Food Packaging

Abhaya Seneviratne

Introduction to Packaging

Products have to be packaged in bulk, intermediate or consumer quantities. Food

in the form of raw materials and ingredients, primary secondary and so on
processed products is very much inclusive and needs packaging in all three ways.

Need for pre-packaged food continues to increase in economies as they develop

and grow as growing population is also fuelling the demand. This is increasingly
the case in countries experiencing rapid urbanization.

In response to the changing consumer lifestyles, large retail companies and food
service industries have evolved. Their success has involved a highly competitive
mix of logistical, trading, marketing and customer service package, which is
dependent on quality of packaging. They have partly driven the dramatic
expansion in the range of products available, enabled by technological
innovations, including those in packaging.

The retailing, food manufacturing and packaging supply industries are continuing
to expand their operations internationally. The sourcing of products from around
the world is increasingly assisted by a reduction in trade barriers. The effect has
been an increase in competition and a downward pressure on prices.

Increased competition has led to a rationalization in industry structure, often in

the form of mergers and takeovers. For packaging, it has meant the adoption of
new materials and shapes, increased automation, extension of pack size ranges
and a reduction in unit cost. Another effect of mergers among manufacturers and
retailing groups on packaging is the reappraisal of brands and their pack designs.

Increasing market segmentation and the development of global food supply

chains have spurred the adoption of sophisticated logistical packaging systems.

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Packaging is an integral part of the logistical system and plays an important role in
preventing or reducing the generation of waste in the supply of food.

It should be noted, however, that some parts of the chain permit the use of
returnable packages.

Packaging assists the preservation of the world’s resources through the

prevention of product spoilage and wastage, and by protecting products until
they have performed their function. The principal roles of packaging are to
contain, protect/preserve food and inform the user. Thereby, food waste may be
minimized and the health of the consumer safeguarded.

Packaging is defined as: “Art, science, and technology of enclosing products for
storage, handling, transport and sale.”

When all expected functions of packaging in general and at a level suitable for
food, while serving specific functions required to be served for food, such
packaging can be identified as food packaging.

Introduction to Food Packaging

As the terminology goes Packaging is the subject and the methodology of

enclosing products in packs. The packed products are then moved to the
consumer through trade depending on the rest of the supply channels. This
process requires;

1. Packaging Materials with a Labeling method

2. Packing Process or enclosing
3. Consolidation and Agglomeration method
4. Handling Storage and Transport Method

Firstly, along with the individual packs that contain the food, there are other
packaging and ancillary materials to make the handling and transport, transit,
and, transfer possible. This total packaging set up is named “Packaging System”.

In the packaging system, depending on the relative position of the pack to the
product, the members or components of the packaging system are identified as

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Primary Packaging, Secondary Packaging, Tertiary Packaging, and Ancillary
materials so on. The primary pack is the one that contains food and secondary
pack is the one that contain the primary pack, and so on.

Primary roles of food packaging system components;

 Containment
 Protection and Preservation
 Function and Convenience
 Presentation and Communication

While serving the above purposes, “Cost and Sustainability parameters” are to be
kept within desirable levels.

Containment

Holding the right quantity of product without losing content or spillage is meant
by containment, which is the inevitable basic most need.

Protection and Preservation

This means that the product is not allowed to deteriorate in the pack during the
designated shelf life. This requires three types of protection.

 Physical Protection
 Chemical Protection
 Biological Protection

The nature of protection and the degree in each parameter is the capability of the
given pack construction, specific packaging material/combination of materials and
relevant packaging technology. The degree of preservation and protection against
the rate of deterioration determines the potential shelf life, the end quality, and
the safety of the food.

Function and Convenience

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Once packaged and protected, the unit in the total supply chain has to perform
required functions to the standard expected and also perform functions expected
by customer/consumer in the end.

In all these stages the stakeholder and consumer look for conveniences.
Depending on the nature of the pack there are many different ways of offering
convenience.

Presentation and Communication

In performing this role, a package has to inform all the stakeholders and the
customer/consumer of the required information some of which are legal
requirement, others may be part of an agreement or that facilitate storage,
handling, purchasing and consumption.

Packaging Materials

There are many base materials used either as single component material or
combined and composite material. Materials used in a food pack or a packaging
system can be put into two groups, depending on the physical association with
food they contain, namely ;Food contact material/component and non-food
contact material/component. Food contact material has to be food grade. If other
materials can come in contact with food contact part at any time, they also have
to be food grade.

Packaging materials can be made of Glass, Metal (Tin and Aluminium), Pulp
(Molded- Pulp , Paper and Paper board), Plastics ( PE, PP, PVC, PET, PS, PA, ABS,
PC etc.,) or other materials ( timber/wood, Composite, Earthenware, Porcelain,
Plant materials etc.,).

Packaging Technologies, Packs, Pack Types and Pack Formats

Packs, Pack Types and Pack Formats

There are many types of packs used in food packaging. Basically the pack type and
its construction is governed by the purpose, required to serve and sometimes the
technology used to preserve. In a traditional method pack can be identified with

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the purpose for which the unit is used. For example if it is at consumer level the
pack is named as consumer pack, if it is a pack for retailing it is named retail pack
and, if it is for moving bulk quantities directly it is named a bulk pack. Similarly, if
it is for any intermediate quantity or intermediate purpose they can be named
Intermediate pack, Transit Pack, Distribution Pack etc.,.

In retail level food packaging, many types, formats and styles of packaging which
constructed using multitude of materials are used. Namely;

Bottles and Jars

Bottles made of Glass, Metal, Plastic materials together with metal or plastic
closures with or without wads or diaphragms, with or without inner cap lining are
used. In terms of filling ambient to hot filling and in the case of glass bottles in
pack sterilization is applied.

Any dry product that is not very hygroscopic and deteriorates only due to
moisture or oxygen, relatively slowly, packing in a given packaging just by filling
and sealing under atmospheric conditions, under ambient air would give an
average shelf life acceptable to the market, if reasonably good packaging
materials are used.

Cans and Canisters

Metal, Plastic, and Composite cans and canisters are used. Depending on the
product type, form and filling conditions, the construction is varied.

Metal can be tin coated steel or Chromium and Chromium oxide coated steel
appropriately. Depending on the type of food internal lacquer coatings are
applied. Metal cans, can be retorted.

Plastic cans, can be multi-layer co-extruded barrier or high barrier for oxygen
sensitive products.

Sachets, Pouches and Bags.

Laminated plastic pouches, with or without aluminium, low, medium and high
barrier film constructions are used for food packaging.
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However, depending on the complexity of deterioration factors, complex barrier
packaging solutions and other packaging technology solutions such as Aseptic
Packaging, Modified Atmosphere Packaging etc., would be required.

In a different solution temperature control with or without above special

technologies may be applied.

Carotns

Cartons are generally made of paper board abut there are many variants such as
those made with poly coated board, Laminated board, Plastic sheets etc., A
specific carton that is of interest to long shelf life primary pack for liquid food is
‘Aseptic Carton’.

Boxes, Crates and Bins

Packaging cartons used for transit and bulk quantities they are known as boxes,
crates or bins. They can be made of Paperboard, plastics or even wooden
material.

Bags and Jumbo Bags.

For bulk and intermediate packaging bags are used and they can be Multiwall
paper bags, Gunny Bags, Woven plastic Sacks, Plastic Bags or composite bags.
Similarly, large quantities are packed in jumbo bags.

Cans, Kegs, Barrels, and Drums.

Above packs are used for liquid and semi-liquid products. They can be made of
Glass, Metal, Plastic or even paper board and composite material.

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Packing Methods and Packaging Technologies.

Aseptic Packaging

Aseptic packaging is the packaging of a commercially sterile product (typically

food or pharmaceutical) into a sterile pack in a sterile environment and
sealing/closing hermetically in a way that the sterility is maintained.

 Why Aseptic Packaging?

 Shelf life for Six months to one year at room temperature

 No Chemicals or Preservatives

 No adulteration possible

 Can be applicable for wide range of products

 Nutritional Value is preserved

 No cold chain required on the supply Chain

 Easy to export

 Bottles( PET, HDPE, Glass), Cartons, Pouches- Different Packaging

Options- Shapes

Food products that are packed includes Juices, Nectar, Beverages, Coconut water,
Milk & Milk Drinks etc.,

Modified Atmosphere Packaging ( MAP)

The principle of MAP is to replace the normal atmosphere by a gas mixture that is
suited to the food in question. The method of the atmosphere replacement will
be de- scribed in more detail in the following chapters. The main gases used for
MAP are Nitrogen,

Carbon Dioxide and Oxygen. However, Argon, Carbon Monoxide, Helium and
other gases are defined as permitted gases for MAP by the European Community.

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The actual use of these gases depends on the demands of the food manufacturer
on the food to be packed.

Modified Atmosphere Storage

Steady state environment comprising of a special blend of oxygen, nitrogen, and

carbon dioxide, monitored and maintained to extend the shelf life of certain
products in a warehouse or storage area.

Vacuum Packaging

Vacuum packaging is another way to increase the shelf life of food products. Here
the product is placed in an air-tight pack, the air sucked out and the package
sealed. This method involves (manually or automatically) placing items in a plastic
film package, removing air from inside, and sealing the package.

Food Labelling

Food labeling is subjected to regulation. Some citations of the Food Act is given
below.

“ 04. (1) The following declarations shall be on the main panel of the package or
container -

a) common name of the product in any two of the three languages and in the
other language on

any other panel;

b) brand or trade name, if any, in any one or more of the three languages in a
manner that shall

not mislead any person;

c) the net contents of the package or container expressed in SI units or by the

international

symbols ‗g‘ or ‗kg‘ in the case of solids, ‗ml‘ or ‗l‘ in the case of liquids and, if
packaged in

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liquid medium, the net drained weight expressed as ‗g‘ or ‗kg‘;

Provided however that the common name may be substituted by any other name
as set out in

Schedule I hereto;

(2)(i) The following declarations shall be on any panel in any one or more of the
three languagesa)

a complete list of ingredients used in the food by their common names in

descending order

of ingoing weight (m/m) at the time of manufacture of the food including any
permitted

food additive either by its common name or its class name and INS number as
prescribed by

regulations made under the Act.

Provided that a food additive carried over to foods at a level less than that
required to achieve a

technological function and processing aids are exempted from declaration in the
list of

ingredients ;

b) the name and address of the manufacturer/packer/distributer;

c) In the case of imported food products :

(i) name and address of the importer; and

(ii) name and address of the packer or distributor in Sri Lanka;

d) the batch number or code number or a decipherable code marking;

e) the date of manufacture;

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f) in case where foods are imported in bulk and repacked, the date of
manufacture and the date of repacking;

g) the country of origin in case of imported foods; and

h) any other declarations stipulated under these regulations;

(ii) Consumer warnings, if any, specified in any regulations under the Food Act, in
any two of the three languages;

(iii) The date of expiry shall be on any panel in any two of the three languages;

Provided however that in the case of bottled food products, the date of expiry,
batch number and

date of manufacture may be stamped on the bottle closure or bottle neck using a
letter size that is legible. In the case of metal cans containing food, the date of
expiry, batch number and date of manufacture shall be displayed indelibly on the
lid of the can either at the top or bottom of the can.

Provided further that the date of expiry may not be required for sugar, tea,
cereals and pulses in wholesale packs or packs for open sale, fresh vegetables,
fruits, roots and tubers and bread, other than sliced bread.

(iv) Instructions for storage and/ or use, if any, in a minimum of two of the three
languages;

where the surface area of the pack is small, exceptions for the use of two
languages can be given by the Chief Food Authority on a case by case basis.”

“Where a label in any one of the three languages has been affixed on the main
panel of an imported package or container of food and a supplementary label
conforming to the regulations shall appear conspicuously and prominently in bold
type in the other two languages, indelibly printed or painted or affixed on any
other panel of such package or container shall be sufficient to satisfy the
requirements of these regulations.”

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Cost

Cost of packaging for food has many components and dimensions. Therefore
always overall cost must be considered. Packaging costs encompass

a) Cost of packaging material,

b) Cost of packing operations,
c) Costs associated with distribution,
d) Costs of expenses/losses due to inappropriate packaging
e) Other intangible costs such as (sales/marketing) gains and losses
accrued to packaging.

Packaging costs can be relatively higher as it moves from Primary product through
to the higher processing levels. However, if the purpose of packaging, both
primary and secondary, is not served it will be a waste. Therefore, food must not
be under-package as much as they must not be over-packaged.

Sustainability

Packaging while it serves a great purpose must not be a burden to environment.

Environmental burden can be minimized by using materials in types and amount
optimum for the purpose. Sustainability of packaging can be improved by
Removal, Reduction, Reuse, Recycling. Therefore, packaging must be designed in
a manner they comply with such principles.

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