25 Integrating intelligent packaging, storage and distribution T. Jarvi-Kaariainen, Association of Packaging Technology and Research. finland All engineering, manufacturing, quality and sales efforts are wasted if your transport packaging fails and your customer receives a damaged product'’(ISTA) 25 1 Introduction: the supply chain for perishable foods Food is a perishable product. It is temperature-, moisture-, and time-sensitive, compared to books, automobile parts, and clothes, however they are shipped globally. The present systems for improving logistics, ordering and networks may cause the special nature of food to be ignored. The new IT systems are first applied to expensive, valuable products, not to commodity products, such as food. Then the commodity products must adapt to the systems, which exist even if the producers have not taken part in the development work 25.1.1 Growth seasons and specialities in different areas of the world In many parts of the world there is only one yearly growing season yielding only one or two crops in a year. However, consumers prefer to eat both fresh produce and the specialities of specific areas the year round. This means that foodstuffs may be transported to the other side of the world Some foodstuffs(canned food, aseptic packages, dried food) can be stored at room temperature. They are not sensitive to small temperature changes if they have been correctly packed. The quality and safety of frozen, chilled, and fresh food tolerates only a very narrow temperature range. Also chilled and fresh food has a limited shelf-life. An average employee in the food industry knows these
‘All engineering, manufacturing, quality and sales efforts are wasted if your transport packaging fails and your customer receives a damaged product’ (ISTA).1 25.1 Introduction: the supply chain for perishable foods Food is a perishable product. It is temperature-, moisture-, and time-sensitive, compared to books, automobile parts, and clothes, however they are shipped globally. The present systems for improving logistics, ordering and networks may cause the special nature of food to be ignored. The new IT systems are first applied to expensive, valuable products, not to commodity products, such as food. Then the commodity products must adapt to the systems, which exist even if the producers have not taken part in the development work. 25.1.1 Growth seasons and specialities in different areas of the world In many parts of the world there is only one yearly growing season yielding only one or two crops in a year. However, consumers prefer to eat both fresh produce and the specialities of specific areas the year round. This means that foodstuffs may be transported to the other side of the world. Some foodstuffs (canned food, aseptic packages, dried food) can be stored at room temperature. They are not sensitive to small temperature changes if they have been correctly packed. The quality and safety of frozen, chilled, and fresh food tolerates only a very narrow temperature range. Also chilled and fresh food has a limited shelf-life. An average employee in the food industry knows these 25 Integrating intelligent packaging, storage and distribution T. Ja¨rvi-Ka¨a¨ria¨inen, Association of Packaging Technology and Research, Finland
536 Novel food packaging techniques facts very well, but there are several steps during transportation where one has no or very limited knowledge of the special requirements or needs of perishable products(harbours, airports, transport terminals). Also, a consumer may purchase products and expose them to too high temperatures or otherwise wrong storage conditions before they are eaten As an example, let us look at the shipment of bananas to Finland where they are everyday commodities throughout the year. What follows are the stages on the route of bananas from tree to table A half-ripe banana cluster is cut from a banana tree It is lifted to a hook of a cableway The cableway transports the banana cluster to the packaging area he banana cluster is rinsed The washed cluster is cut into smaller bunches, usually of about five bananas each Cut bananas are washed Bananas are lifted into a plastic tray, each tray containing about 18kg of bananas The plastic tray is transported to the weighing station Weighed bananas are sprayed with a biocide Banana groups are brand labelled Bananas are moved from the trays into transportation boxes Boxes are stamped with packing date and location. Boxes are lifted on a pallet Pallet loads are transferred to containers Containers are transported to the harbour Containers are lifted to a ship Banana containers are monitored for temperature during the sea trip, which takes about two weeks Containers are unloaded from the ship in Sweden Banana pallet loads are transported to the ship terminal The temperature of the bananas is checked Banana pallet loads are loaded onto a lorry The lorry drives onboard a ship sailing to Finland The lorry drives the bananas to a building where the bananas are allowed ripen Bananas and their temperature are checked on arrival Bananas are moved into a maturing room in order to ripen During the ripening process, which takes about six days, the bananas are checked daily for their temperature and degree of ripeness After ripening the bananas are transferred to a collection point There the banana boxes are lifted either onto a trolley or onto a pallet d to the
facts very well, but there are several steps during transportation where one has no or very limited knowledge of the special requirements or needs of perishable products (harbours, airports, transport terminals). Also, a consumer may purchase products and expose them to too high temperatures or otherwise wrong storage conditions before they are eaten. As an example, let us look at the shipment of bananas to Finland where they are everyday commodities throughout the year. What follows are the stages on the route of bananas from tree to table. • A half-ripe banana cluster is cut from a banana tree. • It is lifted to a hook of a cableway. • The cableway transports the banana cluster to the packaging area. • The banana cluster is rinsed. • The washed cluster is cut into smaller bunches, usually of about five bananas each. • Cut bananas are washed. • Bananas are lifted into a plastic tray, each tray containing about 18kg of bananas. • The plastic tray is transported to the weighing station. • Weighed bananas are sprayed with a biocide. • Banana groups are brand labelled. • Bananas are moved from the trays into transportation boxes. • Boxes are stamped with packing date and location. • Boxes are lifted on a pallet. • Pallet loads are transferred to containers. • Containers are transported to the harbour. • Containers are lifted to a ship. • Banana containers are monitored for temperature during the sea trip, which takes about two weeks. • Containers are unloaded from the ship in Sweden. • Banana pallet loads are transported to the ship terminal. • The temperature of the bananas is checked. • Banana pallet loads are loaded onto a lorry. • The lorry drives onboard a ship sailing to Finland. • Second sea voyage. • The lorry drives the bananas to a building where the bananas are allowed to ripen. • Bananas and their temperature are checked on arrival. • Bananas are moved into a maturing room in order to ripen. • During the ripening process, which takes about six days, the bananas are checked daily for their temperature and degree of ripeness. • After ripening the bananas are transferred to a collection point. • There the banana boxes are lifted either onto a trolley or onto a pallet. • The full trolley or the pallet load is transported to the right gate on the shipping area. 536 Novel food packaging techniques
Integrating intelligent packaging, storage and distribution 537 The driver brings the trolley or the pallet to his truck ed to the shop The driver moves the trolley to the inspection area of the shop The shopkeeper checks and accepts the product Depending on sales the products are put on sale o Bananas are moved to the storage area of the sho The boxes are opened and the bananas are put on display A consumer chooses some bananas and packs them into a bag The bananas are weighed A price label is attached to the bag The customer goes to the till Customer puts the product on the cashier line The scanner reads the price and gives the storekeeper information on the amount of bananas sold The customer packs the products into a carrier bag and takes them home Leppaaho, 2002) The above list shows that bananas were exposed to several different temperature and moisture conditions. They were handled frequently and moved from place to place using a wide variety of transporting media 25.1.2Effect of distance, time, shock, vibration, air pressure, tempera and moisture to the products Transportation can be a long and time consuming process involving several them to shock, vibration, air pressure, and moisture variations in addition to ti different packaging can improve or destroy the quality of a specific product (such as Chonhenchob et al on mangoes, 2002) Distribution packaging is generally tested by integrity and general simulation tests before shipment. The first step in the focused simulation test is to quantify, by actual field measurement, the distribution hazards on the packaged products in terms of their intensities and other conditions. For example, drops and impacts are measured, and the data is analysed according to the height or velocity, package orientation at impact, and frequency of occurrence. Vehicle vibrations are measured, with the data typically analysed as power spectral density plots according to the vehicle type and lading conditions, and time durations(or with a given relationship of time to trip length). Compression is measured in vehicles and warehouses, and data analysed to time and superimposed conditions. Atmos- pheric profiles are measured, and data analysed in terms of extremes, rates of change, and combinations. The measurements have become possible with the help of the currently available small, self-contained electronic field data recorders (Kipp, 2002). These instruments can record both static and dynamic information in order to get the required analyses. They are often smaller in size than a brick
• The driver brings the trolley or the pallet to his truck. • Bananas are transported to the shop. • The driver moves the trolley to the inspection area of the shop. • The shopkeeper checks and accepts the product. • Bananas are moved to the storage area of the shop. • Depending on sales the products are put on sale. • The boxes are opened and the bananas are put on display. • A consumer chooses some bananas and packs them into a bag • The bananas are weighed. • A price label is attached to the bag. • The customer goes to the till. • Customer puts the product on the cashier line. • The scanner reads the price and gives the storekeeper information on the amount of bananas sold. • The customer packs the products into a carrier bag and takes them home (Leppa¨aho, 2002).2 The above list shows that bananas were exposed to several different temperature and moisture conditions. They were handled frequently and moved from place to place using a wide variety of transporting media. 25.1.2 Effect of distance, time, shock, vibration, air pressure, temperature and moisture to the products Transportation can be a long and time consuming process involving several handling steps, as the banana case illustrates. Transportation of goods exposures them to shock, vibration, air pressure, and moisture variations in addition to time and temperature. There are several studies on the vulnerability of foods, and how different packaging can improve or destroy the quality of a specific product (such as Chonhenchob et al. on mangoes, 2002).3 Distribution packaging is generally tested by integrity and general simulation tests before shipment. The first step in the focused simulation test is to quantify, by actual field measurement, the distribution hazards on the packaged products in terms of their intensities and other conditions. For example, drops and impacts are measured, and the data is analysed according to the height or velocity, package orientation at impact, and frequency of occurrence. Vehicle vibrations are measured, with the data typically analysed as power spectral density plots according to the vehicle type and lading conditions, and time durations (or with a given relationship of time to trip length). Compression is measured in vehicles and warehouses, and data analysed to time and superimposed conditions. Atmospheric profiles are measured, and data analysed in terms of extremes, rates of change, and combinations. The measurements have become possible with the help of the currently available small, self-contained electronic field data recorders. (Kipp, 2002).4 These instruments can record both static and dynamic information in order to get the required analyses. They are often smaller in size than a brick. Integrating intelligent packaging, storage and distribution 537
538 Novel food packaging techniques Unique systems must be designed, if temperature and humidity sensitive roducts are ordered by e-mail and shipped to other places( Singh, 2000). Since fresh produce continues to respire after being harvested, this causes an intake of oxygen and release of carbon dioxide. The respiration rate of fruits, vegetables nd flowers is dependent on temperature. An increase of package storage temperature results in an exponential increase in respiration rate that shortens the shelf-life of the produce, resulting in eventual decay. The United States Department of Agriculture has documented this information on recommended storage temperature, relative humidity and approximate shelf-life for various fresh produce(Welby et al., 1997). Most fresh produce has a high moisture content,so it is important to maintain a high humidity environment during transportation in order to prevent moisture loss that would result in drying of the produce. USDA recommends a high humidity environment(80-95% relative humidity) for most fresh produce. Possible solutions include cooling aids and S A company in the USA selling expensive meat parts by e-mail has found an ially insulated packaging materials(Singh, 2002a).7 interesting method for chilling their goods. Instead of shipping meat pieces with cooling aids and fillers, frozen hamburgers are packed into the boxes serving as polers and fillers. The customer gets a usable give-away and the extras increase the incentive for a further purchase(Singh, 2002b) 25.2 The role of packaging in the supply chain The main duties of packaging are to protect, contain, inform, and sell. The right packaging also preserves, as the products are received in a good and usable condition. The package needed for protection is a combination of product characteristics and logistical hazards. Well chosen packaging can reduce the cost of every logistical activity: transport, storage, handling, inventory control, and customer service. It can reduce the cost of damage, safety, and disposal Integrated management of packaging and logistics is required, if a firm is to realise such opportunities to reduce costs(Twede, 1997) 25. 2.1 Interviewing the food industry and trade Tekes, the National Agency of Finland, finances the "Safety and Information in Packaging program in Finland. There have been studies on the needs and wishes of industry and trade in order to gather information for directing the research program. During the summer of 2001 Pakkausteknologia- PTR(Association of Packaging Technology and Research) asked for the opinions of the Finnish food industry with a questionnaire of 93 questions(Pikkarainen et al., 2002) Answers were received from producers of dry foods(sugar, flour), beverages, and ready-to eat foods, dairy products, and so on, covering the different sectors of food industry. Shocks, compression, changes in temperature and packaging closing methods all cause packaging problems for the food industry(Fig. 25. 1)
Unique systems must be designed, if temperature and humidity sensitive products are ordered by e-mail and shipped to other places (Singh, 2000).5 Since fresh produce continues to respire after being harvested, this causes an intake of oxygen and release of carbon dioxide. The respiration rate of fruits, vegetables and flowers is dependent on temperature. An increase of package storage temperature results in an exponential increase in respiration rate that shortens the shelf-life of the produce, resulting in eventual decay. The United States Department of Agriculture has documented this information on recommended storage temperature, relative humidity and approximate shelf-life for various fresh produce (Welby et al., 1997).6 Most fresh produce has a high moisture content, so it is important to maintain a high humidity environment during transportation in order to prevent moisture loss that would result in drying of the produce. USDA recommends a high humidity environment (80–95% relative humidity) for most fresh produce. Possible solutions include cooling aids and specially insulated packaging materials (Singh, 2002a).7 A company in the USA selling expensive meat parts by e-mail has found an interesting method for chilling their goods. Instead of shipping meat pieces with cooling aids and fillers, frozen hamburgers are packed into the boxes serving as coolers and fillers. The customer gets a usable give-away and the extras increase the incentive for a further purchase (Singh, 2002b).8 25.2 The role of packaging in the supply chain The main duties of packaging are to protect, contain, inform, and sell. The right packaging also preserves, as the products are received in a good and usable condition. The package needed for protection is a combination of product characteristics and logistical hazards. Well chosen packaging can reduce the cost of every logistical activity: transport, storage, handling, inventory control, and customer service. It can reduce the cost of damage, safety, and disposal. Integrated management of packaging and logistics is required, if a firm is to realise such opportunities to reduce costs (Twede, 1997).9 25.2.1 Interviewing the food industry and trade Tekes, the National Agency of Finland, finances the ‘Safety and Information in Packaging’ program in Finland. There have been studies on the needs and wishes of industry and trade in order to gather information for directing the research program. During the summer of 2001 Pakkausteknologia – PTR (Association of Packaging Technology and Research) asked for the opinions of the Finnish food industry with a questionnaire of 93 questions (Pikkarainen et al., 2002).10 Answers were received from producers of dry foods (sugar, flour), beverages, and ready-to eat foods, dairy products, and so on, covering the different sectors of food industry. Shocks, compression, changes in temperature and packaging closing methods all cause packaging problems for the food industry (Fig. 25.1). 538 Novel food packaging techniques
Integrating intelligent packaging, storage and distribution 539 Closing of packaging Leakage Moisture changes Change of temperature Other gases Static electricity 1, 3 Vibration Shocks Compression Others I not a problem =>7 major problem Fig. 25.1 Possible causes of trouble in packaging in food industry. Presented as an average of all answers. No problems at all is indicated by number 1, and 7 is given if major problems(Pikkarainen et al, 2002) The interviewees wished to gather more information on the following aspects: circumstances during the storage and transport, temperature changes, breakage of cold chain, and leak detection. They preferred additional properties to be within the packaging material, and also that the new properties would be in transport packages instead of consumer packages. They particularly wanted an active tag or a smart card containing memory to be developed for the distribution package rather than for the consumer package. The main reason is probably the price of the tags. If it were only a few cents then the tags would be accepted also for consumer packages. The profit margin in the food sector is low and therefore all additional costs must be carefully considered Different information is required in consumer packages than in transport and distribution packages. The information in a consumer package is aimed at the consumers, retailers and other parties in the trade need information on distribution and storage conditions. All who replied wished to know about the cold chain, especially if it had been interrupted. Monitoring the temperature during distribution was an important aspect (Fig. 25.2). Only those whose products were not sensitive to temperature did not consider it very important The majority (70%)also preferred the indicator to record information during distribution In the 'Safety and Information in Packaging program the storekeepers in Finland were also interviewed by Pakkausteknologia-PTR(Association of Packaging Technology and Research). All who were interviewed, mentioned that the most important aspects were the retail packages(the size should be right for the size of the store), environmental aspects, economics, alarm systems, and
The interviewees wished to gather more information on the following aspects: circumstances during the storage and transport, temperature changes, breakage of cold chain, and leak detection. They preferred additional properties to be within the packaging material, and also that the new properties would be in transport packages instead of consumer packages. They particularly wanted an active tag or a smart card containing memory to be developed for the distribution package rather than for the consumer package. The main reason is probably the price of the tags. If it were only a few cents then the tags would be accepted also for consumer packages. The profit margin in the food sector is low and therefore all additional costs must be carefully considered. Different information is required in consumer packages than in transport and distribution packages. The information in a consumer package is aimed at the consumers; retailers and other parties in the trade need information on distribution and storage conditions. All who replied wished to know about the cold chain, especially if it had been interrupted. Monitoring the temperature during distribution was an important aspect (Fig. 25.2). Only those whose products were not sensitive to temperature did not consider it very important. The majority (70%) also preferred the indicator to record information during distribution. In the ‘Safety and Information in Packaging’ program the storekeepers in Finland were also interviewed by Pakkausteknologia – PTR (Association of Packaging Technology and Research). All who were interviewed, mentioned that the most important aspects were the retail packages (the size should be right for the size of the store), environmental aspects, economics, alarm systems, and Fig. 25.1 Possible causes of trouble in packaging in food industry. Presented as an average of all answers. No problems at all is indicated by number 1, and 7 is given if major problems (Pikkarainen et al., 2002). Integrating intelligent packaging, storage and distribution 539