Part IV General issues
Part IV General issues
21 Optimizing packaging T. Lyijynen, E. Hurme and R. Ahvenainen, VTT Biotechnology Finland 21.1 Introduction Package design has great significance for the success of foodstuffs nowadays Packages are clearly an integral part of the manufacturing and distribution processes. As clothes speak for their wearers, so too packages speak for the acked food product Packages are developed not only to make weekdays easier for the consumer, but also to make times of celebration more festive. Many food products would not be in shops and on dining tables, if they had not been packed. Nowadays packages face difficult challenges and roles. They have to create the ambience that hitherto was forged by personal service. Packages eplace the salesman In addition, packaging has many other functions and requirements which it has to fulfil more and more effectively and economically. These functions and requirements are changing all the time and their importance in ensuring the success of the product is growing. The aim is to make the optimal package that satisfies all functional requirements in addition to meeting environmental and cost demands as well as possible. The answer to these complex demands is orecision packaging VTT Precision Packaging Concept has been developed in the Technical Research Centre of Finland and it is a new and unique tool to optimize packaging for foodstuff Elsewhere optimization methods for transport packages have been developed, but not for primary packages, which are in direct contact with foodstuff. The VTT Precision Packaging Concept is based on the predetermined minimum shelf-life needed to allow the packed foodstuff to suit the market and the business strategy of the company. A longer shell-iieo reach the consumer's table from the factory. The shelf-life is naturally chosen
21.1 Introduction Package design has great significance for the success of foodstuffs nowadays. Packages are clearly an integral part of the manufacturing and distribution processes. As clothes speak for their wearers, so too packages speak for the packed food product. Packages are developed not only to make weekdays easier for the consumer, but also to make times of celebration more festive. Many food products would not be in shops and on dining tables, if they had not been packed. Nowadays packages face difficult challenges and roles. They have to create the ambience that hitherto was forged by personal service. Packages replace the salesman. In addition, packaging has many other functions and requirements which it has to fulfil more and more effectively and economically. These functions and requirements are changing all the time and their importance in ensuring the success of the product is growing. The aim is to make the optimal package that satisfies all functional requirements in addition to meeting environmental and cost demands as well as possible. The answer to these complex demands is precision packaging. VTT Precision Packaging Concept has been developed in the Technical Research Centre of Finland and it is a new and unique tool to optimize packaging for foodstuff. Elsewhere optimization methods for transport packages have been developed, but not for primary packages, which are in direct contact with foodstuff. The VTT Precision Packaging Concept is based on the predetermined minimum shelf-life needed to allow the packed foodstuff to reach the consumer’s table from the factory. The shelf-life is naturally chosen to suit the market and the business strategy of the company. A longer shelf-life is 21 Optimizing packaging T. Lyijynen, E. Hurme and R. Ahvenainen, VTT Biotechnology, Finland
442 Novel food packaging techniques needed for an export market than for a home market. Depending on the business strategy, the company can favour either short or long best-before times. It should be noted that the selling time of the product does not necessarily have any other connection to the real shelf-life but, naturally, the selling time is always shorter than the shelf-life. This chapter gives a description of the VTT Precision Packaging Concept for the optimization of food packages. At the end of the chapter, examples of optimization are given using different gas-packec foodstuffs 21.2 Issues in optimizing packaging The basic aim in the optimization of food packages is to create a tool for decision-making policy for launching new products. The packaging optimization concept should not only advantageously help food manufacturers, but also packaging material and packaging manufacturers to evaluate and compare the feasibility of their new and present products. In todays competitive market, packaging innovation can be a big advantage in efforts to persuade the consumer to buy a certain brand, and the packaging optimization concept may help to educe the economic support and time needed for package development. Several factors should be considered in the optimization process for packages, covering the performance in logistics, marketing properties, consumer convenience, costs, and environmental stresses(see Fig. 21. 1). The general goals in package optimization are the cost-effectiveness of the packaging process and environmental issues, e.g. source reduction of packaging materials. The importance of these factors is discussed below 21.2.1 Performance in logistics One of the most important tasks of a food package is to afford protection from environmental conditions, like oxygen, light and moisture. This is crucial for maintaining the quality and safety of most packaged foods. Therefore, it is essential that a package has sufficient mechanical strength to protect the packaged product from environmental stresses during distribution and storage Environmental issues, however, demand that packaging material consumption is kept to a minimum and that packaging materials be recoverable. This requires the food industry to use thinner materials that still have both sufficient mechanical strength and barrier properties. An optimized, downsized package may also reduce wholesaler and retailer costs On the other hand, in some cases it may also be favourable to use relatively thick, recyclable monomaterial layers (e.g. polyethylene)suitable for energy recovery. In other words, an optimized food package minimizes the waste in the overall packaged product New packaging solutions should also be technically feasible. That is, they ay not set any limitations on either packaging speeds or the quality of seals ackage dimensions need to be logistically congruent with the secondary
needed for an export market than for a home market. Depending on the business strategy, the company can favour either short or long best-before times. It should be noted that the selling time of the product does not necessarily have any other connection to the real shelf-life but, naturally, the selling time is always shorter than the shelf-life. This chapter gives a description of the VTT Precision Packaging Concept for the optimization of food packages. At the end of the chapter, examples of optimization are given using different gas-packed foodstuffs. 21.2 Issues in optimizing packaging The basic aim in the optimization of food packages is to create a tool for decision-making policy for launching new products. The packaging optimization concept should not only advantageously help food manufacturers, but also packaging material and packaging manufacturers to evaluate and compare the feasibility of their new and present products. In today’s competitive market, packaging innovation can be a big advantage in efforts to persuade the consumer to buy a certain brand, and the packaging optimization concept may help to reduce the economic support and time needed for package development. Several factors should be considered in the optimization process for packages, covering the performance in logistics, marketing properties, consumer convenience, costs, and environmental stresses (see Fig. 21.1). The general goals in package optimization are the cost-effectiveness of the packaging process and environmental issues, e.g. source reduction of packaging materials. The importance of these factors is discussed below. 21.2.1 Performance in logistics One of the most important tasks of a food package is to afford protection from environmental conditions, like oxygen, light and moisture. This is crucial for maintaining the quality and safety of most packaged foods. Therefore, it is essential that a package has sufficient mechanical strength to protect the packaged product from environmental stresses during distribution and storage. Environmental issues, however, demand that packaging material consumption is kept to a minimum and that packaging materials be recoverable. This requires the food industry to use thinner materials that still have both sufficient mechanical strength and barrier properties. An optimized, downsized package may also reduce wholesaler and retailer costs. On the other hand, in some cases it may also be favourable to use relatively thick, recyclable monomaterial layers (e.g. polyethylene) suitable for energy recovery. In other words, an optimized food package minimizes the waste in the overall packaged product. New packaging solutions should also be technically feasible. That is, they may not set any limitations on either packaging speeds or the quality of seals. Package dimensions need to be logistically congruent with the secondary 442 Novel food packaging techniques
Optimizing packaging 443 Alternative packaging Specified shelf-life and VTT Precision Packaging Concept Costs Convenience Fig 21.1 The VTT Precision Packaging Concept is a customized tool for optimization food packagin package and pallet. The ratio of packaged product to package volume should be 21.2.2 Marketing properties The marketing properties of a package should be fulfilled as well as necessary, not as well as possible. This means that, optimally and cost-effectively, only adequate investment is needed to fulfil the need for, e.g., package design in terms of packaging material consumption, decoration and information. Keeping up the brand image of a product should be taken into account when making packaging decisions. It is important that package designers, manufacturers and users can co-operate closely to achieve an optimum package 21.2. 3 Costs From a food manufacturer's point of view, especially, the costs of primary packaging materials as well as indirect packaging costs(storage, transportation energy consumption, and labour costs)should certainly be as low as possible. A cost-competitive package is, of course, a benefit for both the packaging and the food manufacturers. a packaging innovation requiring a minimum of investment and giving consumers products they like, at affordable prices, can be seen to be a very attractive goal. Such innovations could be, e. g, easy-open seals or thinner materials which consumers find more environmentally friendly 21.24 Consumer convenience Such properties of a package that make it convenient for the consumer include it being easy to handle, carry, store and dispose of/re-use, as well as its openability, resealability, and microwaveability
package and pallet. The ratio of packaged product to package volume should be as high as possible. 21.2.2 Marketing properties The marketing properties of a package should be fulfilled as well as necessary, not as well as possible. This means that, optimally and cost-effectively, only adequate investment is needed to fulfil the need for, e.g., package design in terms of packaging material consumption, decoration and information. Keeping up the brand image of a product should be taken into account when making packaging decisions. It is important that package designers, manufacturers and users can co-operate closely to achieve an optimum package. 21.2.3 Costs From a food manufacturer’s point of view, especially, the costs of primary packaging materials as well as indirect packaging costs (storage, transportation, energy consumption, and labour costs) should certainly be as low as possible. A cost-competitive package is, of course, a benefit for both the packaging and the food manufacturers. A packaging innovation requiring a minimum of investment and giving consumers products they like, at affordable prices, can be seen to be a very attractive goal. Such innovations could be, e.g., easy-open seals or thinner materials which consumers find more environmentally friendly. 21.2.4 Consumer convenience Such properties of a package that make it convenient for the consumer include it being easy to handle, carry, store and dispose of/re-use, as well as its openability, resealability, and microwaveability. Fig. 21.1 The VTT Precision Packaging Concept is a customized tool for optimization of food packaging. Optimizing packaging 443
444 Novel food packaging techniques 21.2.5 Environmental stresses nvironmental aspects should be taken into account as far as possible in the optimized package. The relevant issues include the need for low environmental stresses from the packaging material and packaging, the necessity of a low ratio of package weight to product weight, the need for as little of the package volume to be waste as possible, and the incineration possibilities of different packaging materials 21.3 The VTT Precision Packaging Concept The VTT Precision Packaging Concept includes several phases(see Fig. 21.2) The first task is to specify the required shelf-life for a foodstuff and determine the basic requirements for this food package, e.g. by using shelf-life prediction models. After that it is possible to choose different combinations of package types and to optimize the package. Optimization is performed in four steps: (i) scoring the tested package types, (ii) evaluating the importance of package characteristics, (iii)calculating the coefficients for each of the characteristics, and(iv) calculating the optimization result of each of the tested package types 21.3.1 Determination of basic requirements for packaging Precision packaging is based on a pre-determined minimum shelf-life needed to allow the packed foodstuff to reach the consumer's table from the factory. The shelf-life is naturally chosen to suit the market and the business strategy of the company. A longer shelf-life is needed for an export market than for a domestic Minimum required shelf-life for the food stuff Minimu oplimIzation scoring the selected, alternative packaging type calculating the coefficient for the characteristic OPTIMAL PACKAGE
21.2.5 Environmental stresses Environmental aspects should be taken into account as far as possible in the optimized package. The relevant issues include the need for low environmental stresses from the packaging material and packaging, the necessity of a low ratio of package weight to product weight, the need for as little of the package volume to be waste as possible, and the incineration possibilities of different packaging materials. 21.3 The VTT Precision Packaging Concept The VTT Precision Packaging Concept includes several phases (see Fig. 21.2). The first task is to specify the required shelf-life for a foodstuff and determine the basic requirements for this food package, e.g. by using shelf-life prediction models. After that it is possible to choose different combinations of package types and to optimize the package. Optimization is performed in four steps: (i) scoring the tested package types, (ii) evaluating the importance of package characteristics, (iii) calculating the coefficients for each of the characteristics, and (iv) calculating the optimization result of each of the tested package types. 21.3.1 Determination of basic requirements for packaging Precision packaging is based on a pre-determined minimum shelf-life needed to allow the packed foodstuff to reach the consumer’s table from the factory. The shelf-life is naturally chosen to suit the market and the business strategy of the company. A longer shelf-life is needed for an export market than for a domestic market. Fig. 21.2 A scheme for determining the optimal package. 444 Novel food packaging techniques