products and specifications available on the market. While steps have been taken to ensure accuracy, WRAP cannot accept responsibility or be held liable to any person for any loss or damage arising out of or in connection with this information being inaccurate, incomplete or misleading. It is the responsibility of the potential user of a material or product to consult with the supplier or manufacturer and ascertain whether a particular product will satisfy their specific requirements. The listing or featuring of a particular product or company does not constitute an endorsement by WRAP and WRAP cannot guarantee the performance of individual products or materials. For more detail, please refer to WRAP's Terms & Conditions on its web site: www.wrap.org.uk.

Published by Waste & Resources The Old Academy Tel: 01295 819 900 Helpline freephone Action Programme 21 Horse Fair Fax: 01295 819 911 0808 100 2040 Banbury, Oxon E-mail: [email protected] OX16 0AH

Executive summary This report summarises new and upcoming packaging formats and technologies having the potential to assist in the reduction of food waste in the home. As well as primary packaging initiatives, it includes packaging/storage solutions for in-home use as well as packaging/retailer initiatives that help to raise consumer awareness of correct food storage, and hence by inference, the problems of food waste. The report is organised according to the following six sections given here with with their key conclusions:

In-Home Storage Solutions

Changes in consumer behaviour are fundamental to achieving food waste reduction, and the proper storage of partially consumed or already cooked left-over food is a key element in any food waste strategy. There are a number of existing and some new solutions in the form of bags, boxes or other types of container for extending the storage period for food. There is no shortage of effective food storage systems for use in the home, and the newer types are based on good scientific principles of excluding as much oxygen as possible, or controlling the microclimate within the storage headspace or the activity of micro organisms. All these devices require the participation of consumers purchasing the storage device and transferring partially consumed contents or left-over food to it. In practice adoption of these solutions will require significant behavioural change by consumers. One solution that circumvents these problems lies in the design and format of the primary package containing the product. Much more could be done to make this packaging easy to open and resealable, creating a storage solution for the rest of the product.

Retail Environments that May Contribute to Raising Awareness of Correct Food Storage

Three observations are reported from non-UK supermarkets: cool bags clearly on display next to frozen and chill foods, fridge thermometers on display adjacent to chilled foods, and food labels giving clearly recommended refrigerator storage temperatures. Each of these may be available in UK supermarkets to some extent but not extensively. They offer interesting possibilities for more general adoption in the UK. In terms of food waste, they may be valuable in serving as ‘gentle reminders’ to consumers, raising their awareness about the correct storage of food.

Second Generation Time-Temperature Indicators (TTIs)

In 2006, two new time-temperature indicator (TTI) suppliers were in a position to promote their technologies and look for partners willing to trial the new indicators. Significantly, both developments were driven by a desire to improve the accuracy of existing TTIs by more closely matching a visual signal to food degradation associated with bacterial growth kinetics. These second generation TTIs, if they live up to their expectations of significantly improved accuracy, have a good chance of being adopted by retailers keen to offer longer shelf-life on perishable products but without compromising food safety.

Shelf-life Extension without Preservatives?

There is a growing trend for consumers to buy healthier and fresher foods, minimally processed and containing reduced levels of chemical preservatives and other additives such as salt and sugar. At the same time there is growing interest in longer shelf-lives by many consumers. Approaches which extend shelf-lives without recourse to artificial preservatives, ought to appeal to consumers and reduce the possibility that wholesome foods end up in the rubbish bin.

Survey of packaging with potential to reduce food thrown away at home 1

Both oxygen scavenging and controlled modified atmosphere packaging can extend the shelf-life of fresh and chilled products without the use of preservatives. They are well-proven approaches and are likely to see greater acceptance in the future. Controlled modified atmosphere packaging is a promising technology in this context. Such innovation is not necessarily relevant for all fruit and vegetables but can be beneficial for products such as soft fruits and those having a naturally short shelf life. There are many problems with antimicrobial packaging films, suggesting that the technology still has a long way to go in Europe before it sees any form of real commercialisation.

Innovative Portion/Ready-to-Serve Packaging

In France, the portioning of food by packaging is ubiquitous, presumably driven by considerations of the importance of ‘freshness’ and the convenience of single portions. Portion packaging avoids the common problem of partially opened food drying out, and allows consumers to manage their food inventory better. It is also interesting to note the rise in the USA of portion-control packaging as a response to the growing problem of obesity. For example, Proctor & Gamble and Kraft have recognized a market opportunity in portion-controlled food packaging and are releasing 100-calorie packages of some of their popular snacks. Portion size is known to strongly influence consumption. (1)

This suggests that there could be a win-win for food producers , retailers and consumers in food portioning to help reduce both food waste and limit the growth in obesity. This might provide marketing with a justification for the (possibly) slight increase in portion packaging costs, and help defuse claims of ‘overpackaging’ by some members of the public. Small increases in the amount of packaging used to create individual smaller ‘portions’ might lead to useful reductions in the amount of food thrown away in the home. Better packaging for sliced meats and pâtés, etc that allow easy opening and easy reclosing is coming slowly to the UK market. Some of this is suitable for direct table use in attractive reclosable, ready-to-serve packaging. This type of packaging can play a part in helping partially consumed food to remain palatable and therefore more likely to be consumed rather than thrown away.

New Developments in Resealing/Reclosing

Reclosable pouch and bag formats for the flow-wrapping of food products is a new packaging technology that is being introduced for commercial products in Europe and the US. For UK retailers it represents an opportunity to give consumers better storage options for partially consumed food and therefore it needs to be considered as an option as part of any food waste reduction strategy involving packaging.


Contents 1.0 Introduction ............................................................................................................................. 4 2.0 In-Home Storage Solutions...................................................................................................... 5

2.1 Food Storage Boxes...............................................................................................................5 2.2 Food Storage Bags ................................................................................................................7 2.3 Summary ..............................................................................................................................7

3.0 Retail Environments that May Contribute to Raising Awareness of Correct Food Storage ..... 8 3.1 Cool Bags Clearly Visible & Available Next to Frozen & Chill Foods (USA, France, Portugal) ........8 3.2 Fridge Thermometers on Display Next to Chill Foods (France) ..................................................8 3.3 Food Labels That Clearly Give Recommended Refrigerator Storage Temperatures (France, some UK supermarkets) ..............................................................................................................................9 3.4 Summary ............................................................................................................................10

4.0 Second Generation Time-Temperature Indicators (TTIs)...................................................... 11 4.1 Why Second Generation Devices are Needed ........................................................................11 4.2 Ciba Speciality Chemicals .....................................................................................................11 4.3 Cryolog ...............................................................................................................................12 4.4 Summary ............................................................................................................................13

5.0 Shelf-life Extension without Preservatives? .......................................................................... 14 5.1 Oxygen Scavenging .............................................................................................................14 5.2 Closer Control of Modified Atmosphere Parameters................................................................15 5.3 Antimicrobial Packaging .......................................................................................................15 5.4 Summary ............................................................................................................................16

6.0 Innovative Portion/Ready-to-Serve Packaging..................................................................... 17 6.1 Innovative Portion Packaging ...............................................................................................17 6.2 Individual Portions Wrapped in Multipacks ............................................................................19 6.3 Serve/Storage Boxes or Containers.......................................................................................19 6.4 Summary ............................................................................................................................20

7.0 New Developments in Resealing/Reclosing .......................................................................... 21 7.1 Snack Products in Adhesive-Based Resealable Packs..............................................................21 7.2 Summary ............................................................................................................................21

8.0 References ............................................................................................................................. 22 Appendix 1 - Websites/Contact Details of Suppliers Mentioned in Report ....................................... 23 Table of Figures.................................................................................................................................. 24


1.0 Introduction This report summarises the new and emerging packaging formats and technologies having the potential to reduce food waste in the home. It covers primary packaging initiatives, packaging/storage solutions for in-home use packaging/retail environments that help to raise consumer awareness of correct food storage, and encourage the reduction of food waste. In this report ‘food waste’ always refers to food thrown away at home and does not consider the possible impact of what is being discussed on food waste in other parts of the supply chain. It surveys the market situation up to the end of 2006, looking for new initiatives and technological innovations. Although it is UK-focussed, there are inputs and examples from other countries such as the USA and Europe. There is no direct evidence that the non-UK examples given are directly responsible for lower food waste in these countries – but they represent interesting possibilities which may be of value and may suggest helpful approaches when considering the challenges facing the UK. The report is organised according to the following sections:

In-Home Storage Solutions;

Retail Environments that May Contribute to Raising Awareness of Correct Food Storage;

Second Generation Time-Temperature Indicators;

Shelf-life Extension without Preservatives?;

Innovative Portion/Ready-to-Serve Packaging; and

New Developments in Resealing/Reclosing

The report is a companion to, and builds on, an earlier report ‘Packaging Technologies with Potential to Reduce the Amount of Food Thrown Away’ published by WRAP (reference INN0014-009) in January 2006. A full list of the identified manufacturers and suppliers can be found in Appendix 1.


2.0 In-Home Storage Solutions Changes in consumer behaviour are fundamental to achieving food waste reduction, and the proper storage of partially consumed or already cooked left-over food is a key element in any food waste strategy. There are a number of existing and some new solutions in the form of bags, boxes or other types of container for extending the storage period of food. 2.1 Food Storage Boxes Airtight plastic boxes of the ‘Tupperware’ variety are commonplace and will not be considered further here. Although they do prevent food drying out and so are potentially useful in helping reducing food waste, the scope of this report is to look at what is new in this area. A variant of the standard container, but with an easy-to-use method of getting rid of air from inside the storage box, is available in the USA as freshvac™, through the Target supermarket chain of stores, and is now sold in the UK through Lakeland as ‘More Than Storage’ Boxes. This container has a one-way valve that is operated by pressing down on the centre of the box lid to expel air. There is also a date indicator dial that can be set according to the date the food was put into the container (Figure 1). Figure 1 freshvac™ storage boxes have a one-way valve that allows air to be expelled creating a partial vacuum to keep food fresher for longer periods.

An impressive extension of preservation time is claimed by the manufacturer for this container (Figure 2). Figure 2 Typical foods last from between 1.5 to 5 times longer when stored in these containers, according to the manufacturers.


Also available in the USA, is the range of FresherLonger™ Miracle Food Storage Containers exclusive to The Sharper Image chain of shops. These airtight translucent polypropylene containers are impregnated with antimicrobial silver nanoparticles to reduce the growth of micro-organisms in stored foods. The nanoparticles average about 25nm (nanometers) in diameter, and at this size they give the containers a distinctive golden hue. ‘Stop Wasting Food!’ is a key claim for this container, and the results as presented with the product appear plausible given that silver is a known antimicrobial agent (Figure 3). Figure 3 FresherLonger™ food storage containers are impregnated with nanoparticles of silver – a known antimicrobial agent – that inhibits the growth of micro-organisms on food, keeping it palatable for longer.

Finally, from the USA but available in Sainsbury’s and Lakeland in the UK, are the It’s Fresh™ food storage products that consist of zippered storage and freezer bags, and lidded rigid food storage containers, which are made from biodegradable polylactic acid (PLA), produced by NatureWorks®. Their real innovation however is not with the containers but with the single-use colour change freshness indicator labels that are enclosed with the products (Figure 4). According to the accompanying literature, these labels detect gas produced during the food spoilage process and, if food is not fresh, there is a change colour from red to yellow. The instructions are to remove the adhesive overlay from the front of the label and to stick the label onto the inside of either bag or container containing the food so it can be seen, then refrigerate. After 8 hours, freshness checks can be made. It is stated that the indicator will not work for garlic, onions and marinades, and the storage system is only recommended for deli meats, beef, chicken, pork and seafood. For this reason, it is most likely that the gases being detected are amines and the chemical change taking place in the label is a pH one. This would be consistent with the use of methyl red as an indicator, which is red in acidic conditions and yellow in alkaline conditions.


Figure 4 Food storage containers and zipper bags with adhesive freshness labels that change colour according to the freshness of left-over or uncooked food.

2.2 Food Storage Bags Also from the USA, but available in the UK via Lakeland, are Green Bags from Evert-Fresh, branded as Stayfresh Longer bags by Lakeland. According to the website, fruit and vegetables stay fresh longer when stored in these bags which are impregnated with ‘Oya’ a natural mineral, to absorb and remove the ethylene gas which normally stimulates the ageing process. It is claimed that soft fruit last up to 1-2 weeks longer, leaf and salad crops up to 4 weeks, root and hard fruits up to 6 weeks. The bags remain effective for several months so can be reused during this period. The ‘Oya’ ingredient refers to a naturally occurring zeolite material from the Oya, Tochigi Prefecture, in Japan. Zeolites are well-known to be capable of absorbing many types of gases, including ethylene gas generated from foods while being stored, so the bags do have a scientific basis by which they work. 2.3 Summary There is no shortage of effective food storage systems for use in the home, and the newer types are supported by good scientific principles of excluding as much oxygen as possible, controlling the microclimate within the storage headspace or by initiating microbiological action or other means. A number of other innovative food storage systems are available from Lakeland, such as bread bags (Lakeland claim, test results showed after one week a family loaf still tasted as good as the day it was baked), a freezer vacuum pump for removing air from food storage bags before freezing, and the Tefal® Cheese Preserver which stops pieces of cheese from drying out. But all these devices require the participation of consumers in the first place by purchasing the storage solution, and in the second place by actively transferring partially consumed contents or left-over food to them. Adoption by consumers may involve increasing awareness, providing a compelling reason to buy these products and alternative approaches to use them. Solutions that circumvents these problems lie in the design and format of the primary package containing the product. Much more could be done to make this packaging not only easy to open but also reclosable, creating a storage solution for the rest of the product. Examples of this approach are given in section 6.3 of the report.


3.0 Retail Environments that May Contribute to Raising Awareness of Correct Food Storage

In this study, involving visits during December 2006 to supermarkets in the USA (Boston, Shop and Save), France (Calais, Carrefour) and Portugal (Lisbon, Pingo Doce), a number of supermarket features were noted that were different to those generally seen in UK stores, and these features could be of positive benefit in raising consumer awareness as it relates to correct food storage. 3.1 Cool Bags Clearly Visible & Available Next to Frozen & Chill Foods (USA, France,

Portugal) In the three non-UK supermarkets visited, insulated cool bags were on visible display next to the frozen and chilled food, and available for purchase at around £1 each (Figure 5). Full details of the insulating characteristics of the bags were printed on them, from ‘keeps foods frozen up to 3 hours’ (Shop and Save, USA) to a 1 hour claim (Carrefour, France). Figure 5 Cool bags on sale in supermarkets in Lisbon (Pingo Doce – left) and Boston, USA (Shop and Save – right) located directly in frozen food section of store.

Generally, at UK supermarkets, cool bags are available for sale only at check-out. This could be a less effective placement when it comes to correct food storage, since the association between the cool bag and keeping this type of food cool during transport from store to home could easily be lost in the mind of the consumer. 3.2 Fridge Thermometers on Display Next to Chill Foods (France) An initiative only observed in Carrefour in Calais in this mini-survey was the conspicuous positioning of ‘Coco Frigo’ odour eliminating fridge thermometers for sale throughout the chilled food section of the store (Figure 6), acting as a strong reminder to consumers about fridge hygiene and temperature. At the correct fridge temperature the sticker has a blue ‘OK’, set for a temperature below 5ºC. These items are available in UK hardware stores but it was the association of the item with the food that was so striking in France, where they were along every chilled food aisle.


Figure 6 Refrigerator deodorant/thermometers on display next to the chilled food section in Carrefour, Calais. The ‘OK’ sticker on the side of the device turns blue when the refrigerator temperature is below 5˚C.

3.3 Food Labels That Clearly Give Recommended Refrigerator Storage Temperatures

(France, some UK supermarkets) It is generally regarded via Government recommendations (2) and other experts (3) that the warmest part of the home refrigerator should be at no more than +5°C and that perishable foods should be kept at refrigerator temperatures lying between 0 and 5ºC. Ignorance of correct refrigerator storage temperatures together with data showing that most refrigerators are running at higher than recommended temperatures (4) ,and the fact that few refrigerators have thermometers fitted lead to the obvious conclusion that unfortunately the words ‘Keep Refrigerated’ are probably insufficient information to raise awareness of the correct storage regimes for perishable foods. In the UK, Marks & Spencer and some other UK stores have started to list recommended temperatures (Figure 7), as is commonplace in, for example, France.


Figure 7 Food labelling information regarding the correct refrigerator temperature for storage of food across UK retailers can be either general (left) or specific (right).

3.4 Summary These three observations of the retail environment in non-UK supermarkets are just that – observations. There is no intention to claim that these are totally absent from all UK supermarkets, nor that they are directly responsible for lower food waste in these countries – just that they represent interesting possibilities which may be of value and may suggest helpful approaches when considering the challenges facing the UK. The belief is that they are valuable in terms of food waste because they serve as ‘gentle reminders’ to consumers, raising their awareness about the correct storage of food.


4.0 Second Generation Time-Temperature Indicators (TTIs) In 2006, two new time-temperature indicator (TTI) suppliers entered the market. Significantly, both were offered to improve the accuracy of existing TTIs by more closely matching a visual signal to food degradation bacterial growth kinetics. 4.1 Why Second Generation Devices are Needed Existing first generation TTIs, such as Fresh-Check® from TempTime, rely on a single polymerisation chemical reaction with a fixed activation energy calculated to coincide with the exponential rapid second stage of microbial growth for the food in question. Although the chemistry can be adjusted to change the activation energy according to food type, the TTI only mimics the second stage of growth and neglects the initial first lag phase when bacterial growth is slow. Under certain conditions, when the lag phase is long, this can cause the TTI to be inaccurate in changing colour too early when the food is still safe to consume. Since the chemistry of Fresh-Check starts to work at the point of label production, further inaccuracies can arise if the labels are incorrectly stored, and the need to apply labels cold is a feature disliked by retailers. While these inaccuracies and inconveniences exist, retailers will be reluctant to adopt the technology. If these problems cannot be overcome there is the possibility of establishing a more accurate and realistic shelf-life coding system. Existing food date coding is probably quite conservative, but with accurate and reliable TTIs, existing shelf-life might be extended by several days. This would be a gain worth having from a retailer point-of-view, and could contribute to a reduction in food waste since if food lasts for longer it has a greater chance of being consumed. 4.2 Ciba Speciality Chemicals OnVu™ is the new name from Ciba Specialty Chemicals for the old FreshPoint TTI developed from research done by Professors Haarer and Eichen, and continued R&D work in labs in Israel and Germany. In late 2004, FreshPoint signed a global exclusive agreement with Ciba for the development, marketing and global sales of the TTI. Figure 8 A composite picture showing the OnVu™ colour change TTI label fading from blue to white as a function of time and temperature. Increases in temperature have a significantly greater effect on the colour change rate compared to changes in time.

As printed, the TTI label consists of a heart shaped ‘apple’ containing an inner heart shape. An advantage is that this image is stable, and can be stored at room temperature until activated by UV light from an LED lamp, when the inner heart changes to a deep blue colour. A filter is then added over the label to protect it from deliberate recharging. The blue inner heart changes back to white as a function of time and temperature in the normal manner (Figure 8). A further advantage is that this system can be applied as a label, or more importantly directly printed onto the package. Decay length parameters are easily adjusted to meet shelf-life variables for different product groups, and it is understood that the initial focus of effort with this TTI is in the meat, poultry and fish packaging industry, particularly for minced meat where the initial bacterial loading can be considerable due to the large surface area of product.


4.3 Cryolog Cryolog is a 2002-founded French company with strong scientific and industrial partners, and has developed two versions of TTI relevant to food waste management, (eO)® for consumers and TRACEO® for retailers. (eO)® is an adhesive label TTI aimed initially at the sandwich, salads and take-away meal market. The indicator, in the form of a small gel pad shaped like the petals of a flower, changes from green (good) to deep red (not good) as shown in Figure 9. Figure 9 The (eO)® TTI changes colour directly from green to dark red when the ‘use by’ date is reached.

The key feature of this TTI is that the colour change represents a pH change due to microbial growth of food grade micro-organisms within the gel itself, so the indicator should accurately track what is happening microbiologically within a food product. Calibration of the label is possible from 1 to 10 days at a target storage temperature of 3ºC or 4ºC. A second advantage is that the colour change, unlike other TTIs, is abrupt at the end point from green to red and does not transition with time. This means that consumers should not sort through food items having this TTI to find the one with the least colour change, i.e. the freshest, nor would they be in any way confused over whether the end point had been reached, as might happen for example with the OnVu™ colour change. TRACEO® (Figure 10) is a transparent adhesive label placed over the barcode on food packaging. The label changes from colourless to red to indicate that the product has exceeded its use-by date, at which point the product should be removed from sale. If a consumer were to purchase the item inadvertently, it would be rejected by the scanner at check-out. Cryolog have worked extensively with departments in the Institut Pasteur on the development of both these indicators so there is sound science behind them. Trials are underway in France but the exact nature and product type has not yet been disclosed.


Figure 10 TRACEO® is a colourless TTI label that covers a barcode. It changes to a red colour once the food product has reached its use by date, rendering the barcode unrecognisable by the scanner at check-out.

4.4 Summary These second generation TTIs, if they live up to their expectations of significant improved accuracy, have a good chance of being adopted by retailers keen to offer longer shelf-life on perishable products but without compromising aspects of food safety. Ciba’s OnVu™ has the advantage of being directly printable on packaging, further reducing costs while Cryolog’s TTI should be especially accurate for fresh meat and fish products where the principal degradation process determining shelf-life is microbial spoilage.


5.0 Shelf-life Extension without Preservatives? A growing trend for consumers is for healthier and fresher foods, minimally processed and containing reduced levels of chemical preservatives and other additives such as salt and sugar. This drive for more ‘natural’ products is sometimes at odds with the opposing consumer desire of less-frequent shopping and hence longer shelf-life products. However there are approaches, discussed in this section, that are being adopted providing ‘win-wins’ for the consumer, where shelf-lives can be extended without recourse to artificial preservatives. This ought to create a climate where wholesome food remains edible for longer, reducing the possibility that it finds its way into the rubbish bin. 5.1 Oxygen Scavenging Oxygen scavenging as a technology has been available for a number of years and is in widespread use in the Japanese market which represents by far the largest market for oxygen absorber sachets. Inside the sachets are activated iron filings and the process of oxygen absorption is one of iron oxidation which is claimed to absorb oxygen inside sealed packaging to less than 0.01% and maintain it at this level. European market analysers have looked at sachet forms of oxygen scavengers but have generally concluded that consumers may mistake the sachet contents for condiments. New developments in adhesive label or flat printed card versions which can be incorporated into the packaging are much less likely to cause this confusion. Multisorb, for example, has three different format versions of oxygen scavengers. FreshMax® is the adhesive label version of the sachet, but preferred by European legislators and consumers since it cannot be detached from the package nor, hopefully, mistaken for part of the food product. It has been specifically designed for adhesion within packaging of high value foods where oxygen absorption requirements are at levels below 50cc. FreshPax™ comes in separate packets or strips, suitable for snacks, fresh pasta and moist or semi-moist foods such as breads and cakes. Finally FreshCard™ is a flat-profile oxygen absorber which can be printed like a label in sizes up to 4" x 4". Standa is the only European manufacturer of oxygen scavenging systems, trademarked as ATCO®. An interesting commercial trend in France is the use of oxygen scavengers to help food companies and especially small producers cut back or eliminate completely added preservatives and allow them to market more ‘natural’ products without compromising shelf-life. One example noted is in traditional all-natural country-style bakery products where clearly preservatives are completely against the image of the product. The incorporation of oxygen scavenging sachets into the packaging has given traditional producers the shelf-life they were looking for while retaining the quality, freshness, taste and no-preservative benefits (Figure 11). Figure 11 Traditional bakery products sold at French markets and specialty shops use oxygen scavenging sachets to provide the required shelf-life without the use of preservatives.


5.2 Closer Control of Modified Atmosphere Parameters Modified atmosphere packaging is commonplace in food packaging to slow down spoilage and thus extend the shelf-life of the product without changing it, as is the case with preservatives, or to maintain the red colour in fresh meat. During the packaging process, the air is evacuated from the pack and replaced by other nitrogen(N2)/carbon dioxide(CO2)/oxygen(O2) gas mixtures, according to food type. For example, CO2 dissolves in water and forms carbonic acid (H2CO3), which acts as a preservative film on the surface of products that contain water. The acid environment inhibits microbial growth. CO2/O2 mixtures, with N2 , are used for fruit and vegetables to extend shelf-life, and it has been known for some time that for every harvested product there is an optimum ratio of O2, CO2 and N2 at which its shelf-life and freshness are lengthened considerably. Based on these principles, Multivac has developed their FreshSAFE packaging concept for fruits and vegetables. The product is surrounded by an atmosphere optimised for its individual requirements so that it can continue its natural respiration. The top film is micro-perforated to control gas permeation according to product type and gas need. With this system, it was claimed that the advantage for producers and retailers is that even with an extended shelf-life, the product reaches the consumer in fresh condition, massively reducing waste. The development is apparently based on extensive studies by the University of Gent and the University of California among others to determine the optimum gas mixture. Multivac then supply packers and fillers with individual ‘tailored’ packaging solutions of ideal film, protective gas mixture and storage temperature for the best effect on the product and required shelf-life. The packaging is first evacuated, and then filled with a gas mixture in a controlled process, which substantially reduces the atmosphere filling time and the amount of gas required. A special in-line device makes microscopically small perforations in the upper web just before the package is sealed. This allows the customer to use a normal plastic film as a lid or upper web and convert it into a micro-perforated film “inline“ during the packaging process, with a variable number and configuration of holes. This allows considerable savings on consumable material. The freshness and quality of the products remain optimum until they reach the consumer – without having to use additives. The concept clearly works, as it has already been applied in various countries, including Germany, the Netherlands, Poland and Spain, and with various different products. For example, one of the largest fruit companies in Europe packs up to 1,000 tons of strawberries a week – until now using clam shell packages. This season, the company also implemented FreshSAFE with a micro-perforator. The success of the system was evaluated by a local University: in the normal packaging at 12°C, the strawberries are rotten after around 6 days – in FreshSAFE they stay fresh for 9 days and showed no signs of rotting even after 12 days. The technology of micro-perforating the top film in a controlled and specific way for each type of product allows defined amounts of oxygen to enter the pack while carbon dioxide and ethylene can escape at the same time. Degradation is delayed, enabling shelf-life to be extended. Such innovation is not necessarily relevant for all fruit and vegetables but can be beneficial for products such as soft fruits and those having a naturally short shelf life. 5.3 Antimicrobial Packaging The use of antimicrobials in packaging materials to extend the shelf-life of foods has received considerable interest in the last 20 years. While many materials have been evaluated and claimed to have efficacy, few commercial products exist outside of Japan, but using natural antimicrobials rather than chemical preservatives might be one approach to securing a longer shelf-life. Herbs and spices, such as horseradish, cinnamon, cloves, black pepper, coriander and turmeric have antimicrobial properties. Natural antimicrobials are generally not as effective as synthetic ones, so in any replacement programme, a greater quantity of plant extracts needs to be used, normally at around the 1% level in the packaging film, which can make food unpalatable. Also when it comes to bacterial inactivation, most natural antimicrobial agents are very strain specific, whereas food products generally harbour mixed cultures of micro-organisms. Many people believe that successful approaches to the use of antimicrobials must involve a number of agents as a ‘cocktail’. The final problem is that currently within the EU, labelling and the approval of food additives is still a grey area and likely to represent a significant hurdle to commercialisation of antimicrobial packaging.


5.4 Summary Both oxygen scavenging and controlled modified atmosphere packaging can extend shelf-life of fresh and chilled products without the use of preservatives. They are well-proven approaches and are likely to see greater acceptance in the future. Controlled modified atmosphere packaging is more ‘interactive’ than the current offering of modified atmosphere packaging. The Multivac technology ought to be cost-competitive since all that is involved is the creation of product-specific micro-perforations in the top packaging film as opposed to needing a range of different films according to application. There are problems with antimicrobial packaging films, suggesting that the technology still has some way to go in Europe before commercialisation.


6.0 Innovative Portion/Ready-to-Serve Packaging 6.1 Innovative Portion Packaging In French supermarkets, such as Carrefour, portion packaging is the rule rather than the exception for cooked meats, pâtés, dried fruits, nuts, and other convenience snacks such as Croque Monsieur. Many products are presented in two side-by-side plastic containers and the individual portion packs can be easily separated via a perforation along the connecting seal (Figure 12). Figure 12 Portion packaging in Carrefour for prepared meats (top) and dried fruit and nuts (bottom).

Larger portions of prepared meats and pâtés would seem especially suited to this form of packaging. In this supermarket, a 130g slice of pâte is presented as two side-by-side 65g portions, complete with two easy-open top seals (Figure 13). By contrast, in the UK many of the larger portions of pâté can be found in single packs (Figure 13) that are not resealable, increasing the chances that some portion of this type of food product will end up drying out and getting thrown away.


Figure 13 Two ways in which a larger-size serving of pâté can be packaged – in a single non reclosable pack (left) or two easy-open portions containing half servings (right). The empty weight of both packs is virtually identical.

In the UK, a different form of portioning, this time inside an individual pack of fresh vegetables, was discovered in Aldi, consisting of ideal amounts of vegetables for a single person or couple in a very simple pack (Figure 14). For these types of households, growing in number in the UK, this ought to represent a way of buying just enough potatoes and healthy vegetables for a meal without the possibility of creating some food waste by buying whole heads of cauliflower and broccoli, some of which may go uneaten. The chosen packaging solution may be capable of further optimisation. Figure 14 A vegetable selection pack from Aldi UK allows smaller households to purchase and consume healthy portions without generating significant food waste.


6.2 Individual Portions Wrapped in Multipacks From the USA, is an example of wrapping individual servings of a product inside a multi-serve package in the form of General Mills’ new Pillsbury Perfect Portions biscuits (scones) which offers five peel-open twin-pack pouches inside a bakery-style box (Figure 15, left). According to a spokesperson from General Mills, “Our research shows that consumers in smaller households are ready for a more convenient form of refrigerated biscuits that enables them to enjoy just-baked biscuits, without waste. The packaging allows people to bake just two biscuits at a time and refrigerate the rest of the dough to bake later”. Other examples found were individually wrapped ‘Pain au Chocolat’ from Asda in the UK (Figure 15, right). For portion packaging to be viable, any increases in packaging must be capable of generating a significant reduction in food waste. Rough calculations for the ‘Pain au Chocolat’ example, suggest that the increased weight of packaging represents about one fortieth of an individual pain au chocolat, suggesting that in this instance there is a strong likelihood of an overall decrease in food waste associated with the small increase in packaging waste. Figure 15 Convenience in being able to consume one or two portions at a time and store the rest may result in less food being wasted. Portion packaging may be perceived as contributing to packaging waste, but small increases in packaging may provide much larger decreases in food waste.

6.3 Serve/Storage Boxes or Containers The ‘Serve Box’ concept from Multivac is a high-quality reclosable packaging for sliced products, processed meat, cheese, and convenience/snack foods, designed for table presentation and the multiple use storage of food. The pack consists of a rigid plastic tray, sealed with a transparent plastic dome lid for optimal product visibility (Figure 16, left). Another example is from Plasti-Lax, part of Groupe Lacroix, of a reusable, resealable hinged plastic container containing either 24 or 36 Coraya brand fish sticks (Figure 16, right).


Figure 16 Left: Multipac serving boxes for sliced meats and cheese provide easy-open, easy-close packaging that can be brought straight to the table. Right: These plastic shaped and hinged containers are for the purchase and storage of ‘fish sticks’ and can be refilled from vacuum packed bags of product.

A third example is from the Madrange’s l’Etouffée brand of sliced meats in France, where TV advertisements (featuring French rugby coach Bernard Laporte) showcase the smoothly reclosable feature of the packaging once a slice or two has been consumed (see sequence pictures below taken from French TV advert, Figure 17). Figure 17 Sequence of stills from a French TV ad featuring Bernard Laporte and stressing the easy reclosable feature of the packaging for Madrange l’Etouffée sliced hams.

6.4 Summary In France, the portioning of food by packaging is ubiquitous, presumably driven by considerations of the importance of ‘freshness’ and the convenience of single portions. But it is also interesting to note the rise in the USA of portion-control packaging as a response to the problem of obesity. For example, Proctor & Gamble and Kraft have recognized a market opportunity in portion-controlled food packaging and are releasing 100-calorie packages of some of their popular snacks. Portion size is known to strongly influence consumption. (1)

It is interesting to speculate about the dynamics of food waste in the examples shown. On the one hand we have increase in the amount of packaging used, but this small increase (often fractions of a gram) might lead to several grams reduction in food waste. Better packaging for sliced meats and pâtés, etc that allow easy opening and easy reclosing is coming slowly to the UK market. This type of packaging can play a part in helping partially consumed food to remain palatable and therefore more likely to be consumed rather than wasted.


7.0 New Developments in Resealing/Reclosing 7.1 Snack Products in Adhesive-Based Resealable Packs The problem of providing easy open/reclosability features on flow-wrapped food products such as dried foods and biscuits has been neatly solved by Etik Ouest (Figure 18). The contents of a pack are accessed via panels that once opened by peeling can be reattached using an adhesive backing film. A marked edge of the package pocket is cut partly and acts as an opening aid. A tamper-evident feature is included i.e. a broken off corner shows the package has been opened. Once the package is opened, the sealing layer sticks to the package pocket, so the upper web is separated in the sealing area and exposes the adhesive layer incorporated in the film combination. This means that the pack can be reclosed repeatedly after the product has been removed and still ensures that it is air and aroma-tight. Figure 18 Easy-open/easy close features are now possible on flow-wrapped dried beans.

A similar technology is in use in the USA, where packages of Kraft Foods’ Nabisco Chewy Chips Ahoy! chocolate chip cookies have been launched with Kraft’s Snack ’n Seal resealable packaging (Figure 19). A large portion of the pack’s top can be peeled open to access the biscuits, then resealed for freshness and to keep the remaining biscuits crunchy. Figure 19 USA example of easy-open/easy close features on flow-wrapped biscuits.

7.2 Summary Reclosable pouch and bag formats for the packaging of food that is flow-wrapped is a new packaging technology that is being introduced for commercial products in Europe and the US. For UK retailers it represent an opportunity to give consumers better storage options for partially consumed food and therefore it needs to be considered as part of any food waste reduction strategy.


8.0 References (1) ‘Bottomless Bowls: Why Visual Cues of Portion Size May Influence Intake’ Brian Wansink*, James E. Painter & Jill North: Obesity Research 13, 93-100, 2005. (2) www.tendringdc.gov.uk/TendringDC/Business/Food+Hygiene/Food_Safety_at_Home.htm. (3) ‘Keeping it Safe’ Advisory Statement issued by Institute of Food Science & Technology Trust Fund, 2000. (4) ‘How cold is your fridge?’ Steve James & Chris James review recent surveys on temperatures within domestic refrigerators: Food Refrigeration and Process Engineering Research Centre, The University of Bristol; www.frperc.bris.ac.uk/home/opinion/items/item0002.htm.


Appendix 1 - Websites/Contact Details of Suppliers Mentioned in Report freshvac™ (www.freshvac.com) Lakeland (www.lakeland.co.uk): More Than Storage Boxes, Stayfresh Longer Bags, Bread Bags, Vacuum Pump, Tefal® Cheese Preserver FresherLonger™ Miracle Food Storage Containers exclusive to The Sharper Image (www.sharperimage.com - product: ZN024) It’s Fresh (www.ismyfoodfresh.com) NatureWorks® (www.natureworksllc.com) Evert-Fresh (www.evertfresh.com) Green Bags Serve ’n Store™ manufactured by the Pactiv Corporation (www.pactiv.com) Fresh-Check® TTIs from TempTime (www.lifelinestechnology.com) OnVu™ (www.onvu.com) TTIs: originally FreshPoint TTI (www.freshpoint-tti.com) Cryolog (www.cryolog.com) Multisorb (www.multisorb.com) Oxygen Scavenging Technologies: FreshPax™, FreshMax® and FreshCard™ Standa (www.standa-fr.com) Oxygen Scavenging Systems, trademarked as ATCO® Multivac (www.multivac.com) FreshSAFE Packaging Concept Long Life Solutions (www.longlifesolutions.com) Smart Bread Wrap Pillsbury (www.pillsbury.com/view/breads/perfectportions.aspx) Perfect Portions Multivac (www.multivac.com) Serve Box reclosable packaging Plasti-Lax, part of Groupe Lacroix (www.groupe-lacroix.com), reusable, resealable hinged plastic container Madrange (www.madrange.com/fr/actualites.php?actualite=13) TV advertisement showcasing reclosable packaging Etik-Ouest (www.etikouest.com) Nabisco (www.nabiscoworld.com/chipsahoy) Chips Ahoy! Snack ‘n Seal Packaging


Table of Figures FIGURE 1 FRESHVAC™ STORAGE BOXES HAVE A ONE-WAY VALVE THAT ALLOWS AIR TO BE EXPELLED

CREATING A PARTIAL VACUUM TO KEEP FOOD FRESHER FOR LONGER PERIODS. 5 FIGURE 2 TYPICAL FOODS LAST FROM BETWEEN 1.5 TO 5 TIMES LONGER WHEN STORED IN THESE

CONTAINERS, ACCORDING TO THE MANUFACTURERS. 5 FIGURE 3 FRESHERLONGER™ FOOD STORAGE CONTAINERS ARE IMPREGNATED WITH NANOPARTICLES OF

SILVER – A KNOWN ANTIMICROBIAL AGENT – THAT INHIBITS THE GROWTH OF MICRO-ORGANISMS ON

FOOD, KEEPING IT PALATABLE FOR LONGER. 6 FIGURE 4 FOOD STORAGE CONTAINERS AND ZIPPER BAGS WITH ADHESIVE FRESHNESS LABELS THAT

CHANGE COLOUR ACCORDING TO THE FRESHNESS OF LEFT-OVER OR UNCOOKED FOOD. 7 FIGURE 5 COOL BAGS ON SALE IN SUPERMARKETS IN LISBON (PINGO DOCE – LEFT) AND BOSTON, USA

(SHOP AND SAVE – RIGHT) LOCATED DIRECTLY IN FROZEN FOOD SECTION OF STORE. 8 FIGURE 6 REFRIGERATOR DEODORANT/THERMOMETERS ON DISPLAY NEXT TO THE CHILLED FOOD SECTION

IN CARREFOUR, CALAIS. THE ‘OK’ STICKER ON THE SIDE OF THE DEVICE TURNS BLUE WHEN THE

REFRIGERATOR TEMPERATURE IS BELOW 5˚C. 9 FIGURE 7 FOOD LABELLING INFORMATION REGARDING THE CORRECT REFRIGERATOR TEMPERATURE FOR

STORAGE OF FOOD ACROSS UK RETAILERS CAN BE EITHER GENERAL (LEFT) OR SPECIFIC (RIGHT). 10 FIGURE 8 A COMPOSITE PICTURE SHOWING THE ONVU™ COLOUR CHANGE TTI LABEL FADING FROM BLUE

TO WHITE AS A FUNCTION OF TIME AND TEMPERATURE. INCREASES IN TEMPERATURE HAVE A

SIGNIFICANTLY GREATER EFFECT ON THE COLOUR CHANGE RATE COMPARED TO CHANGES IN TIME. 11 FIGURE 9 THE (EO)® TTI CHANGES COLOUR DIRECTLY FROM GREEN TO DARK RED WHEN THE ‘USE BY’

DATE IS REACHED. 12 FIGURE 10 TRACEO® IS A COLOURLESS TTI LABEL THAT COVERS A BARCODE. IT CHANGES TO A RED

COLOUR ONCE THE FOOD PRODUCT HAS REACHED ITS USE BY DATE, RENDERING THE BARCODE

UNRECOGNISABLE BY THE SCANNER AT CHECK-OUT. 13 FIGURE 11 TRADITIONAL BAKERY PRODUCTS SOLD AT FRENCH MARKETS AND SPECIALTY SHOPS USE

OXYGEN SCAVENGING SACHETS TO PROVIDE THE REQUIRED SHELF-LIFE WITHOUT THE USE OF

PRESERVATIVES. 14 FIGURE 12 PORTION PACKAGING IN CARREFOUR FOR PREPARED MEATS (TOP) AND DRIED FRUIT AND NUTS

(BOTTOM). 17 FIGURE 13 TWO WAYS IN WHICH A LARGER-SIZE SERVING OF PÂTÉ CAN BE PACKAGED – IN A SINGLE NON

RECLOSABLE PACK (LEFT) OR TWO EASY-OPEN PORTIONS CONTAINING HALF SERVINGS (RIGHT). THE

EMPTY WEIGHT OF BOTH PACKS IS VIRTUALLY IDENTICAL. 18 FIGURE 14 A VEGETABLE SELECTION PACK FROM ALDI UK ALLOWS SMALLER HOUSEHOLDS TO PURCHASE

AND CONSUME HEALTHY PORTIONS WITHOUT GENERATING SIGNIFICANT FOOD WASTE. 18 FIGURE 15 CONVENIENCE IN BEING ABLE TO CONSUME ONE OR TWO PORTIONS AT A TIME AND STORE THE

REST MAY RESULT IN LESS FOOD BEING WASTED. PORTION PACKAGING MAY BE PERCEIVED AS

CONTRIBUTING TO PACKAGING WASTE, BUT SMALL INCREASES IN PACKAGING MAY PROVIDE MUCH

LARGER DECREASES IN FOOD WASTE. 19 FIGURE 16 LEFT: MULTIPAC SERVING BOXES FOR SLICED MEATS AND CHEESE PROVIDE EASY-OPEN, EASY-

CLOSE PACKAGING THAT CAN BE BROUGHT STRAIGHT TO THE TABLE. RIGHT: THESE PLASTIC SHAPED

AND HINGED CONTAINERS ARE FOR THE PURCHASE AND STORAGE OF ‘FISH STICKS’ AND CAN BE

REFILLED FROM VACUUM PACKED BAGS OF PRODUCT. 20



FIGURE 17 SEQUENCE OF STILLS FROM A FRENCH TV AD FEATURING BERNARD LAPORTE AND STRESSING

THE EASY RECLOSABLE FEATURE OF THE PACKAGING FOR MADRANGE L’ETOUFFÉE SLICED HAMS. 20 FIGURE 18 EASY-OPEN/EASY CLOSE FEATURES ARE NOW POSSIBLE ON FLOW-WRAPPED DRIED BEANS. 21 A SIMILAR TECHNOLOGY IS IN USE IN THE USA, WHERE PACKAGES OF KRAFT FOODS’ NABISCO CHEWY CHIPS

AHOY! CHOCOLATE CHIP COOKIES HAVE BEEN LAUNCHED WITH KRAFT’S SNACK ’N SEAL RESEALABLE

PACKAGING (FIGURE 19). A LARGE PORTION OF THE PACK’S TOP CAN BE PEELED OPEN TO ACCESS THE

BISCUITS, THEN RESEALED FOR FRESHNESS AND TO KEEP THE REMAINING 21

Written by: Paul Butler Packaging Materials & Technologies Ltd www.smartpackaging.co.uk

Published by Waste & Resources The Old Academy Tel: 01295 819 900 Helpline freephone Action Programme 21 Horse Fair Fax: 01295 819 911 0808 100 2040 Banbury, Oxon E-mail: [email protected] OX16 0AH www.wrap.org.uk

http://www.smartpackaging.co.uk/

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