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Global Trends Packaging Requirements
Packaging and Processing
Source: Standard Chartered
The Middle Class Spending Journey
Middle class rise
Increase in available
consumer credit Small amount to
LARGE number
LOW income
Purchase BIG ticket :
Electronic,Furniture,
Auto
lifestyle
Choose where to shop or
entertained.
Farther home
Increase demand for
travel and leisure service
Greater emphasize for
entertainment and leisure Retirement
Healthcare
Child education
Increased demand
for financial
services
means Modern living FMCG
drive the growth
Fast growing segment (>15%)
Years ahead : Indonesia retail growth 2nd best after china
Megatrends
•Convenient
•Healthy
•Feel good
•Look good
Brand engagement to boost consumption
We - commerce
Easy to use packaging
The Business
Stuck on the -er words
• Bigger
• Brighter
• Better
• Stronger
• Faster
• Easier
• Newer
• Cheaper !
imagin
Co
pyr
igh
t ©
2013
Th
e N
iels
en C
om
pan
y. C
on
fid
enti
al a
nd
pro
pri
etar
y.
31
No differentiation means price
More Convenient
Anytime, anywhere
HOW YOU CREATE POSSIBLE
SURPRISE
THAT KIDS AND FAMILY LOVE …
Experience Economy
Lets move
The Magic Triangle of Packaging:
Customer
Packaging Material Packaging Machine
Packaging System
Functionality
compliance
Globalization Customer Delivered Value Networked Technology Product Life Cycle Compression Supply Chain Management Mass Customization Digital Business
Productvalue
Servicesvalue
Personnelvalue
Imagevalue
Total customer valueTCV
Monetarycost
Timecost
Energycost
Psychiccost
Total customer costTCC
Customer delivered valueCDV
CDV = TCV - TCC TCV = Bundle of benefits expected from product TCC = Bundle of costs expected to evaluate, obtain,
and use the product
Raw Material Suppliers
Converters (at full capacity/overcapacity)
Food/Pharma Manufacturers
Consumers
Converters are squeezed
Design Process
Packing Process
Distribution Process
HIGH-PERFORMANCE BARRIER FILMS: Examining Global Trends from Our Perspective
The global packaging market is huge; offering many opportunities in barrier packaging, led by flexibles.
N. America and Europe account for roughly 55% of global packaging value, but growing at slower rates than rapidly developing regions such as Asia
Global Packaging Market(value of shipments-all structures)
$450 Billion
Annual Growth2-3%
(>5% Asia)
High-performance barrier packaging films is specific, as follows.
Film structures providing high barrier levels to oxygen, water vapor,aromas/flavors, and/or UV light
– A barrier film is usually a coextruded, coated, or metallized substrate
– Barrier components include PVdC resin/coating, EVOH, nylon, MET films,or Al2O3 or SiOx
– But excludes all structures that use Al foil as the barrier, paper as astructural member, or MET films used only for graphic enhancement
Film structures <10 mil (e.g. multilayers of printed layer, barrier & sealant)
Includes film structure laminations (with a barrier film), or a coextrusioncontaining a layer of barrier resin, or a substrate coated with a barriermaterial that might also function as a sealant
A mono-structure of only barrier film is very rare; real value is created when the barrier film is a ‘component’ that enables the final package
The market for H.P. barrier packaging films is positively influenced by many factors.
Cost ReductionRigids to flexible; less R.M. & lower freight
Process ImprovementCoEx & laminatesoffset resin cost
High growth ofConvenience food
Home Ready - Ready to Cook
Smaller packagesMore barrier needed,
Higher surface-volume ratioAlternative Packaging
Smart, security, reclosability, etc.
Market forMarket forHigh PerformanceHigh PerformanceBarrier PackagingBarrier Packaging
FilmsFilms
Geo-Cultural & Trade
Impacts
Our focus is on food packaging, with some comments on medical devices
Business opportunity emanates from the value chain continuum of application, film and structure.
PackageStructure
Markets &Applications Barrier Film
Perishable Food-Fresh meat-Prepared food-Processedmeat & cheese
Dry Food-Confections &snack bars
-Pet food-Snacks &baked snacks
Medical & others
PVdCEVOHNylonMetallizedSpecialty oxidesCoEx. &laminates
BagsLid stockStand-uppouchesFormingwebWraps
Barrier Film
Package Structure
Markets & Applications
BusinessOpportunity
Barrier Film
Package Structure
Markets & Applications
BusinessOpportunity
US H.P. Barrier Film$1.2 BIL
We use sophisticated applications model to combine film & package conversion costs, area and package structure to determine various market size relationships
StructureFilm Markets
The overall barrier film market is forecast to grow at a good AAGR of 4.8% over the next five years.
0
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Overallmarket, 4.8%
Aver
age
annu
al g
row
th, %
Perishable food Dry food
Freshmeat
Processedmeat
Cheeseand dairy
Preparedfood
TotalPerishable
Food($950 MIL)
Snackfood
Bakedsnacks
Drymixes
Confectionsand snack bars
Petfood
Coffee
TotalDry Food
($250 MIL)
Largest Share82% Perishables
Smallest3% of Perishables
Largest Share70% Dry Food
Coffee & Pet Small Share<5% of Dry Food
StructureFilm Markets
In perishable food, consumption of barrier films for fresh-meat applications is to grow AAGR of 5.6%.
Key Stats: Fresh Red Meat:•$720-740 MIL Film•5.6% Growth/yr•82% of Perishables•67% of Barrier Pkg
Examples:•Case-ready red meat focus•Pork & poultry alreadycase-ready & maturing
Penetration of case-ready meat to drive growth of barrier films
Trend toward the production of more case-ready red-meat products
Increase in the use of shrink bags for case-ready and value-added products
Refrigerated space allocated for fresh meat expected to decline, asconsumers demand convenience products; i.e. need increased O2 barrier &shelf life
StructureFilm Markets
Processed meat, cheese and dairy segments will exhibit more steady growth, at about 3-3.5%.
Key Stats: Proc. meats, cheese, dairy:•$100-110 MIL Film•3-3.5% Growth/yr•14% of Perishables•11% of Barrier Pkg
Examples:•Deli meat & cheese slices•Natural chunk cheese•Milk, pudding, yogurt
The image of processed meats (deli) as unhealthy is changing, with someproducts now viewed by consumers as convenient sources of protein
The use of barrier films to package cheese will continue to increase asconsumers’ preference for natural cheese continues to grow at the expense ofprocessed cheese that requires less barrier packaging
Consumer demand for smaller, more convenient packages will contribute to theincrease in barrier film consumption
Cost reduction will continue to drive the trend toward replacement oflaminations with coextrusion technology
StructureFilm Markets
In dry-foods, consumption of barrier films for dry-mixes is forecast strong AAGR of 4.2%.
Key Stats: Dry mixes:•$25-30 MIL Film•4.2% Growth/yr•12% of Dry Foods•2% of Barrier Pkg
Examples:•Cake mixes•Pudding powder•Powder flavoring
The dry food category is much smaller than perishables at about $250 MIL,or 20% of barrier film share
Dry mixes is a relatively small part of the dry food category, driven byconsumer preference for standup pouches and away from rigid packaging
To reduce investment risk, many companies are increasing the use ofcontract packagers as a means of converting to standup pouches
Trend toward clear packaging to view contents favors clear barrier filmsolutions
StructureFilm Markets
Snack-foods & baked-snacks to have respective modest growth, at AAGR of 2.3% & 2% each.
Key Stats: Snack food/baked-snacks:•$160-170 MIL Film•2-2.5% Growth/yr•79% of Dry Foods•16% of Barrier Pkg
Examples:•Chips, nuts, cookies, driedfruits, raisins, etc
•Baked (healthy snacks) –no preservatives
One of the biggest trends in snack foods is the move toward productspackaged in single servings that are easily portable and consumed on-the-go; we work 24/7, have a family and need convenience
The snack food category will continue to move away from rigidcontainers in favor of flexible packaging (SUP), with new introductions bymajor suppliers of snack nuts, cookies, and most recently, crackers
The use of barrier films in the baked-snack segment is expected toincrease overall, driven by consumer desire for healthier products thatrequire more protection from moisture and oxygen to retain freshness
StructureFilm Markets
High-growth expected in perishable foods for EVOH & Al2O3-PET films (8%+); in dry-foods PVdC-PET (9.2%).
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9
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Overallmarket, 4.8%
Aver
age
annu
al g
row
th, %
Perishable food Dry food
PVdC45%
EVOH25%
Nylon25%
PVdC-coated
PET
TotalPerishable Food
($950 MIL)
Al2O3-coated
PETMETnylon
SiOx-coated
PET
PVdC-coated
PP
PVdC-Coated PP
50%MET-PP
35%
MET-PET10%
PVdC-coatedPET
EVOH
TotalDry-Food
($250 MIL)
METPETFresh &
Processed Meats
Fresh Foods, Meats & Tray
Lidding
Fresh Foods, Meats &
Lam-Trays
Retort; Japan & Europe interest
Retort; Japan & Europe interest
High-growth, but small
market today
Snacks & Baked
Snacks & Baked
Displacing PVdC
SUP Clarity Applications
StructureFilm Markets
Primary converters of shrink bags for fresh & processed meat entrenched in PVdC CoEx-tech.
Although PVdC is inherently difficult to process, primary converters of shrink bags for packaging fresh and processed meat (Cryovac, Curwood,and Amcor) are entrenched in PVdC coextrusion technology for narrow web
Dow has introduced patented encapsulation technology to blow multilayerfilm and for producing wider width substrate. Licensing of this technology islikely to spur growth of PVdC resin for blown multilayer film
New growth markets for PVdC include lid stock and retort applications forprepared foods, which require moisture stability
Despite environmental issues, PVdC is still widely used for shrink bags inEurope, and its use in the U.S. does not appear to be a threatened
StructureFilm Markets
PVdC-coated PET, used as lid-stock & inner ply of clear standup pouches for is growing.
Increase in the use of PVdC-coated PET lid stock for packaging preparedfoods – MAP, hot-fill and retort
The use of PVdC-coated PET in packaging processed meats will decline
Lamination and coating processes are being displaced by coextrusions
However, PVdC-coated PET, commonly used as the inner ply of standuppouches for snack foods, dry mixes, and pet food, is expect to grow forapplications requiring clarity
BARRIER COATED FILMS
Barrier Coated Moisture Barrier Films on BOPP, on PET and on NYLON
are specially coated films to enhance Moisture Barrier and Oxygen
Barrier. There are able to reduce Moisture Barrier and Oxygen Barrier by
more than 50 % of uncoated plain films. It is also more cost effective than
PVDC and EVOH. The Barrier Coating materials is 100% Waterbased.
And this film totally environmentally friendly. It is proven to be more
cost effective, when compared to 3 or 4 layers laminating structures
without compromising the Moisture/Oxygen Barrier of the Packaging.
Most importantly these Films are able to reduce Carbon Footprint in
Flexible Packaging by minimum 10%.
MOISTURE / OXYGEN BARRIER OF VARIOUS FILMS &
COATINGS
* Total Film+ Coating Thickness 25µ gms/sqm gms/100 in² cc/sqm cc/100 in² EVOH* Dry 0.20 0.01
Moist (90%RH) 58.90 3.80 2.70 0.17 HB-PVDC* 0.78 0.05 1.20 0.08 PVDC (15µ BOPET) ∆ 14.00 0.90 6.00 0.40 HDPE 25µ ∆ 9.00 0.30 3,000.00 195.00 LDPE 25µ ∆ 18.00 1.20 8,000.00 519.00 CPP 25µ ∆ 12.00 0.80 4,200.00 272.00 BOPP 20µ ∆ 8.00 0.50 2,500.00 162.00 MYLAR™ BOPET 12µ ∆ 40.00 2.60 140.00 9.00 BOPA 15µ ∆ 250.00 16.20 90.00 5.80 K-BOPET 15µ 5.40 0.35 7.00 0.45 K-NYLON 17µ 4.00 0.25 6.00 0.40 EVAL™ EF-CR 15µ ∆ 142.00 9.20 1.50 0.10 EVAL™ EF-XL 15µ ∆ 29.00 1.90 1.00 0.06 BICOR™ 20MB666 7.00 0.45 1,000.00 65.00 BICOR™ 21MB866 (PVOH) 4.00 0.26 0.70 0.05 Barrier Coated-P20 (BOPP 20µ) 5.00 0.30 1,210.00 79.00 Barrier Coated-P18NS (BOPP 18µ) 6.00 0.40 8.00 0.50 Barrier Coated-P20NS (BOPP 20µ) 5.30 0.35 8.00 0.50 Barrier Coated-T12NS (BOPET 12µ) 14.00 0.90 4.60 0.30
MVTR (24 hrs/38°C/90%RH) OTR (24 hrs/23°C/1 ATM)FILMS
* Coated on BOPP 25µ Films
BarrierCoated Films Tested by Labthink Instruments Co., Ltd. On Perma W03/030 MVTR Unit (ASTM F1249) & Perma OX2-231 OTR Unit (ASTM
D1434) Source *: Current Technologies in Flexible Packaging- STP 912 by Michael L. Troedel
Source ∆: Dupont Teijin Film™ Specification Sheet.
BICOR™ is a product of ExxonMobile
EVAL™ is a product of Kuraray Co., Ltd.
MYLAR™ is a product of Dupont Teijin Film™
Polyamide provides
oxygen and aroma barrier
heat resistance
good mechanical properties
thermoformability
Polyethylene provides
high water barrier
sealability
multilayer film combines properties of multiple components
Multi-layer Film
2
5-layer PE/tie/PA/tie/PE
+ PA protected from humidity
7-layer PE/tie/PA/tie/PA/tie/PE
+ split PA - improved thermoformability
7-layer PE/tie/PA/EVOH/PA/tie/PE
+ very high barrier
+ good thermoformability
● 9-layer PE/PE/tie/PA/EVOH/PA/tie/PE1/PE2
+ sealing PE + antiblock/slip in PE1
+ reclosable in PE2
Coextrusion Film: Symmetric Structures
5
+ fast sealing due to heat-resistant PA skin layer
- curl
● 3-layer PE/tie/PA
● 5-layer PE1/PE2/PE2/tie/PA
+ sealing material, antiblock/slip in PE1
+ simple polyolefins in PE2
● 5-layer PE/tie/PA/tie/PA
+ split PA - improved thermoforming
● 5-layer PE/tie/PA/EVOH/PA
● 7-layer PE/tie/PA/EVOH/PA/tie/PA
● 9-layer PE/tie/PA/EVOH/PA/tie/PE/tie/PA
Coextrusion Film: Asymmetric Structures
6
Double/Triple bubble process
o Extrusion (downward/watercool)
o Blow-up
o Annealing
40-50% shrink
For :
o shrink bottom seal bags
o shrinkable lidding for rigid tray
o shrinkable bottom + lidding film
Shrink Bag / Shrink Film
10
StructureFilm Markets
Growth in case-ready MAP for fresh meat will translate into growth for multilayer EVOH film.
EVOH coextrusions in packaging processed meats and cheese willcontinue to displace more expensive PVdC-coated films
Trend toward clear EVOH/nylon structures as replacements for METPET in prepared foods and bag-in-box wines
EVOH to continue growing in laminated food trays
StructureFilm Markets
MET PP has all but replaced higher-priced MET PET in the snack foods category.
MET PP is the film of choice in packaging candy and snack bars (graphicsappeal)
Use of MET PET as the inner ply of standup pouches for snack foods, drymixes, and pet food will continue due to good dimensional stability and heatresistance are critical
The use of MET PET bags in foodservice applications, will continue to growwith the trend toward clear barrier films, replacing metal cans
StructureFilm Markets
Barrier packaging films for lid stock & standup pouchesin the food sectors forecast to grow at above rates.
Lid stock
-4
-2
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Overallmarket, 4.8%
Aver
age
annu
al g
row
th, %
Perishable food Dry food
Lidstock
Bags
Standuppouches
Wraps Totalperishable
foodsegment
Bags Wraps Totaldry-foodsegment
Formingweb
Standuppouches
interestAbove average growth
Above average growth
Above average growth
StructureFilm Markets
Bags continue to be the major flexible barrier packaging structure, growing at average rates.
Bags are extensively used in packaging dry foods — most are pillow packs & bag-in-box type, supplied as rollstock to end users to run on form/fill/seal lines
Square-bottom bags, used to package coffee, becoming popular for other dryfood with improved graphics, reclosability & overall cost reduction vs. bag-in-box
Increases in oil prices will continue to fuel growth in 1 gal foodservice bags asreplacements for #10 metal cans
The use of barrier shrink bags for packaging case-ready & processed meatsgrowing at about 3-4%, led by convenience products - fresh meat & cooked
StructureFilm Markets
Standup pouches are being introduced into every category of dry-foods to differentiate products.
Standup pouches with zippers offer reclosability, improved barrier & materialsavings in a one-component flexible package vs. multi-component rigidcontainers they are replacing for packaging dry food
Rising fuel prices drive the trend toward metal can replacement with standuppouches; one truckload of flat bags/pouches equals 25 truckloads of cans
Sales of shelf-stable foods in retort pouches grown 20-30% in recent years,reaching $100 MIL in pouches. Many are foil laminates with clear barrier films
Standup pouches are also gaining popularity for packaging processed meatslike bacon bits and pre-cooked bacon.
Thermoforming
– forming (bottom) web
– lidding
Bags
– tubular bags
– side-seal bags
Pouches
– VFFS vertical form/fill/seal
– HFFS horizontal form/fill/seal
Shrink Bags / Film
Barrier Film Applications
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PE/tie/PA 75-150µm Heavy bulk bags (unprinted)
CPA//PE 75-150µm Bulk bags
BOPA//PE 60-120µm Printed pouches
PE/tie/PA/tie/PE 60-100µm Pouches /face-to-back sealing
BOPET//PE/tie/PA/EVOH/PA/tie/PE
60-100µm
High-barrier pouches (printed)
BOPET//Alu//BOPA//PE
90-120µm
High-barrier pouches for
retort applications
Typical Bag/Pouch Film Structures
PE / tie / PA
CPA // PE
BOPA // PE
BOPET // (PE/tie/PA/EVOH/PA/tie/PE)
70-120µm
thickness of lidding film is determined as the residual wall thickness of formed web
Typical Structures of Lidding Film
8
Going forward, the outlook for high performance barrier packaging films is very positive.
Large and non-cyclical market
Sustainable growth drivers– Cost reduction– Convenience-oriented food– Smaller packages– Demand for alternate packaging formats
Product Name Existing Developing
Detergent Powder:Philippines,Indonesia.
PET (12µ)/Print/LLDPE (45µ)
OTR: 200gm/m²/24hrMVTR: 7.0gm/m²/24hr
• 2 Ply Laminate Structure
Barrier Coated-P35NS/Print/LTS2502,LTS2502H
OTR: 5.0gm/m²/24hrMVTR: 2.0gm/m²/24hr
• 1 Layer Structure
•Coated-P35NS : BOPP 35µ
Global Customer Move
Pattern Coat, 3 gsm for Sealing
Purpose: Reduce Plastics Consuming from 2 Layers to 1 Layer.
ProductName
Existing Developing
Snacks/Chips:Indonesia,
South Africa-NAMPAK Flexible
Packaging.
• PET/Print/MPET/LLDPEOTR: 1.20gm/m²/24hrMVTR: 0.90gm/m²/24hr
• PET/Print/PE/MPET/LLDPEOTR: 1.0gm/m²/24hrMVTR: 0.75gm/m²/24hr
Barrier Coated-P18NS/Print/VMCPP OTR: 0.15gm/m²/24hr MVTR: 0.80gm/m²/24hrorBarrier Coated-T12NS/Print/VMCPP OTR: 0.07gm/m²/24hr MVTR: 0.90gm/m²/24hr
• 2 Layers
•Coated-P18NS : BOPP 18µ•Coated-T12NS : BOPET 12µ
Global Customer MovePurpose: Reduce Plastics Consuming from 3-4 Layers to 2 Layers.
Product Name Existing Developing
Instant Noodle:Malaysia,Indonesia
Salad/Vegetables:Australia
BOPP/Print/PPOTR: 1100gm/m²/24hrMVTR: 5.0gm/m²/24hr
BOPP/Print/PEOTR: 1300gm/m²/24hrMVTR: 5.0gm/m²/24hr
PET/PRINT/LLDPEOTR: 200gm/m²/24hrMVTR: 7.0gm/m²/24hr
•2 Ply Laminate Structure
BARCO-P35NS/Print/LTS2502,LTS2502HOTR: 5.0gm/m²/24hrMVTR: 2.0gm/m²/24hr
• 1 Ply Laminate Structure
•BARCO-P35NS : BOPP 35µ
Global Customer Move
Pattern Coat, 3 g. for Sealing
Purpose: Reduce Plastics Consuming from 2 Layers to 1 Layer.
Cost Competitive StudyProductName
Existing Structures Laminating Structures using Barrier Coated Films
InstantCoffee:
Indonesia
A)PET/Print/Al/LLDPEOTR: 0.20gm/m²/24hrMVTR: 0.30gm/m²/24hrCost/100sqm: USD 42.00
B)PET/PRINT/VMPET/LLDPEOTR: 1.20gm/m²/24hrMVTR: 0.90gm/m²/24hrCost/100sqm: USD 37.00
C)PET/PRINT/VMPET/CPPOTR: 1.60gm/m²/24hrMVTR: 0.80gm/m²/24hrCost/100sqm: USD 26.50
•3-Ply laminate Structures
Barrier Coated-P18NS/Print/VMCPP OTR: 0.15gm/m²/24hr MVTR: 0.80gm/m²/24hrCost/100sqm: USD 26.50
• 2-Ply Laminate Structures.
• Coated-P18NS : BOPP 18µ
•58% lower cost with Coated 2-Ply > (A).•39% lower cost with Coated 2-Ply > (B).
Reduction of laminating structures from 3 Layers to 2 Layer.
In pharmaceuticals, flexible H.P. barrier packaging is insignificant; growth of unit-dose blister packs
The pharmaceutical segment is comprised of prescription drugs, medications, and dietarysupplements sold over-the-counter (OTC)World demand for pharma packaging to reach $24 BIL in 2009, increasing 4-5% annually.80% of demand from the US, Japan, China, Germany, France, UK, Italy, & Switzerland. The USwill remain the largest consumer driven by aging baby boomersBlister packaging is the fastest-growing segment of the pharma market. Worldwide demandexpected to grow 7% AAGR, reaching $5.6 BIL by 2009, driven by unit dose & sterile applicationsIt is estimated that less than 1% of all pharmaceuticals are packaged in barrier films, as definedby our definition and therefore not a significant consuming segment of barrier filmsHowever, future barrier may be needed to maintain drug potency or inhibit degradation. Amoisture barrier is critical for gels or liquids, sensitive to moisture loss. Foil used for UV barrierIn addition to unit-dose blister packs, companies are converting to flexible pouchesUnit doses maintain the ‘five rights’ of medicine monitoring: Right patient, right drug, right dose,right time, and right route of administration. Thus safer & tamper resistantNew delivery systems, nasal, transdermal and parenterals in home-care and self-care applicationsalso growing - not having to visit a doctor’s office cuts costs and saves timeKey trend is aging population - 75% of pharma consumers are senior citizens
– Healthy lifestyle & fitness craze has fuel popularity of vitamins and dietary supplements– The market for cosmeceuticals also experiencing rapid growth - aged refuse to look old– Opportunities exist for the growth of barrier films in alternative pharma delivery. The use of
Al2O3- and SiOx-coated films are expected to grow in niche applications
Packaging opportunities gleaned from other regions.
Drivers Western Europe China & Japan
ConsumerPreference
Traditional frequent trips to marketFew long lunches at home; grab-n-goHigher income – spend more at stores
Rapid lunches-aesthetics outweigh costsLocal shops provide flexible single serveRefrigerator limitations (small or none)
Low birth-rateMore singles & elderlyDisplaced families - move to coastal cities
Environmental directives affect plastics useSpace and waste reduction, recyclingEnergy from incinerationEye-catching aesthetics importantEnvironmental awarenessWant more efficient products, i.e. reducepackage size - easy to store/use
Packagers switch to new materialsLess concern on amortizing investmentsUsing new barrier films for perishable foodJapanese resin innovation, e.g. Mitsui
Demographics Smaller families – singles,working womenGrowth in aged and non-married womenSmall apartments, urban pop. densitySmaller package – growth of single-serve
Environment European Union packaging directiveSpace and waste reduction, recycling
PromotionMarketing
Package catches the consumer’s eyeBrand owner marketing influenceBrand owner environmental awarenessPerception that less is more; buy efficientproducts, e.g. dry detergent; smaller size
InnovationTechnology
New solutions – quick digital printing, e.g.– team logo on package, quick to shelf
Use of alternative substrates, e.g. barrierNew resin technology drives innovation
–- e.g. Topas COC, new metallocenes
Europe & Asia markets have similarities and yet differences vs. the US; but, flexibles are favored.
Europe– Improved package shelf-life; high-quality techno-product needs; new advances in
flexible aseptic dairy packaging - flexibles environment & disposal convenience– Bundle brand recognition and functionality with new flexible designs– Coffee in single portion flexibles to increase convenience; coffee in regular size flex
packs increase product quality, brand differentiation– Growth in frozen food flexible packaging market due to stronger brand development
and increased popularity of prepared foodsAsia
– Improved aesthetics via flexible constructions; improve recloseability and dispensingsystems, less freight for flexibles (China is key)
– Japan leads in different MAP balances for different products; create new asepticflexible packaging designs; unique combination of materials for new function
– Flexible structures to withstand pasteurization at 116 degrees C - crucial in thesterilization of low-acid foods like milk, meat and vegetables.
– Need shelf-life with no significant difference in taste, compared to glass– Compared to Japan, the rest of Asia is less advanced in packaging. Many rely on
innovations from Japan and West; advances from S. Korea, Singapore & Taiwan– Packaging materials in Japan, Singapore, Korea are influenced by disposability
recycling laws; incineration laws ban PVC; China’s new 5-year plan pro-environment
To summarize, opportunities are created when your solution meets the unmet needs of end users.
Adhesive &Ink
Producers
SpecialtyFilm
Producers
Resin Producers
Con
vert
ers
Increasing difficulty of communication
Packagers/Brand
Owners/Retailers
Packagers/Brand
Owners/Retailers
MaterialsSuppliers
Technologies:LaminationCoextrusionAdhesionPrintingConversion
Materials/ Resin
Influencers
Materials:PETEVOHNylonPolyolefins
Capturedvalue
Needs-based analysis is difficult
due to communication / business-related
industry barriers…
TechnologyInfluencers
Protection and integrity Quality and safety Shelf-life Environmental respect Supply Chain handling and identification On-Shelf/ Off-Shelf needs
Image and appearance Aesthetic and appeal Brand awareness Visual Communication Display needs
Cost competitiveness Manufacturing and supply chain performance Machinability Specifications Modularity and flexibility
Emotion / satisfaction Consumer benefits Differentiation Information
Ergonomic Convenience Easiness and comfort
Any package is a Combination of three Core Requirements influenced by four main Factors
Worldwide Regulatory Compliance
All information available required by the FDA guideline “Container Closure Systems for Packaging Human Drugs and Biologics”. All information available required by the EU guideline EMEA “Plastic Immediate Packaging Materials” (May 05). An up to date DMF type III is on file at the FDA and reviewed in conjunction with NDA’s on a regular basis All production facilities are ISO9001 certified All production facilities work under cGMP standards.
Goal: trouble free global submissions of new products in USA, Europe and Japan:
Packaging Center New: camera inspection system operational
Position on the reel Type of defect, Size of defect,
AFAP Product Safety System Description - Documents Product Safety Policy Statement
Product Safety Policy
Raw Material Approval
• Questionnaires for suppliers• Procedure
Product Development
•Questionnaire forcustomers •Documents of Compliancetemplates • Procedure (PSCS)
Documented Change Control
•Procedure and standard•Template for temporary deviation tocommercial spec
Product Safety Excellence Base (PSEB)
audit document
Product Safety Alert
• Procedure• Template
• higher level of convenience & functionality
easy opening
dispensing systems
reclose options
valves
design
• product differentiation
Add-on features and design
Proprietary & Confidential ©2014 Printpack, Inc. All rights reserved.
100% Degradable applications
Stretch Wrap
Carrier Bags
Food Packing Trays
Garbage bags
Healthcare
Bubble Wrap
Label & tapes
Stretch Films
Cutlery and Cups
Slider Zip lock Bags
Flower wraps
Bread Bags
Process Product
Material
• Flavored carbonated soft drinks, such as colas,are micro-biologically stable, i.e. “not sensitive”
• Micro-organism can’t grow in the beverages,due to:• Very low pH• High CO2 level• No fruit juice content
Definition
• Package is sterilized andbeverage is bottled in acold aseptic environment
• Milk, juice, tea, andisotonics are possiblecandidates for asepticfilling
5-Jul-12
103
• Commercial sterility is “the absence ofmicroorganisms capable of reproduction inthe food under normal conditions of storage anddistribution”• not necessarily kill the germs, but make sure
they cannot multiply• Inhibit the process
• “Commercial sterility” and “sterility” are twodifferent concepts
56
• Carbonation or sugar content• Preservatives• Hot Filling• Aseptic Filling• In bottle sterilization
• Pasteurization• Retort
• Selection of filling methods dependupon:• Product• Cost• Brand image• Shelf life expectation
57
Technique Strength Weakness
Peroxyacetic Acid (PAA) Well established Cold Sterilant
Needs rinsing Strong Smell Wet Environment Long Treatment
Hydrogen Peroxide Well established for Peroxide residues high cartons temperature requirement
Ozonized Water Unknown Efficiency Level
UV Irradiation Simple, no residues Shadow Effect
Gamma Irradiation Well established in medical application
Expensive Batch Process
Heat (Steam, air) Used widely for machine sterilization
Not possible for heat sensitive plastics
Aseptic Filling Line
Sources: Krones
24-Mar-14 110
