FOOD MARKET & PACKAGING

MEGATREND
SHARING ECONOMY IN PACKAGING
Henky Wibawa

Todays contributor
Henky Wibawa
Henky Wibawa serves as Indonesian Packaging Consultant and
Executive Director of Indonesian Packaging Federation based in
Jakarta. He has more than 30 years of experience in market and
business development and research across the packaging
manufacturing industries: Argha Karya PI, VAW Europack, Alcan
Flexipack, Amcor Flexibles Indonesia.

Henky studied and graduated as Electrical Engineer from RuhrUniversitaet Bochum, Germany.

Agenda
Market & Packaging Trend in Asia & Indonesia
Importance of Packaging

Technology Innovation,Shelf
Life,Convenience, and
Regulatory Compliance

An evolution in the Food

Industry and Trade
Consumption

World Population over

7 Billions

Lifestyle
changes
More concern about food
safety, health, Halal,
Double Burden of
malnutrition, NCD, etc

Supply
Decreasing of
agricultural land &
natural resources

Era cheap price is

over, related to global
climate change,
reduction of productive
land, increasing
demand of food &
energy

Competitiveness &
struggling to reduce
High cost economy
Misleading information,
Chemical phobia

Trade

Liberalization Tariff is on going ,

unbalanced & sometimes unfair

Food Regulation more

stringent & NTMs increased,
related to Food Safety,
Standard
Eco-friendly products.
(APEC 2012) (max 5%
Tariff)

Food Fight: Impact of Politic

Advances in technology >double-edged sword: Support
innovation and competitiveness
or Encourage NTMs
Development of IT: Interconnected and easier to
36
access information

Bigger and faster Indonesia

Copyright 2013 The Nielsen Company. Confidential and proprietary.

2005
Size economy
Consumer market
GDP per capita
Urban population

Source: World Bank,McKinsey

US$ 0.7 Trillion

US$ 0.3 Trillion
US$ 1500
43%

2015

2025

US$ 1 Trillion US$ 2 Trillion ++

US$ 0.6 Trillion US$ 1.5 Trillion
US$ 9000
US$ 4000
68%
50%

INDONESIA ANNUAL PACE

+4

PERCENT

ONE OF THE MOST RAPIDLY URBANIZING COUNTRIES IN THE

WORLD.

By 2025 :
Source : WB

68

percent

vs 52 percent in 2012 (according to UN projections).

Packaging Megatrends
Convenient

Healthy
Feel good

Look good

innovation
Moment of truth
The shelf is where that happens.
With 80% of purchase decisions being made at shelf
Successful packaging design is about connecting emotionally
Packaging that sells is friendly to the mind and connected to

the heart of the shopper.

Awareness + Emotion In A Nano-second

Packaging
fulfils.

Meet the consumer needs

Packaging is part of the bundle and plays a critical role in the
total consumer experience
and contributes to making the difference vs competition.
Once the product is purchased, packaging is opened and used. The 2nd five seconds
Consumer relevant Added Values :
For example:

Delivers Convenience

Easy opening
Reclose feature

Drives Positioning

Premium/gifting cues
Enables Sharing

Brings Functionalities

Dispensing feature
Easy storage

Enables consumption

On the go
In the car

Package Sizing for Lifestyle

Smaller pack sizes for urban living and on the go

Packaging Technologies
Combination of
packaging
technologies to
extend shelf life
of food products

PROTECT

Material

Process

Product

Product Technology

What we do?
Replace traditional packages with advanced packaging that extends
shelf life, and improves sustainability

What affects Food Shelf Life?

Foods are complex chemicals. They undergo variety of biological
& chemical changes over time.
Food Shelf Life = Microbiological Safety + Sensory + Nutrition

Food for Microbes

Food
Microbes require food to grow
Proteins
Carbs
Sugars

Limiting the amount of available food will limit

microbial population
Particularly important for cleanliness of the
factory & packaging materials

Summary of Main Factors affecting Microbes

Organism
Bacteria

pH Range Water
Activity
4.4 to 9.8 >0.85

Yeasts

1 to 11

>0.60

Molds

1 to 12

>0.60

Oxygen

Temperature

Some it
depends

Cant survive
high temp.
Hibernate at
low
Helps but
Can not
not must to survive high
have
temp
Oxygen
Needs
Oxygen

Can not
survive high
temp

Hurdle Technology
Hurdles is a technique to impart the
greatest degree of resistance to
microbial growth.

Hurdles states that by

confronting microbials with a
multiple set of barriers that
each inhibit growth, they will
be challenged to such a degree
that the organisms are
effectively eliminated.

Sensory
What affects sensory qualities of food
Oxygen
Color change, rancidity, smell

Moisture
Soggy or becomes hard

Time
Some chemical interactions & enzymatic reactions

Nutrition
What affects nutrition of food
Oxygen
Degradation of vitamins, proteins, fats

Temperature
Degradation of vitamins, proteins, fats

Light
Light induced degradation esp dairy

Temperature
Temperature induced degradation esp dairy
Accelerates all reactions

Time
Effect over time

How can we extend shelf life of food?

Kill the bad microbes or inhibit their growth
Protect & Preserve Sensory & Nutrition
How?
Process: Add Hurdles
Temperature
Surrounding Atmosphere (gases)
Pressure

Packaging
Withstand process conditions
Protect what is inside for longer time: sensory, nutrition
Keep out external microbes, odors, gases with Hermetic Seal

Modern Food Preservation

Thermal sterilization:
Hot filling & Pasteurization
Combination of moderate heat and higher acidity
Retort process
Developed in 1795 for France military (Napoleon)
Retort pouches were developed in the US in 1960s for US
military
Aseptic packaging of liquids and pulps
First developed in 1910s in Europe & US
MATS
Ohmic heating

Modern Food Preservation cont.

Temperature could affect some desirable sensory &
nutrition properties for some food products.

Then What?
Non Thermal sterilization:
MAP: Modified Atmosphere Packaging
High Pressure Pasteurization

Trends in food packaging

Consumer preference driving growth in higher convenience formats
Shelf stable, Portion packs
Advanced packaging technology enabling newer formats
Shapes, Clear, Colours
Novel processing technologies have the potential to revolutionize
shelf stable quality
Nutrition, No preservatives
Urbanization in D&E markets driving faster adaption of consumer
friendly packaging
Easy to open, Heat, Eat

Barrier Containers Value Proposition

Customized and economical

Protects food long life

Food
Science

Light weight

Easy to open

Less Energy consumption

Non breakable
Easy to shape

Material
Science

Colors and prints

Consumer
Needs

Easy to use
Recyclable

How we do it?
Technology of High Barrier Sheet & Thermoforming
Polymer-1
Polymer-2

Adhesive
Barrier
Adhesive
Polymer-3
Polymer-4

Combination of polymers
High precision Thermoforming
Capable of 11+ layers
Flat, coined seal surface
Various structure arrangements
Best for retort, hermetic heat seal
General thickness: 0.75 to 2.30 mm

Shelf Stable Food = Sterilization + Packaging

Traditional Thermal
Hot fill - Pasteurization
Retort

Aseptic
Hydrogen Peroxide
Steam

In Package Cooking with Aseptic

Packaging
Advanced Thermal
Microwave Assisted Thermal
Sterilization
Ohmic Heating

Advanced Non-thermal
Modified Atmosphere
Packaging
High Pressure Pasteurization

Temperature Assisted Pressure

Steps Involved In Retort Processing

Product preparation
Need to adjust precooking to compensate for cooking
during sterilization
Select ingredient to minimize heat damage

Filling & sealing

Select speed suitable to pack for one batch load in
less than 45mins
Cold fill, Ambient fill, Hot fill

Retort Sterilization
Heat, Hold, Cool while controlling OVER /
COUNTER PRESSURE

Products from Retort Sterilization Process

Advances in Thermal
Sterilization

MATS: Mw Assisted Thermal Sterilization

Faster and Uniform Heating Pattern
Conductive Heating

Mw Volumetric Heating

How is MATS different?

Packaged food is simultaneously heated externally by
pressurized hot water, and internally by the patented
microwave system
Food rapidly reaches sterilization temperature,
significantly reducing process times and heat damage

Provides vastly better quality and higher nutritional value

Heating Differentials of MATS vs Retort

Sterilization Time to Achieve Same Target Fo
PRODUCT

MATS
TIME
(min)

CONVENTIONAL
RETORTING TIME
(min)

300g Mashed potato

250g Salmon & Alfredo

10.1
6.8

28.8
24.0

250g Chicken dumpling & Sauce 6.5

21.0

250g Cheese Tortellini

46.5

7.3

Shorter Sterilization Time provides:

Better Sensory
Better Nutrition retention

Impressive results!

Conventional Retorted
Chicken and Dumplings

62

Microwave Sterilized
Chicken and Dumplings

Functionality of Packaging
Protects product from
Oxygen
Gain or loss of moisture
Light
Keep good aroma in and odors outside
Neutral to foods
Withstands range of sterilization processing techniques
MAP
Aseptic
Packaging does not
Hot fill
Pasteurization
sterilize food
Retort
MATS
HPP.

Innovation begins here..

Process Technology

A typical roll configuration in calendering

Blowing
pipes

Slitting device

Pipe shaping

Air Blowing

Sealing

Heating
Tunnel

Mold

Roll Unwind

Economic Advantages
Wide multilayer plastic sheet
A uniform distribution of the plastic material
A low investment cost
Costs savings in transport, storage and
handling

=
PLASTIC SHEET

Milk Packaging Distribution Channels

Milk Value Chain
Farmer &

Dairy

Retail

Consumer

Dairy

Product Quality

Quality

Quality

Raw Product

Process

Logistics

Shop Handling

Convenience

Quality

Packaging

Stock

Shop Display

Storage

Collection

Handling

Distribution

Shop Waste

Waste

Secondary Packaging

Cost, Competition, Marketing, Promotion

Environmental impact

How Milk are delivered to the Consumer?

Processing & Packaging
Technology to make milk shelf stable and
ready to reach the Consumer In good

Shape

WVTR

O2TR

Distribution & Retailing

What does the Market require for logistics,
distribution and sales?

Integration of UHT-Process and Aseptic

Packaging
= One closed System
to ensure total
Process/Packaging
Sterility

From Product Safety to Food

Contact Material Compliance
Leachable chemicals can come from any layer
of our packaging products and not only from
the layer in contact with the food.
So All components of the packaging can have
a huge impact on Food safety and not only the
contact layer.

Examples of Product Safety Issues

Milk in plastic bottle 2009
Carcinogenic component from inks:

Benzophenone / 4-Methylbenzophenone found in the milk.

It is a migration issue. The inks component migrated from the surface

of the label to the milk through the bottle.

Cereal liner in Europe in 2009

Carcinogenic component from inks :

Benzophenone / 4-Methylbenzophenone found in muesli.

It is a migration issue through the carton and the plastic inner liner.

What do we have to do?

What needs to be achieved to be level 3
People

Named individual and trained

System

3 procedures in place
PS alert implemented

Product Development

All projects in System

Customer Questionnaires in place
Developmental / Commercial Product Specs (DPS / CPS)

Raw material Data

List of all supplier grades used

Supplier Questionnaires sent to all suppliers
DOC for 100% of the supplier grades

Process Control /
Quality

CPS implemented

Compliance Testing

List of all the active CPS

80% of your CPS ready to be tested

Reactive systems
Dossiers

A dossier available for each CPS

Declaration of
Compliance

Use standard templates and only these templates

54

Main EHS initiatives and systems

> CLEAN is mandatory for our business

Comments:

CLEAN

SAFETY
HEALTH
ENVIRONMENT
HOUSEKEEPING PRODUCT
HYGIENE

CLEAN is an initiative to
improve day to day
behavior at the shop floor.
It calls for a safe and clean
workplace, good
housekeeping, friendly
working environment and
conditions.
FOOD SAFETY SYSTEM
CERTIFICATION 22000

Ecology
Ecology

Environmental

materials ecology
consumer concerns
"clean" materials
ecological solutions
life cycle analysis (LCA)
(eco balance)
recycleability

"Ecological" S

regulatory compliance
eco audit
ISO 14000

olutions are oft

en "Economica

4 R: Reuse Reduce Recycle - Renewable

l" Solutions

henkywibawa@yahoo.com
YOUR FUTURE PRODUCT
DEVELOPMENT DETERMINE OURS !