Introduction To Packaging 2j623e

GLOBALTRAINING PROGRAMME FOR THE PARTICIPANTS FROM SRILANKA IIP,INDIA

27TH APRIL,2011

INTRODUCTION TO PACKAGING PROF. N.C. SAHA DIRECTOR INDIAN INSTITUTE OF PACKAGING

BACKGROUND • INDIAN ECONOMY IS BASED ON AGRICULTURE. • 2ND LARGEST PRODUCERS OF FOOD GRAINS,SUGAR,FRUITS AND VEGETABLES. • 3RD LARGEST PRODUCERS OF COTTON.

• 7TH LARGEST PRODUCERS OF FISH. • DESPITE OF THIS, INDIA S ONLY 1.5 % OF INTERNATIONAL TRADE. • ONLY 7% OF FRESH PRODUCE IS PROCESSED.

BACKGROUND • ON THE CONTRARY, A NATIONAL LOSS OF FRESH PRODUCE IS ABOUT 35-40%. • MAJOR CAUSES ARE DUE TO MISHANDLING DURING STORAGE AND TRANSPORTATION, LACK OF STORAGE FACILITIES AND IMPROPER AND UNSCIENTIFIC PACKAGING.

INDIAN CONSUMER • PREFERS TO BUY FRESH PRODUCE AND COOK AT HOME. • CAUSES TO LESS PURCHASE OF PROCESSED FOOD ITEM. • GENERAL PERCEPTION IS THAT PROCESSING REDUCES THE NOURISHMENT DURING PROCESSING • PACKAGING ADDS TO THE COST. • MISCONCEPTION OR MYTH ARE TO BE REMOVED IMMEDIATELY THROUGH AWARENESS PROGRAMME.

PER CAPITA CONSUMPTION OF PACKAGING MATERIALS COUNTRY INDIA

QUANTITY 6.7 KGS



208.3 KGS

JAPAN

172.5 KGS

GERMAN

164.9 KGS

CHINA

11.5 KGS

KOREA

21.0 KGS

WHAT IS THE MEANING OF

PACKING & PACKAGING

PACKING IT IS AN OPERATION RELATED TO ANY ACTIVITIES OF PACKAGING

PACKAGING • A COORDINATED SYSTEM OF PREPARING GOODS FOR TRANSPORT, DISTRIBUTION, STORAGE, RETAILING AND END USE. • AN ESSENTIAL TOOL IN PRODUCT PROTECTION, DISTRIBUTION, MARKETING & CONSUMER SATISFACTION.

PACKAGING • PACKAGING IS NOT MERELY WRAPPING THE PRODUCT AND PUT TO THE MARKET. • A COMBINATION OF SCIENCE, ART & TECHNOLOGY. • AN INSTRUMENT OR TOOL FOR MARKETING. • THE HEART OF MERCHANDISING.

PACKAGING • LINKAGE BETWEEN PRODUCTION AND MARKETING. • AN INSTRUMENT FOR MARKETING. • LAST OUTPUT FOR PRODUCTION BUT FIRST INPUT FOR MARKETING. • PACKAGE ACTS AS A SILENT SALESMAN.

PACKAGING SERVES TWO BASIC FUNCTIONS MARKETING LOGISTICS

PACKAGING • INVOLVES TO BASIC TWO AREAS MARKETING • PACKAGE PROVIDES INFORMATION ABOUT THE PRODUCT • PROMOTES THE PRODUCT THROUGH ATTRACTIVE GRAPHICS • ATTRACTS ATTENTION TO THE CUSTOMER. • ACTS AS A SILENT SALESMAN LOGISTICS • A MEANS OF ENSURING SAFE DELAIVERY TO THE ULTIMATE IN SOUND CONDITION AT MINIMUM COST.

PACKAGING THOUGHT PACKAGING ADDS TO COST OR PACKAGING ADDS THE VALUE TO THE PRODUCT

ROLE OF PACKAGING • PACKAGING PLAYS A VITAL ROLE FOR – FOOD PRESERVATION. – PROTECTION DURING STORAGE, HANDLING, TRANSPORTATION AND DISTRIBUTION.

• A SYMBOL OF VALUE ADDITION. • A CONVEYOR OF CONVENIENCE TO CUSTOMER.

PACKAGING • REDUCES WASTE DUE TO MISHANDLING, IMPROPER STORAGE AND TRANSPORTATION

• ASSURED ABOUT RIGHT QUANTITATIVE AND QUALITATIVE FOODS

PACKAGING • PACKAGING PLAYS A SIGNIFICANT STRETEGIC ROLE AND TOOL FOR BUSINESS DEVELOPMENT AND IMPROVED BUSINESS PERFORMANCES.

• IT IS ALSO CONSIDERED AS NEED BASED TECHNOLOGY. • IT IS AN IMPORTANT PART OF THE BRANDING PROCESS.

HISTORY OF PACKAGING • PACKAGING INDUSTRY STARTED IN 1950’s. • HOWEVER, IT BECAME NOTICEABLE IN 1960’s. • THESE INDUSTRIES GREW IN SIZE IN 1970. • REVOLUTIONALIZED HAPPENED ONLY IN 1980. • THE TECHNOLOGIES GOT UPDATED IN THE LATE 1990’s AND 2000.

PACKAGING • IN SHORT, PACKAGING IS THE SYSTEM WHICH COMPLIES WITH “3M” CONCEPT – M - MATERIALS – M - MACHINERIES – M – MANPOWER • FUNCTIONS OF PACKAGES DENOTED BY “3P” – P - PRESERVATION – P - PROTECTION – P - PRESENTATION

6-P ELEMENTS FOR CONSUMER PRODUCTS PROTECTION

PRICE

PRESERVATION

PACKAGING

PRESENTATION

PROFIT

PROMOTION

PACKAGING • RECENTLY, IT HAS GAINED POPULARITY DUE TO - GROWING CONSUMER AWARENESS - WILLINGNESS TO PAY FOR VALUE AND HYGENIC PRODUCTS. - INCREASE IN GROWTH OF EXPORTS - DEMAND FOR BETTER, ATTRACTIVE, VALUE ADDED, CONSUMER FRIENDLY PACKAGE.

PACKAGING ATTRIBUTES • THE PACKAGE MUST ATTRACT ATTENTION. • THE PACKAGE MUST TELL THE PRODUCT STORY. • THE PACKAGE MUST BUILD CONFIDENCE.

• THE PACKAGE MUST LOOK CLEAN AND SANITARY. • THE PACKAGE MUST BE CONVENIENT TO HANDLE, TO CARRY AND TO USE. • THE PACKAGE MUST LOOK LIKE GOOD VALUE.

PACKAGING OF FISH AND FISH PRODUCTS

FISH AND FISH PRODUCTS •FRESH FISH •FROZEN FISH •CANNED FISH •DRIED FISH •VALUE ADDED FISH PRODUCTS

PRODUCT CHARACTERISTICS •EXTREMELY PERISHABLE PRODUCT.

•PRONE TO MICROBIAL ATTACK. •TENDENCY TO BECOME DRY. •WEIGHT LOSSES. • UNACCEPTABLE FISHY SMELL.

• DETERIORATION OF QUALITY IN OF TASTE AND COLOUR. • LIMITED SHELF LIFE-5 TO 6 HOURS.

REQUIREMENT OF PACKAGING FOR FRESH OR RAW FISH PACKAGES SHOULD HAVE LOW TEMPARATURE RETENTION CAPACITY. SHOULD HAVE GOOD MECHANICAL STRENGTH.  SHOULD HAVE PROPER DRAINAGE FACILITY FOR MELTED WATER.

REQUIREMENT OF PACKAGING FOR PROCESSED FOOD PRODUCTS 

SHOULD BE COMPATIBLE WITH FOOD PRODUCT.

 EASY TO HANDLE AND CARRY.  SHOULD BE ECO-FRIENDLY.  EASY TO IDENTIFY.

 SHOULD MEET THE INTERNATIONAL MARKET REQUIREMENT.

PACKAGING REQUIREMENTS FOR FRESH FISH •TO REDUCE DEHYDRATION •TO PREVENT FAT OXIDATION •SHOULD BE EASY TO WASH

•ACCESS TO DRAIN OUT EXCESS WATER. •TO PREVENT ODOUR PERMEATION •LOW TEMPERATURE RETENTION THROUGH PROPER INSULATION •SHOULD HAVE GOOD MECHANICAL STRENGTH

FRESH FISH - PACKAGE FORMS AND MATERIALS BULK TRANSPORT / PACKAGING • TRADITIONAL BASKETS - POLY SHEET LINER • PLYWOOD BOXES • COLLAPSIBLE ALUMINIUM CONTAINERS • INSULATED MOULDED PLASTIC CONTAINERS • MOULDED CONTAINER - EXPANDED POLYSTYRENE (EPS)

FRESH FISH - PACKAGE FORMS AND MATERIALS RETAIL PACKAGING  SHALLOW TRAY WITH OVERWRAP FILM AND PRESSURE SENSITIVE LABEL TRAY MATERIALS:

 MOULDED PULP  FOAM POLYSTYRENE  CLEAR POLYSTRENE

OVERWRAP FILM:

 GENERALLY FOOD GRADE PVC

barrier flexible films. These high barrier films are ideally suited as lidding films on readymade trays and as top webs on all thermoform-fill seals lines

MOULDED EXPANDED POLYSTYRENE CONTAINER

EPS FISH BOXES

Example of plastic packaging (retail display) Dried Fish

OYESTER TRAYS

MODIFIED ATMOSPHERE PACKAGING FOR FRESH FISH  INCREASE IN SELF-LIFE BY MAP AS COMPARED TO NORMAL PACKAGING.  IF SHELF-LIFE IS TAKEN AS HIGH QUALITY AT EARLY STAGE, MARGINAL EXTENSION IS OBSERVED  IF SHELF-LIFE IS TAKEN AT A POINT ACCEPTABLE TO THE PUBLICHEALTH SERVICE, THE EXTENSION IS CONSIDERABLE

PLASTIC CONTAINERS AND LIDDING FILMS FOR MAP OF FRESH FISH PET

PA

EVOH

PVDC

PVDC

PC

LDPE

LDPE

HDPE

LDPE UPVC

EVA

LDPE EVOH EPS

SELECTION OF PACKAGING MATERIALS FOR MAP SPECIFIC REQUIREMENTS  GAS BARRIER  WATER VAPOUR BARRIER  HEAT SEALABILITY  RESISTANCE TO MECHANICAL DAMAGE  OIL RESISTANCE  TRANSPARENCY  DRIP ABSORBANCE  INSULATION

New Printed Trays

Fresh MAP seafood – shelf-life determination

Time-temperature indicators (e.g. VITSAB) can be used to evaluate shelflife of fresh MAP fish under dynamic temperature storage conditions

GROWTH OF SPOILAGE BACTERIA IN FRESH MAP COD FILLETS

COOKED MAP STRIPS

COLD WATER SHRIMPS (PANDALUS BOREALIS) • MAP WITH 20 - 40% CO2 • 1.5-2.0 % NACL IN THE WATER PHASE • PH ~ 7.7 • POTENTIEL GROWTH OF LISTERIA MONOCYTOGENES LIMITS SHELFLIFE OF THIS READY-TO-EAT PRODUCT

Cooked and brined MAP shrimps

Dried fish

WHITE TUNA - IN WATER

PROCESSED FROM FRESHLY CAUGHT TONGOL TUNA, SOLID PACK, 15% FLAKES, EASY OPEN CANS.

PACKAGING REQUIREMENTS FOR FROZEN FISH SPOILAGE FACTORS

* MOISTURE LOSS / DEHYDRATION * OXIDATION / RANCIDITY * ODOUR PERMEATION

PACKAGE REQUIREMENTS

* LOW WATER VAPOUR BARRIER * LOW OXYGEN BARRIER * AROMA RETENTION * STABILITY AT SUB-ZERO TEMPERATURES

BLOCK FROZEN SHRIMPS PACKAGE FORMS AND MATERIALS PACKAGE FOR BLOCK / PLATE FROZEN SHRIMPS  GLAZING  INNER WRAPPER BAG  PRIMARY CARTON  MASTER CARTON

 STRAPPING / SHRINK PACKAGING

STORAGE AT MINUS 180 C

BLOCK FROZEN SHRIMP/SQUIDS

READY SALADS AND FISH PUDDING PACKAGING IN TRAY SEALING IN MODIFIED ATMOSPHERE (MAP) IN RIGID TRAYS

Frozen fish fillets packaging in vertical machine (vffs) in reclosable pack

IQF SHRIMP PACKAGE FORMS AND MATERIALS PACKAGE FOR INDIVIDUALLY QUICK FROZEN SHRIMPS  GLAZING

 UNIT POUCH/WRAPPER / PLASTIC TRAYS  PRIMARY CARTON

 MASTER CARTON  STRAPPING / SHRINK PACKAGING

STORAGE AT MINUS 180 C

IQF LOBSTER

LAMINATED CARTON FOR IQF SHRIMP

PLASTIC TRAYS FOR IQF SHRIMPS

PLASTIC TRAYS FOR IQF CRABS

PRINTED PLASTIC LAMINATED POUCH FOR IQF SHRIMP

PRODUCT CHARACTERISTICS OF DRI FISH- SPOILAGE FACTORS  MOISTURE ABSORPTION  OXIDATION / RANCIDITY  INSECT INFESTATION

PACKAGE FORMS  BASKETS WITH HESSIAN LINING  HESSIAN SACKS

REQUIREMENTS  USE OF MODERN PLASTIC BASED LAMINATES  POSSIBILITY OF GAS FLUSH/ VACUUM PACKS

DRIED FISH VENDING

Dried fishery products

Frozen products Frozen shrimp is the most important marine export of India. Conventionally shrimp was frozen as 2 kg blocks in duplex board cartons lined with low density polyethylene (LDPE) and 10 such cartons are packed in a master carton made of 5 ply or 7 ply corrugated fibre board boxes. There is now great demand from importing countries for shrimp in individually quick frozen (IQF) form (Figure 2). IQF shrimp is packed into plastic film pouches. The other major IQF products are cooked whole lobster, lobster tail, lobster meat, cuttle fish fillets, boiled clam meat and fish fillets from white lean fish.

VALUE ADDED FISH PRODUCTS BATTERED AND BREADED PRODUCTS

FROZEN STORAGE - THEMOFORMED TRAYS WITH PLASTIC FILMS

FISH CURRY

RETORTABLE FLEXIBLE POUCHES

SURIMI

PACKED AS BLOCKS IN PLASTIC FILM WITH AN OUTER PAPERBOARD CARTON

AFD PRODUCTS

FLEXIBLE LAMINATE POUCH - LOW OTR & WVTR

FISH SOUP POWDER

FLEXIBLE LAMINATE POUCH - LOW OTR & WVTR

PACKAGING FOR FISH & SEAFOOD VACUUM PACKAGING

PACKAGE REQUIREMENTS • EASY TO OPEN. • EASY TO CLOSE. • EASY TO DISPOSE OFF. • EASY TO DISPENSE. • EASY TO HANDLE. • EASY TO IDENTIFY. • EASY TO RECYCLE. • PILFER-PROOF. • EYE-APPEAL.

• EASY TO PRINT ON THE PACKAGE. • SHOULD HAVE GOOD IMPACT RESISTANCE. • ECONOMIC AND SAFE. • EASY TO DISPLAY. • CONVENIENCE IN SIZE AND SHAPE. • INSTRUCT.

FACTOR RESPONSIBLE FOR REQUIREMENT OF PACKAGING CRITICAL FACTORS OF FOOD PRODUCTS : WHO ? HOW ? WHERE ? HOW LONG ?

PACKAGING MATERIALS PRIMARY • • • • • • • •

PAPER & PAPERBOARDS. PLASTIC FILM AND LAMINATES. PLASTIC CONTAINERS. GLASS CONTAINERS. METAL CONTAINERS. COMPOSITE CONTAINERS NATURAL FABRIC MATERIAL. SYNTHETIC FABRIC MATERIALS

PACKAGING MATERIALS ANCILLARY • VAST VARIETY OF COATINGS. • DIFFERENT KINDS OF SEALENT LAYERS. • A LARGE VARIETY OF ADHESIVES. • LARGE VARIETY OF PRIMARY INKS. • VAST VARIETY OF LACQURES & VARNISHES.

REQUIREMENT OF PACKAGING FOR EXPORT MARKET 

SHOULD MEET THE LABELLING REQUIREMENT.

 LABELS SHOULD BE BAR CODED.

 ‘ECOMARK’ LABELS FOR EEC COUNTRIES.  MAINTAIN THE ISPN-15 MEASURES SPECIALLY FOR WOOD BASED TRANSPORT PACKAGES.

REQUIREMENT OF PACKAGING FOR EXPORT MARKET 

METAL ELEMENTS LIKE LEAD, COPPER, ETC. OF

PAPER AND PAPERBOARD WITHIN PERMISSIBLE LIMIT.  SHOULD COMPLY WITH FOOD GRADE PACKAGING MATERIALS.

PACKAGING REQUIREMENT FOR GLASS CONTAINERS •

LIGHT IN WEIGHT

•

LEAK PROOF

•

GOOD WORKMANSHIP

•

CHEMICALLY TREATED

PACKAGING REQUIREMENT FOR METAL CONTAINERS • FOOD GRADE LACQUERS • LEAK PROOF • HIGH VACUUM RESISTANCE • ROHS COMPLIANCE

PACKAGING REQUIREMENT FOR FLEXIBLE PACKAGES •

HIGH TEMPERATURE RESISTANCE.

• HIGH BARRIER PROPERTY • ADEQUATE PEEL BOND STRENGTH. • GOOD HEAT SEAL PROPERTY.

•

PEARLISED, HOLOGRAPHIC ETC. TO ENHANCE APPEAL.

UNIT PACKAGES •

PAPER BAGS.

•

PAPERBOARD CARTONS.

•

PLASTIC FILM AND LAMINATE BASED POUCHES.& BAGS.

•

GLASS AMPULES & VIALS, BOTTLES & CONTAINERS.

•

METAL CANS.

•

COMPOSITE CANS.

•

PLASTIC BOTTLES & JARS.

•

JUTE BAGS.

•

PLASTIC WOVEN FABRIC BASED BAGS..

BULK PACKAGES •

PAPER SACKS.

•

STEEL CONTAINERS.

• . •

METAL DRUMS & BARRELS

•

PLASTIC DRUMS & BARRELS.

•

PLASTIC WOVEN SACKS.

•

CORRUGATED FIBRE BOARD BOXES.

•

WOODEN BOXES.

•

PLYWOOD BOXES.

•

FLEXIBLE INTERMEDIATE BULK CONTAINERS.

•

RIGID INTERMEDIATE BULK CONTAINERS.

COMPOSITE CONTAINERS.

STATUTORY LABELLING • PRE-PRINTED ON CONSUMER PACKAGE (UNDER P.C. RULES) – – – – – – –

NAME & ADDRESS OF MFRR./PACKER MONTH OF YEAR OF PACKING COMMON / GENERIC NAME OF PRODUCT NET QUANTITY (WT. OR VOL.) BEST BEFORE……. (FOOD) EXPIRY DATE ……. (PHARMA) NOT INTENDED FOR RETAIL SALE (GROUP OR MULTI-PIECE PACKAGE)

STATUTORY LABELLING • PRINTING ON CONSUMER PACKAGE AT THE TIME OF PACKING – BATACH NO. – MAXIMUM RETAIL PRICE OR M.R.P. - RS…. (INCLUSIVE ALL TAXES)

STATUTORY MARKING PRE-PRINTED ON CONSUMER PACKAGE FOR PROCESSED FOODS • VEGETARIAN – SYMBOL OF FILLED GREEN CIRCLE WITH SQUARE GREEN OUTLINE ON WHITE BACKGROUND – NON-VEGETARIAN • SYMBOL OF FILLED BROWN CIRLE WITH SQUARE DOUBLE BROWN OUTLINE

– LOGO OF FPO (FOR FRUIT PRODUCTS) – LOGO OF MPO (FOR MEAT PRODUCSTS)

TO DECLARE THE IMPORTANT INFORMATION AS PER THE STATUTORY REQUIREMENT

OPTIONAL MARKING • FOR EXPORTS – LOGO OF APEDA • FRESH & PROCESSED FOOD

– LOGO OF MPEDA • MEAT/ FISH/ POULTRY

– BAR CODE • FOR ORGANIZED SECTOR

– ECO-MARK • TO EEC COUNTRIES

. TO CARRY THE SYMBOL OF ECO-MARK OR ECO-LABELING TO MEET THE REQUIREMENT OF INTERNATIONAL TRADE.

1. PICTORIAL MARKINGS ARE NORMALLY PRINTED ON THE OUTSIDE SURFACE OF TRANSPORT PACKAGES