An Assignment on:

“Emerging Trends & Need In Dairy Products Packaging”

SUBMITTED BY:

NITIN RANA : 1720910013

SASANKA SEKAR DASH : 172910017

M.TECH-FOOD & NUTRITIONAL BIOTECHNOLOGY

2nd YEAR

SRM UNIVERSITY

WHAT IS PACKAGING

Integral part of Production

Means a system of preparing goods for transport, distribution, storage, retailing and end-use.

Part of Physical Distribution

A means of ensuring safe delivery to the ultimate consumer in sound condition at minimum overall cost.

A techno-economic function aimed at minimizing cost of delivery while maximizing sales.

A tool for marketing .

FUNCTIONS OF A PACKAGE

1. Containment : Keep its contents secure between end of packaging and consumption2. Protection and Preservation: It is required from both mechanical damage during

handling and deterioration by climate(s) during distribution and storage3. Communication: It must identify the content, legal requirement, promotion of sales,

instruction for handling and storage, display etc. 4. Machinability : Smooth movement of packages, material economics and ability of

packaging material during packaging operation are important5. Convenience and Use: Easy to Open, close, dispensing, disposal, recycle, information,

eye appeal, warnings, distribution etc.

Indian Market Scenario

• Though India is one of the largest producer of food and agro based products, 20% gets wasted due to non-availability of processing/ packing/inefficient supply chain – cold storage facilities etc.

• Food processing sector has the potential of attracting Rs 1,50,000 crore (US$ 33billion) of investment in 10 years and generate employment of 9 million person days.(Source- CII)

• Packaged food industry in India is growing at more than 15% p.a.

• One of the fastest growing consumer markets.

• 300 million upper & middle class consumers ad 200 million + very rich consumers expected by 2010.

• Huge domestic demand.

• Consumer expectation and behaviour is changing and demand.

• Convenience in packaging are on rise.

• With increasing number of modern trade outlets face of trade is changing for ever.

Consumer Behaviour & Trends

Urban is where the action is

• Large: 1 billion population : 30% Urban

• India is urbanising in a rapid rate of 2.5% per annum

• The number of cities over 10 lacs population is expected to be double in next 20 years. (35 to 70 cities)

• No. of millionaires in India up by 20%, second only to S Korea.

• India had 83,000 millionaires in ’05, up from 70,000 in ’04.

• Boosting demand for housing, lifestyle product and consumer goods including packaged food product.

Consumer Convenience

• Easy to handle packs are preferred. In use convenience is the call of the day.

• Easy to use packs are gaining popularity. People are ready to pay premium for “In use” convenience

Shelf & Consumer Appeal

• Shelf visibility and consumer appeal is becoming very important.

• Modern trade outlets call for instant consumer attraction.

• Pack appearance and ability to engage consumers are becoming the key consideration for any new packaging design.

Packaging materials & techniques

Packaging Materials

• Tin Containers,

• Aluminium Foil/Containers,

• Paper Carton Boards,

• Glass,

• Corrugated Board,

• Plastic Materials.

Packaging Techniques

• Vacuum Packaging,

• Modified Atmosphere Packaging,

• Oxygen Absorbers/Scavengers,

• Poly Clip System,

• Aseptic Packaging,

• Computer-Aided Designing,

• Edible Packaging,

• Disposal of Packages,

• Recycling,

• Recommended Packaging and Storage.

Packaging Machines

• Tin Can Filling Machine,

• Seaming Machine,

• Form-Fill-Seal (FFS) Machine,

• Cup Thermo-Fill and Sealing Machine,

• Pre-formed Cup Filling and Sealing Machine,

• In-line Cup Filling,

• Sealing and Cartoning Machine,

• Multi-Fill Machine,

• Vacuum and Gas Machine,

• Shrink Wrapping Machine.

Aseptic packaging System- A packaging for healthy lifestyle

• Aseptic packaging can be 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.

• The term “aseptic” is derived from the Greek word “septicos” which means the absence of putrefactive micro-organisms.

Advantages of Aseptic Packaging Technology

1. Packaging materials, which are unsuitable for in-package sterilisation can be used. Therefore, light weight materials consuming less space offering convenient features and with low cost such as paper and flexible and semi-rigid plastic materials can be used gainfully.

2. Sterilisation process of high-temperature-short time (HTST) for aseptic packaging is thermally efficient and generally gives rise to products of high quality and nutritive value compared to those processed at lower temperatures for longer time.

3. Extension of shelf-life of products at normal temperatures by packing them aseptically.

Conventional Canning v/s Aseptic Packaging

Aseptic Processing – Methodology

Sterilisation of the products before filling.

Sterilisation of packaging materials or containers and closures before filling.

Sterilisation of aseptic installations before operation (UHT unit, lines for products, sterile air and gases, filler and relevant machine zones).

Conventional Process Flow Aseptic Process Flow maintaining sterility in this total system during operation; sterilization of all media entering the system, like air, gases, sterile water.

Production of hermetic packages.

Composition of Tetrapak Aseptic Carton

Type of Package Forms available in India

Summary of packaging materials / containers used in Dairy Industry

Solutions for Liquid Food Packaging

Plastic Packaging

With over 20,000 machines installed in 150 countries, the Sidel Group is one of the world leaders in solutions

for packaging liquid food.Our vision is to become, by 2010, the undisputed world leader in packaging

equipment and lines for liquid food packaged in glass, plastic and cans, by producing the most innovative,

competitive solutions and equipment for our customers.

One Group, Five Brands

Five great brands – Sidel™, Simonazzi™, Alfa™, Gebo™, and Cermex™ - have combined their skills,

experience and passion to forge a powerful pioneering new group, a unique partner for the liquid food

industry. Water, carbonated beverages, fruit juice, sensitive drinks, dairy products, beer and edible oil:

whatever the needs, for plastic, glass bottles and cans, the new Sidel will provide you with the adapted solution.

Plastic Packaging

In the early 1960s, Sidel™ created the world`s first machines to produce plastic bottles. And for the past

40 years, Sidel™ has been behind the technological solutions that have sustained the phenomenal growth

of this new recyclable package.

Sidel™ has truly been a pioneer in one of recent history`s greatest revolutions in how we consume liquid food.

One concrete example is the production rate of Sidel™ blow molding machines that has tripled in ten years,

while the weight of PET bottles has been cut in half.

Plastic Bottle Technology

Since its early years, Sidel™ has routinely crossed borders to share new plastic bottle technology around the

world. Sidel`s™ clients are numerous and international in scope. Today, over 4,000 Sidel™ blow molding

machines and 2,000 fillers are operating in 150 countries around the world. Sidel™ equipment is

manufactured in Europe, North America, South America and Asia.

PVC, HDPE and PET Bottles

Sidel™ anticipates and accommodates the needs of its customers -beverage manufacturers. Since its founding,

Sidel™ literally created the plastic bottle industry. It launched the first PVC bottles in the early 1960s for

water, oil and wine, followed by HDPE bottles for milk, and finally PET bottles in the 80s for all liquid

food. Sidel™ has maximized bottle performance boosting strength and barrier properties while considerably

reducing their weight. As speeds have increased, equipment maintenance has been simplified. And while

bottle format changeovers are faster than ever, global machine efficiency has reached 97 to 98 percent.

Blow molding, barriers and fillers

Sidel™ is unquestionably the world leader in plastic bottle producing equipment. More than half of all PET

bottles worldwide are produced in a Sidel™ mold on a Sidel™ blow molding machine. And its Actis

technology offers an industrially viable solution to strengthen PET bottle impermeability in order to

expand the use of PET to package beer and carbonated drinks in small format bottles. Sidel™ has also

developed a range of fillers especially for PET bottles. Finally, the company invented the Combi concept

that integrates PET bottle blowing, filling and capping in a single piece of equipment.

FILLING MACHINES

Simonazzi™ brand is considered one of the top suppliers in fillers and end of line equipment and it owes that

reputation, in large part, to its highly proactive strategy of innovation.Simonazzi™ customer references are

numerous and span the globe. Currently, over 2,000 Simonazzi™ fillers, 700 rinsers, 550 bottle washing

machines, 500 pasteurizers, 800 mixers, not to mention thousands of palletizers/depalletizers and case packers

are up and running around the world.

Innovation by and for clients

Since its inception, Simonazzi™ has embraced the innovation mindset. It launched the first rotary filler in

1958, first filling valve specially designed for PET bottles in the early 1980s, first electronic filler in 1995,

and the first infrared data transmission system. The long-lasting, genuine relationships that Simonazzi™

has built with customers have enabled it to anticipate needs and technological advances that will affect the

beverage industry.Year after year, thanks to unflagging efforts in R&D for bottling, Simonazzi™ has designed

machines that are increasingly refined and automated. This equipment, such as the Eurostar filler range,

internationally renowned for its reliability, satisfies the most demanding specifications. Simonazzi™ offers

packaging solutions for all liquid food, even beer, in three families of packaging: glass, plastic and metal.

New Formats

• On the Go- To meet the demand of fast pace of life. Have your food “Anywhere & Anytime”

• Vending formats- Strongest emerging format

Nutritional labelling

Label declaration

• More and more labels are coming with nutritional information. Enhance consumer awareness

• List of ingredients / nutrients

• Serve size / % Daily Requirement

• Benefits

LABELING MACHINES

Eleven hundred bottles per minute is the record-breaking output of the Rollquattro range of

labeling machines, the latest equipment model manufactured by Alfa™ (120 people) in Mantua

(Italy). This roll-fed labeling technology is so popular that since the first Alfa Rollquattro was

sold in Great Britain in 1996, 320 machines have been installed for bottle packaging operations

for water, fruit juices and carbonated drinks. The Alfa™ equipment offers models operating at

various speeds, for different bottle sizes using several different labeling technologies such as

self-adhesive, hot melt and cold glue.

Key player in the beverage industry

Alfa™ customer references are to be found in just about every country in the world and Alfa™

takes a certain pride in knowing many of its customers just keep coming back for more. Since

the first installations 30 years ago, today there are currently over 3,000 Alfa™ labelers up and

running around the globe.

High Speed Labeling

In 1989, Alfa™ decided to initiate a programme dedicated to high speed labeling. It launched a

unique cold glue cut and stack labeling machine, implementing a top down design philosophy of

the labeling station, a must for clients in high production, heavy duty working environments. In

1995 the innovative high speed roll-fed labeler programme followed, which opened up a whole

new frontier in both speed and marketing possibilities for clients in the beverage industry. These

Alfa™ programmes and their successful implementation have had a very positive impact on the

beverage world.

Labeling Solutions

The precise, automated Alfa™ equipment refined over the years by an impeccable R&D, such as

the Rollquattro labeling range, satisfies the most demanding specifications. Alfa™ offers

labeling solutions for all liquid food, including beer, in three families of packaging: glass, plastic

and metal.

Anti-counterfeit measures

Counterfeit leads to :

• Health risks and lawsuits

• Loosing consumer loyalty

• Loosing sales and profits

“Smart label” RFID(Radio-Frequency IDentication) tag:

• Ordinary range of several meters

• Simply calls out (unique) name and static data

References

1. Aseptic Processing and Packaging of Particulate Food, Edited by Edward M.A.

Willhoft.

2. Aseptic Packaging of Food, Edited by H. Reuter.

3. Tetrapak Company Magazine No. 76.

4. Handbook of Canning and Aseptic Packaging, Edited by Ranganna.

5. The Wiley Encyclopedia of Packaging Technology.

6. Modern Food Packaging, IIP Publication, Aseptic Packaging by Dr. Bern Hard Von

Bookelmann, A. B. Tetra Pak, Lund, Sweden.

7. Aseptic Packaging, Modern Processing, Packaging and Distribution Systems for Food

by Frank A. Paine.

8. Websites

• www.tetrapak.com • www.serac-group.com

• www.sgi.com • www.brevettiangela.com

• www.hassia.de • www.boschpackaging.com

• www.packexpo.com • www.indiadairy.com

• www.rfid-cusp.org