Innovations in Packaging for Food Products. Dairy and Dairy Products. Date: 27 th Feb 17 Slide No: 1

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1 Innovations in Packaging for Food Products Dairy and Dairy Products Date: 27 th Feb 17 Slide No: 1

2 Dairy and Dairy Industry Date: 27 th Feb 17 Slide No: 2

3 Great Milestones Largest Volume, Meets Per-Cap Availability World No.1 In Diary Significant Vol. Growth 6.26 %. CAGR 150 Million T In 2015 Per Cap Availability 323 g White Revolution- Journey Source: Economic survey : Press Information Bureau, Government of India, Ministry of Finance, 26-February-2016 Date: 27 th Feb 17 Slide No: 3

4 Milk Production in Million Tonnes Milk production projected to grow to 160 +Million Tons by EU India USA China Russia Pakistan Brazil NZ Ukraine Argentlna Australia Mexico Source: Authors representation based on FAO report and other various reports Date: 27 th Feb 17 Slide No: 4

5 Organized sector Growing faster Unorganized being large (80%) Indian Dairy Industry Organize d Unorgani zed Private Dairies (National ) Private Dairies (Internatio nal) Cooperat ives Governm ent Organized, 20 % Total Category 15% Organized 22-24% Un Org. 80 % Total Source: dairy-sector-anticipates-rapid-growth-in-next-three-years Date: 27 th Feb 17 Slide No: 5

6 Packaging in Dairy Industry Date: 27 th Feb 17 Slide No: 6

7 VAD is on the rise, demand for Packaging up ASIA-PAC is estimated to be the fastest growing globally. India amongst the region is likely to be the second fastest growing market Ʃ Paneer 1% Dairy Whitener Cheese 1% 2% Butter 4% Yoghurt/ Curd 8% Ghee 8% Others 20% Polypack Milk 56% Demand More Consumers Innovations **Source: Markets and Markets Analysis(2015) Source: ver-story/indian-dairy-market-is-on-a-teardue-to-new-players/story/ html Date: 27 th Feb 17 Slide No: 7

8 Consumer Demands will fuel Packaging Innovations 1. Great Tasting & Conveniece 2. Food Safety & quality 3. Affordability & Innovations Date: 27 th Feb 17 Slide No: 8

9 Product innovations have always led Food FMCG. Packaging Led Innovations gaining importance Consumer Habits & Demands Date: 27 th Feb 17 Slide No: 9

10 Rigid & Flexible plastics widely used in Diary Flexibles Injection Molding Blow molding Thermoforming Poly PET HDPE PS Date: 27 th Feb 17 Slide No: 10

11 Enhance shelf life through Packaging Poly Pack Pouch Process: Pasteurization Shelf Life - 2 Days Pasteurized Milk ESL Pouch Process: UHT Shelf Life Days Extra shelf life Aseptic Cartons Process: UHT Shelf Life - > 90 Days Process: UHT Process plays a vital role here Date: 27 th Feb 17 Slide No: 11

12 Extra shelf life Milk Raw milk UHT Process Heating ( C for 2-4 sec.) and Aseptic Homogenization (75-80 C, 150/50 bar) Aseptic Cooling (20-25 C) and Storage in Sterilized Tank Aseptic Filling into ESL Pouches and On-Line Coding KEY ADVANTAGES: Higher product Quality Extra shelf Life Ambient temperature stable Opens up new & unique horizons Cost > Poly Pouch LDPE ( White Master batch) Tie layer EVOH 9 to 10% Tie layer LLDPE/MLDPE ( Black Master batch ) Date: 27 th Feb 17 Slide No: 12

13 EVOH provides excellent Oxygen Barrier & shelf life LDPE Monolayer EVOH Multilayer Structure (µm) LDPE 100 LDPE/ tie/ EVOH/ tie/ LDPE 42.5 / 5 / 5 / 5 / 42.5 OTR (cc/m²,day,atm ) Condition : 20 C-65% RH (out)/65% RH (in) Date: 27 th Feb 17 Slide No: 13

14 Special Sealants Leak proof seal High seal strength Low barrier Low shelf life Low cost Enhanced Barrier Light protection Band seal H2O2 sterilization UHT pack Shelf life days Convenience Reclosability, Handle for holding Present Emerging Trend Likely Future Trend Convenience + Food safety Date: 27 th Feb 17 Slide No: 14

15 2. Rigid Packaging for milk Regular HDPE Bottle HDPE Multi layer Bottle Sku s - 1litre ; Weight 40g Sku s- 1litre ; Weight 50g Structure :- Mono layer HDPE material + additives Structure :- (outer to inner side) Layer 1 HDPE material Layer 2 Regrind material Layer 3 Adhesive as Tie layer Layer 4 Barrier layer (EVOH) Layer 5 Adhesive as Tie layer Layer 6 HDPE material Induction Wad:- Paperboard coated/ Wax coated Aluminum foil / sealant poly film Press & Heat sealing:- Aluminum foil / Easy peel sealant film Shelf life :- 5 days Shelf life :- 4 months Caters to niche growing consumer segment Date: 27 th Feb 17 Slide No: 15

16 Milk Products Fresh cultured Frozen Long shelf life Curd & Ice-cream Regular Market THERMOFORMED HIPS (Hi Impact PS) Cups Long shelf life dominated by multi layer laminate structure Heat Sealable Wide working Stability From +37 C to - 22 C Temperature Oxidation Barrier Light protection Date: 27 th Feb 17 Slide No: 17

17 Thermoform Technology Advantages Production Efficiency & Speedy Turnaround Cost-effectiveness Branding and Design Flexibility High speed machine, multiple cavity up to 24 in numbers Low cost manufacturing Thermoformed product cost 15 % less Vs. injecting molding product Plate making is cost effective High speed printing possible with good graphics with newer technology like Dry Offset Material Compatibility Hi Impact Poly Styrene: Dimensional Stability at freezing as well as temp. up to 70 deg C Heat Sealable Easy to use and Recyclable 1. Fast Tooling 2. Higher Turn Around 3. Cost Effective Date: 27 th Feb 17 Slide No: 18

18 Improve Graphic design Dry off-set printing New consumer High quality 7- Colour printing- Greater detail and sharpness with a halftone screen 3- Sync with the great tasting product Enhanced Graphics Printed cup More sustainable solution 2- Keeps the Brand Youthful Advancement in printing technology for thermoformed cups 4 Color text printing 1- Attractive Shrink Sleeved Cup vs. Off-set Printing Date: 27 th Feb 17 Slide No: 19

19 Packaging to the rescue of Fraudulent Products Regular Four panel Lined carton Ghee Lined carton: Penta panel Ghee Lined Carton: Penta Panel with changed Artwork Date: 27 th Feb 17 Slide No: 20

20 Key tests to ensure innovation success Migration of Residual chemicals - Additives & coatings, inks TESTED AND CONTROLLED Barrier assessment Loss of seal integrity Machine-ability tests Transit test - Packaging Failure Transportation, Display & Shelf Shelf Life testing Date: 27 th Feb 17 Slide No: 21

21 Good packaging is the essence to consumer trust. Packaging continues to drive Product acceptance & is certainly playing a vital role in taking a big slice of the innovation cake. Thank - you Date: 27 th Feb 17 Slide No: 22