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Global Food & Drink Trends Food & Drink Innovation Network Packaging Innovation by Richard Roberts, Principal Consultant Pira International 20 October.

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Presentation on theme: "Global Food & Drink Trends Food & Drink Innovation Network Packaging Innovation by Richard Roberts, Principal Consultant Pira International 20 October."— Presentation transcript:

1 Global Food & Drink Trends Food & Drink Innovation Network Packaging Innovation by Richard Roberts, Principal Consultant Pira International 20 October 2004

2 Innovation WHY INNOVATE? The only sustainable competitive advantage comes from out innovating the competition. James Moore

3 Innovation Need to understand: –Consumer perspectives –Customer perspectives –Supplier perspectives

4 Innovation 1995 Quality Cost/price Service Customer focus Investment Delivery Flexibility Technology Account Management NPD 2001 Quality Cost/price Service Innovation Partnership Supply chain Flexibility Technology Account Management NPD

5 Single serve

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7 Innovative shapes

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9 Convenience - easy dispensing

10 Rumblers Twinpots sleeved together

11 Active & Intelligent Packaging

12 Oxygen scavengers - mechanisms Iron powder oxidation Polymer oxidation (metal catalyst) Ascorbic acid oxidation Photo-activated organic compound Enzymatic oxidation Complexation

13 Selected commercially available oxygen scavenging systems Sachets –Ageless® (MGC) –Freshilizer (Toppan) Labels –ATCO® (EMCO) –Freshmax® (Multisorb)

14 Selected commercially available oxygen scavenging systems Closure liners –DarExtend (Darex) –Pureseal (WR Grace) –Oxycap (Standa Industrie)

15 Oxygen scavenging plastics Films, bottles, trays, cups Shelf plus O 2 (Ciba S.C) Oxyguard ® (Toyo Seikan) BindOX (Amcor) Amosorb® DFC (BP Amoco) OS1000/2000 (Cryovac) OSP (Chevron Phillips) ZerO 2 (CSIRO)

16 Benefits of oxygen scavengers Extend shelf-life –reduce distribution losses –reduce spoilage claims Meets consumer demand for natural foods –eliminate or reduce food additives –reduce use of sugar and/or salt –maintain nutritional value Reduce need for extremely low levels of O 2 in MAP –accelerated line-speeds

17 Ethylene scavengers - mechanisms Potassium permanganate –Ethysorb (StayFresh Ltd) Activated carbon/Pd catalyst –Sendo-mate (Mitsubishi Chemical Corp) Activated carbon/bromine-based chemical –Hato-fresh (Honshu paper) Disadvantages: –Toxicity/migration –Non-specific –Not suitable for packaging films

18 Ethylene removing films Everfresh, Orega, Profresh, Peakfresh PE based films containing activated clay

19 CSIROs ESP technology The only ethylene scavenging technology developed for packaging films Specific Colour change Transparent colourless to pink transparent Overcomes drawbacks of ethylene scavenging sachets

20 Thermochromic Inks Reversible and irreversible Various temperature ranges Limited colours Combination with conventional ink can reveal messages

21 Reversible ink for use on milk labels

22 TTIs Provides irreversible evidence of a physical or physicochemical change, typically a colour or shade change Function –Provide information on exceeding a temperature threshold or exceeding a cumulative time-temp history –To inform the supply chain and consumer that correct storage conditions have or have not been adhered to Benefit –Provides reassurance to consumers –Real environment information rather than implied fitness (use/sell by date) –Highlights problems in supply chain –Can reduce shrinkage/wastage

23 Freshness indicators Provides irreversible evidence of a chemical or enzymatic change, typically a colour or shade change Function –Provide information on actual degradation spoilage of products –To inform the supply chain and consumer of product freshness Benefit –Provides reassurance to consumers –Real product information rather than implied fitness (use/sell by date) –Highlights problems in supply chain –Can reduce shrinkage/wastage

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26 Current applications Findus Combined technology TTI and RF data tag One product line monitored in Sweden from early 2003 using Bioetts TTI Device the size of a credit card Cost 15 to 25 Euro Cents Device records temperature change through supply chain which can be read by hand held scanner Enzyme based reaction provides data and power source Large Swedish dairy Skanemejerier are also using these devices

27 Current Applications Lifelines (US) US retailer Trader Joe require suppliers to apply LifeLines TTIs to any fresh produce supplied to the company Monoprix the low cost French retailer uses the labels on 175 of its private label chilled products LifeLines sold over 200 million TTIs in 2002 and project 25% pa growth

28 Steamers Steams food Valve releases excess pressure

29 Self-Heating/Cooling Tempra –both heating and chilling technologies

30 Self heating/Self cooling packaging

31 Barrier Technologies Improvements to O 2 /CO 2 barrier –new resins or improved PET resins –coatings –multilayers - overmoulding or co-injection –inclusion of nanocomposites

32 New Resins Polyethylene naphthalate (PEN) –use on its own or as blend with PET –higher glass transition temperature –barrier improvements about 5x –cost increase Polyglycolic acid (PGA) –O 2 barrier 10x better than MXD6 –similar melting point to PET –FDA approval 2004?

33 Transparent barrier coating - films SiO x or AlO x barrier similar to metallised films

34 Transparent barrier coatings - bottles External –no food contact issues –can be scratch resistant and friction of bottle can be improved Internal –not easily damaged –protects drink from gases/chemicals in bottle wall –easier to incorporate PCR PET

35 External coatings Resin coatings from PPG/SIPA, Du Pont, Dow SiO x - plasma - Krones / Coca Cola / Leybold

36 Internal coatings Diamond like coatings (carbon), plasma and acetylene –Nissei, Mitsubishi/Kirin, Sidel (ACTIS) –brownish colour Silicon oxide –plasma Tetra Pak (Glaskin), SIG Schott HiCotec

37 Multilayer Co-injection of EVOH or MXD6 –Kortec, Owens Illinois, Pechiney Active –Oxbar - MXD6 + cobalt catalyst –SurShield (Owens Illionois) –Dar Eval - O 2 scavenger in EVOH layer

38 Multilayer - active

39 Multilayer Active –Amosorb 3000 - transparent O 2 scavenging copolyester –OSP (Chevron Phillips Chemical) - oxidisable polymer resin cyclohexenyl methyl acrylate + photoinitiator and catalyst

40 Nanocomposites Improved mechanical properties, eg strength to weight Improved thermal stability and heat distortion temperature Improved barrier properties Better chemical resistance Better transparency, appearance

41 Nanocomposites Mitsubishi Gas Chemical Co + Nanocor –nanoclays combined with polymers –silicate clays, 100-1000 x 1nm, large surface area, high aspect ratio –nanocomposites retain flexibility, transparency of unfilled polymer –permeability greatly reduced 2-20x, filler levels 1- 5% –improved barrier for film and PET bottles –first application Imperm 105 in films - still clear –second application Imperm 107 in bottles - currently hazy –potential cost reduction - fewer layers


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