Advances in Dairy and Food

Packaging (DT-522)
Introduction
Assignment
The international trend toward sustainable packaging is motivated by escalating
environmental issues, changing consumer demands, and strong regulatory systems.
Packaging, especially in frozen foods and dairy industries, is an integral factor for
the preservation of the product, its safety, and market appeal. Nevertheless,
conventional packaging material, most importantly plastics, are significant sources
of pollution and wastage, recycling merely a minor portion of the materials. This
has encouraged innovations in sustainable substitutes, including recyclable,
biodegradable, and bio-based products, to minimize ecological impacts without
compromising functionality.
The frozen food industry, particularly dairy, has special challenges in packaging
design, i.e., compatibility with low temperatures, moisture, and mechanical forces.
These technical demands need to be offset by environmental advantages of the
solution. New developments have been bio-based polymers such as PLA and PHA,
waste materials derived from agro-industries, and active packaging systems
enhancing shelf life. In addition, there is growing consumer demand for sustainable
alternatives and regulatory pressure, including the EU's ambitions to have 100%
Topic:
recyclable Innovations
packaging by 2030, that are driving in sustainable
industry change.
This article packaging for frozen
examines why the packaging industry needs food
to be sustainable, its
economic and environmental advantages, and innovative technologies specific to
dairy products and frozen foods.products.
It also investigates future trends such as smart
packaging and regional regulatory factors in order to present a complete picture of
the industry's Exploring new packaging
sustainable development.
material and design suitable for
Need for Sustainable Packaging
Environmental issues, consumer trends, and regulatory forces drive the increasing
need for sustainable packaging. Packaging materials are an everyday part of life,
and they are used widely in grocery retail, medicines, and the food sector. Yet their
Submitted by: Gurdeep SUBMITTED TO: DR. PN RAJU
end-of-life contribution presents great challenges. Plastic waste globally comes
SENIOR SCIENTIST ICAR -
Singh (24-M-DE-03) and
mainlyYashwant
from packaging, and just 2% is recycledNATIONAL
(24-M-DE-07) M.
back intoDAIRY
new packaging
RESEARCHmaterial.
The other waste tends
Tech toyear
1st be directed to landfills, water sources,
INSTITUTE , KARNALor get incinerated,
which results in serious ecological damage. Multi-material laminates, which are
mostly employed due to their strength and looks, pose a special challenge as they
are not recyclable. Green packaging seeks to overcome these problems by
emphasizing recyclable, reusable, or compostable materials, minimizing the use of
virgin resources, and lessening environmental impacts.
Consumer consciousness is a main driver, as 79% of shoppers see recyclable or
compostable packaging as important. Retailers and manufacturers are increasingly
turning to sustainable alternatives, but obstacles exist. For example, recyclable
films tend to have poorer heat resistance compared to traditional lamiantes,
impacting manufacturing efficiency. Advances in materials science in the form of
bio-based polymers and more efficient recyclable films will help break these
limitations. Moreover, compost packaging, though promising, needs the right
infrastructure to work. Recycling is often preferable in most situations, particularly
for clean, dry packaging such as sauceless frozen food packs.
Sustainable packaging aids environmental resilience by curbing wastage, carbon
footprint reduction, and natural resource preservation. Petroleum-based plastics are
cost-efficient, highly versatile, yet non-biodegradable and pollution-causing.
Biopolymers based on starch, cellulose, or microorganisms present biodegradable
alternatives with equal functionality. For instance, polylactic acid (PLA) and
polyhydroxyalkanoates (PHA) find growing use in food and cosmetics packaging
as a result of their environmentally friendly nature.
The financial advantages of sustainable packaging are long-term cost reduction due
to material efficiency and regulatory compliance. The European Union's vision to
have 100% reusable or recyclable packaging by 2030 identifies the move towards
circular economy practices. Materials such as aluminum and glass are very
recyclable, while paper packaging covered with biodegradable polymers can
substitute plastic in most uses. Transitioning to sustainable materials, however,
needs balancing performance, cost, and consumer access.

Innovations in Frozen Food Packaging

Eco-Design in Frozen Food Packaging

Eco-design combines environmental and social goals into packaging, employing
life cycle assessment to minimize impact (Cruz et al., 2024). For frozen foods, the
packaging should withstand low temperatures, moisture, and grease while being
sustainable. It is characterized by material minimization through light cartons and
thinner films, and the utilization of recoverable materials such as recyclable PET ,
with 25% recycled plastic content in PET bottles being required in the EU by 2025
(Cruz et al., 2024). Recyclable materials such as cardboard are embraced by
consumers, who link them with sustainability and health, although there are
continued misconceptions between "bio-based" and "biodegradable" (Cruz et al.,
2024). Skillet and top-load cartons, which are manufactured from recycled fibers,
provide crush resistance for stacking in transit (Harrison & Croucher, n.d.).

Recyclable and Bio-Based Materials

One-time-use plastics such as polyethylene and polypropylene, which are used in

frozen food packaging, create environmental concerns, leading to the use of
recyclable and bio-based options (Cruz et al., 2024). PET is utilized in trays, but
recycling involves rigorous sorting to avoid contamination (Cruz et al., 2024). EU's
2022 regulation guarantees food-grade recycled plastics (Cruz et al., 2024). Bio
polyethylene (Bio-PE) produced from sugarcane is recyclable, captures 2.5 tons of
CO₂ per ton, and is applied in frozen food bags (Cruz et al., 2024). Biodegradable
bioplastics such as polylactic acid (PLA) and polyhydroxyalkanoates (PHAs)
provide toughness at cold temperatures, with PLA trays exhibiting grease and
water resistance (Cruz et al., 2024; Harrison & Croucher, n.d.).

Agro-Industrial Wastes Utilization

Valorization of agro-industrial wastes enables sustainable packaging, enabling a

circular economy (Cruz et al., 2024). Potato peel, pineapple core, or jackfruit seed
starch produces biodegradable films and trays. Pineapple stem starch film is water-
proof, heat-sealable, and flexible and increases shelf life up to 50% in certain
products (Cruz et al., 2024). Rice straw and sugarcane bagasse-derived cellulose
find applications in cardboard cartons as well as in films, where films of
carboxymethyl cellulose are prepared from okra waste for improvement in barrier
function for frozen vegetables (Cruz et al., 2024). Fish collagen and gelatin of
processing wastes constitute biodegradable films for frozen fishery products,
usually incorporating antimicrobial compounds such as neem extract as a UV
protective agent (Cruz et al., 2024). Collagen films from tilapia skin, blended with
starch, are suitable for frozen food trays (Cruz et al., 2024).

Active and Intelligent Packaging: Active packaging enhances frozen food

quality, while intelligent packaging tracks conditions (Cruz et al., 2024).
Microwave susceptors, utilizing metallized polyester films laminated to board,
facilitate crisping and browning in microwave ovens to 240°C (Harrison &
Croucher, n.d.). pH-sensitive films based on cassava starch and blueberry waste
serve as freshness indicators, color-changing to indicate quality changes in frozen
products (Cruz et al., 2024).

Emerging Technologies
3D printing produces personalized frozen food packaging from biopolymers such
as PLA or starch-based composites, maximizing material usage and barrier
function (Cruz et al., 2024). Rice husk composite trays are biodegradable and have
low weight (Cruz et al., 2024). Chitosan or gelatin electro spin nanofibers include
antimicrobial components, ensuring improved safety and shelf life for frozen meat
and seafood (Cruz et al., 2024).

Packaging Material and Packaging Design for Frozen Dairy Products

Frozen dairy foods, including ice cream, frozen yogurt, and dairy desserts, need
special packaging to ensure quality, safety, and consumer attractiveness. Proper
packaging keeps the product fresh, avoids spoilage, and makes it more marketable.
This paper discusses the pivotal role of packaging materials and design for frozen
dairy foods based on information from given documents and supplemented with
further knowledge to cover particular requirements in this industry.
Importance of Frozen Dairy Product Packaging
Frozen dairy product packaging is important in that it performs several roles: it
guards the product against environmental conditions, lengthens shelf life, and
serves as an advertising vehicle. In the document "Why Packaging Is Important for
Frozen Products," packaging maintains the quality and nutrients of frozen foods
because it prevents freezer burn, oxidation, and contamination. These concerns are
most important for dairy foods, which can degrade in texture and lose flavor
because of exposure to moisture and air. Packaging also protects foods from
outside forces such as moisture, air, and light, which can ruin taste, texture, and
attractiveness. For frozen dairy, texture retention and the avoidance of the
formation of ice crystals are especially important, so strong barrier properties are
vital.
In addition to purpose, packaging is also affecting customer purchasing choices.
Aesthetic presentations and informationally labeled packages transmit brand value
and product advantages and establish confidence. In frozen dairy foods, open
packaging or transparent windows allow viewing of rich coloration, tantalizing
consumers, while transparent labelling helps the product adhere to food safety
rules and advise against allergens or nutritional composition.

Packaging Materials for Frozen Dairy Products

Packaging material selection is critical to the quality and safety of frozen dairy
products. The papers describe several materials that can be applied to frozen foods,
particularly relevant to dairy use.
Cardboard and Paperboard
Cardboard and paperboard, as mentioned in "Why Packaging Is Important for
Frozen Products" and "packing material part 2," are cost-effective and sustainable
solutions commonly employed for secondary packaging, e.g., corrugated boxes.
These materials offer transportational structure and are simple to print on, enabling
brands to showcase bold graphics and product details. For frozen dairy foods like
ice cream containers or bulk dessert packaging, corrugated boxes provide strength
and stackability. Nevertheless, poor water resistance of cardboard requires
coatings, including wax or plastic, in order to resist moisture absorption in freezer
temperatures. Wax-coated cardboard, noted in "packing material part 2," provides
internal moisture equilibrium, not allowing outside water to penetrate and destroy
the package.
Solid bleached sulfate (SBS) paperboard, also noted, provides high brightness and
smoothness, perfect for superior printing to promote consumer appeal. Although
less durable than rigid plastics, SBS paperboard is appropriate for luxury ice cream
cartons where appearance is paramount.
Recyclable Plastics
Plastics, especially recyclable plastics such as polyethylene (PE), polyethylene
terephthalate (PET), and high-density polyethylene (HDPE), are essentials in
frozen food packaging because they are flexible, resistant, and barrier material. The
report "packing material part 2" focuses on PE shrink film's high resistance to
extremely low temperatures, making it suitable for packaging frozen dairy
products. PET is also known for its ability to withstand sudden temperature shifts,
important for products that go through freezing and thawing processes, such as
frozen yogurt packaging. Low-density polyethylene (LDPE) offers strength and
water resistance, safeguarding products such as ice cream pints during
transportation.
For frozen dairy, recyclable plastics can be used in rigid containers or flexible
pouches. Rigid plastic containers, outlined in "packing material part 2," are light,
shock-resistant, and transparent so customers can see the product. These are typical
for single-serve frozen yogurt or dessert cups. Flexible pouches, emphasized in
both "Why Packaging Is Important" and "packaging design," provide convenience
with reseal features, cutting down on waste for multi-serve ice cream or frozen
dessert packs.
Flexible Pouches
Flexible pouches, constructed of layered materials such as PE, polypropylene, or
nylon, are commonly used for frozen dairy foods. The report "packaging design"
defines stand-up pouches as tamper-resistant, water-resistant, and economical and
fit for portion-controlled dairy desserts. Mylar package bags, as mentioned, are UV
resistant and environmentally friendly, which is perfect for premium frozen dairy
foods wherein sustainability is a selling factor. Retort pouches, through their
sterilizing features, provide long-term preservation and odorless storage, which
proves to be useful in export-oriented dairy products.
Aluminum Foil and Metal Packaging
Aluminum foil, as explained in "packing material part 2," provides great barrier
properties to moisture, air, and microorganisms. Though not as popular with frozen
dairy, it is utilized in specific uses, like foil-lined trays for luxury ice cream cakes,
to provide hygiene and shelf extension. Metal packaging, like tin cans, provides
robust protection and is fully recyclable, as noted in "Why Packaging Is
Important." However, their weight and cost make them less prevalent for
mainstream dairy products.
Bioplastics
The report "materials-18-00673-v2" points to bioplastics as a greener alternative to
conventional plastics. Biobased and biodegradable materials like polylactic acid
(PLA) and polyhydroxyalkanoates (PHA) are picking up steam because of green
issues. In frozen dairy, bioplastics have the potential to substitute trays or films,
providing similar barrier behavior to fossil-based plastics. Yet their technical
performance, especially in barrier behavior and processability, needs to be
enhanced, possibly with Industry 4.0 technology like digital twins for optimized
manufacturing.
Structural Design Factors: Structural packaging design of frozen dairy products
harmonizes functionality, convenience to the consumer, and sustainability. The
report "packaging design" specifies some designs that are applicable to dairy use.
Pouches

source- IBEX Packaging. (n.d.). *Frozen food packaging*.

https://ibexpackaging.com/product/frozen-food-packaging/

Pouches are the top option for frozen dairy as they are convenient and save space.
Stand-up pouches, PE or PP, can hold different portion sizes and are convenient to
store. Their resealability makes them more convenient for consumers, enabling
partial use without affecting quality. Pouches, for instance, are convenient for soft-
serve mix ice creams or frozen yogurt beads.

Trays
Source- IBEX Packaging. (n.d.). *Frozen food packaging*.
https://ibexpackaging.com/product/frozen-food-packaging/

Trays, constructed of plastic, cardboard, or aluminum, are employed for formatted

dairy foods such as ice cream cakes or multi-layered desserts. The report mentions
that trays are strong but less adaptable in volume and therefore ideal for single-
serving or quality products. Clear polypropylene wraps offer better visibility,
appealing to customers in store environments.
Boxes
Source- IBEX Packaging. (n.d.). *Frozen food packaging*.
https://ibexpackaging.com/product/frozen-food-packaging/

Frozen dairy products in bulk are packaged using corrugated and cardboard boxes,
for example, gallon-sized tubs of ice cream. Both the shape and size of the boxes
can be altered for branding and shipping purposes. Window-cut boxes, as
mentioned, provide visibility, which increases demand for high-end ice cream
packaging.

Vacuum and Shrink Wrap Packaging

Source- IBEX Packaging. (n.d.). *Frozen food packaging*.

https://ibexpackaging.com/product/frozen-food-packaging/

Vacuum packaging, which removes air to maintain shelf life, is useful for frozen
foods such as cheese desserts, protecting against oxidation. Shrink wrap,
mentioned in "packaging design," tightly wraps products, providing clear
protection for smaller servings such as ice cream bars. Both practices maintain
product integrity in transport.

Paperboard/Cardboard Frozen Packaging

Source- IBEX Packaging. (n.d.). *Frozen food packaging*.
https://ibexpackaging.com/product/frozen-food-packaging/

Paperboard and Cardboard food boxes are the most sustainable, sturdy, and eco-
friendly and can be recycled after usage. Frozen food industries preferably use
these for bulk shipments and more food storage. Moreover, they are used as
secondary packages (the outer layouts in packaging) to protect raw food items
from external damage during shipment. The compostable packaging boxes are
customizable and printable, brands print their logos, company names, labels,
product instructions, and preservation instructions on them. These packages come
in different shapes and styles like square, rectangular, triangle, and other
customized styles.

Future Scope in Sustainable Frozen Food Packaging

The worldwide flexible frozen food packaging market is on the brink of a
substantial increase, with increasing demand for high-quality, convenient frozen
meals and snacks, as well as a growing focus on sustainability. With changing
consumer choices towards sustainable, lightweight, and resistant packaging, the
market is undergoing a metamorphosis with respect to materials, designs, and
technologies. Between 2025 and 2035, the market will expand from USD 3,512.3
million to USD 10,431.4 million, registering a compound annual growth rate
(CAGR) of 11.5%. This report examines the future horizon of sustainable frozen
food packaging based on developments in materials, smart technologies, regulatory
factors, and regional trends, mainly from the given document on the outlook of the
flexible frozen food packaging market.

Source - https://www.snsinsider.com
Market Drivers and Opportunities
Several critical drivers propel growth in sustainable frozen food packaging. Rising
demand for convenient, ready-to-eat meals, portion packs, and e-commerce
delivery foods is leading manufacturers to deploy flexible, eco-friendly options
such as pouches, wraps, and bags. These pack forms provide enhanced barrier
protection, shelf life extension, and cost effectiveness over rigid packages. The
report points out that pouches, specifically, are the market leaders because of their
flexibleness, resealability, and high-barrier performance against moisture, oxygen,
and freezer burn, and are best suited for frozen vegetables, soups, and ready-to-
cook meals.
Sustainability is the focal opportunity, where the one-step trend is towards bio-
based films, recyclable multilayer packs, and compostable ones. Consumers and
authorities are calling for less plastic waste, and as a result, brands are reducing
conventional plastic use. The report observes that growth in online food shopping
and direct-to-consumer food delivery further boosts demand for lightweight,
sustainable packaging with extended shelf life. Higher disposable incomes and
urban lives also lead to demands for frozen meal kits and convenience foods,
necessitating environmentally friendly packaging to meet consumer values.
Smart packaging technologies are another major opportunity. Technologies like
temperature-sensing sensors, QR code traceability, and blockchain-based tracking
are improving food safety and transparency. The report forecasts that by 2035,
innovations like AI-based predictive food freshness tracking and smart anti-freezer
burn coatings will go mainstream, maintaining product integrity and minimizing
waste. These technologies are in line with the increasing consumer demand for
secure, sustainable food systems.

Regional Trends and Regulatory Influence

Regional trends take a central place in the usage of sustainable packaging for
frozen food. In North America, there is a compelling demand for convenience
foods that impels the adoption of resealable pouches, vacuum-sealed film, and
recycled materials. The report points to the U.S. market concentration on reusable
containers as a method of minimizing wastage, sustained by innovative suppliers
of packaging materials. In Europe, Germany, France, and the UK take the lead
towards sustainable choices, encouraged by mature frozen food markets and EU
laws such as the Packaging and Packaging Waste Directive. The EU's 11.5%
CAGR is mostly due to high uptakes from multilayer films, resealable pouches,
and bio-based materials.
In the Asia-Pacific region, rapidly modernizing nations such as China, India, and
Japan are witnessing growing demand for on-the-go frozen foods and snacks. The
report identifies that urbanization and increasing middle-class aspirations are
pushing the demand for sustainable supply chains. Japan's high-barrier film and
antimicrobial coating innovations, at a CAGR of 11.4%, reflect emphasis on
freshness and space saving. South Korea, at a CAGR of 11.6%, is witnessing high
growth in microwave-safe and recyclable packaging with the support of
government policies for green materials.
Regulatory environments are a major driver. The report foresees more stringent
sustainability requirements and biodegradable packaging regulations by 2035,
mainly in the EU and UK. Such rules will accelerate the transition to compostable
and carbon-neutral packaging, pushing manufacturers to spend on environmentally
friendly options. Regulations on AI-powered supply chain monitoring will also
make compliance possible, greater transparency and accountability included.

Competitive Landscape and Market Leaders

The competitive outlook for sustainable frozen food packaging is dynamic, with
key players like Amcor plc (18-22% market share), Sealed Air Corporation (12-
16%), and Mondi Group (10-14%) driving innovation. Amcor’s AI-optimized
pouches and recyclable films set industry standards, while Sealed Air’s vacuum-
sealed packaging ensures moisture resistance and temperature stability. Mondi’s
paper-based solutions and Berry Global’s bio-based films address sustainability
demands, supported by AI-powered performance analysis. Sonoco Products
Company, at a 5-9% stake, specializes in custom pouches and cold-chain
technologies.
Emerging companies such as Coveris, Constantia Flexibles, and ProAmpac are
driving next-generation solutions through the use of AI-based packaging toughness
and food preservation. The report points out that these organizations, together with
specialty material distributors, jointly control 30-40% of the market, reflecting a
varied and competitive market structure. Their emphasis on recyclable high-barrier
films and intelligent packaging mirrors consumer and regulatory directions.
Consumer Trends and Application Insights
Consumer trends are dictating the future of eco-friendly frozen food packaging.
The report identifies the leadership of the ready-to-eat meal category due to hectic
lifestyles, urbanization, and Frozen food sales are driven by demand for pizza,
pasta, and cooked entrees. Vacuum packaging and high-barrier coatings improve
freshness and shelf life, and environmentally friendly packaging satisfies greens.
So also does the meat and poultry market, which demands tight, leak-proof
packaging to avoid freezer burn, as recommended by USDA standards.
Pouches are leading product forms because of their convenience and eco-
friendliness. Resealable zipper pouches and stand-up pouches are designed to meet
the portion-controlled, go-to-meal demand, while bio-based and recyclable
products meet the environmental imperatives. Bags are still in high demand for
bulk packaging frozen meat and seafood due to durability and affordability. The
report foresees compostable films and intelligent freshness indicators boosting
consumer attractiveness by 2035 in line with convenience and sustainability
demands.
Future Directions and External Insights

Source - https://www.snsinsider.com
In the future, the flexible frozen food packaging industry will develop further
through sustainable innovation. The report's vision of edible packaging films and
fully compostable pouches implies a revolutionary change toward zero-waste
solutions. Although not yet scalable, these developments have the potential to
revolutionize the industry, especially for frozen dairy and plant-based products.
Development in bio-based coatings and nanocomposites, as observed externally,
will improve the low-temperature resistance of sustainable materials, overcoming
existing limitations.
Consumer education will be key to equating perceptions with life cycle analyses,
so that sustainable packaging is accorded value. Influential outsiders imply that
partnerships between food brands and packaging companies will propel the take-up
of smart technologies, including spoilage-detection sensors, to increase safety and
confidence. The application of circular economy values, underpinned by AI-based
recycling systems, will further minimize environmental footprint, making
sustainable frozen food packaging a pillar of global food manufacturing.
Conclusion
The shift to sustainable packaging in the frozen and dairy sectors is no longer just
desirable but a reality, propelled by environmental need, consumer demand, and
regulatory requirements. Materials innovations—bio-based polymers, recyclable
films, and agro-industrial wastes composites—reflect major advances in lowering
dependency on conventional plastics. These innovations overcome key challenges
such as temperature stability, moisture barriers, and recyclability while being
circular economy compatible.
The financial advantages of sustainable packaging, from cost savings over the long
term to compliance benefits, further highlight its sustainability. There are, however,
challenges to be overcome, such as maintaining performance while being
sustainable, scaling up new technologies, and enhancing infrastructure for
composting and recycling. Regional trends and regulations, especially in the EU
and North America, play a central role in determining the market, and consumer
demand for convenience and eco friendliness continues to influence innovation.
In the future, the convergence of smart technologies, including freshness sensors
and AI-based tracking, has the potential to increase sustainability and functionality.
New technologies like edible films and compostable pouches may transform the
industry, but scalability and consumer awareness are necessary for mass adoption.
Through the adoption of these emerging technologies, the frozen food and dairy
industries can bring about a sustainable future, reducing environmental footprints
while addressing the needs of an expanding, sustainability-focused market.
This transformation toward sustainable packaging continues, but with synergistic
cooperation across industries, governments, and consumers, a more sustainable,
resilient packaging system is within sight.
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