“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.

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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.

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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.

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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.)

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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.

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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

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Photosource: EverFresh

Sachets Based on Ethylene Scavengers

Antimicrobial

Technology

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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.

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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”

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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

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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)

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GardIn Fresh's FreshExtend nanotechnology uses a silver coated

nanoparticle additive to retard food spoilage

Bio Degradable Packaging

Concepts

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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

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Sustainable Whey Based Protein Packaging

Figure : Whey-based Composite Film Layers

(Source: Wheylayer Consortium)

Aseptic Packaging Concepts

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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

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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.

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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