Innovations in Packaging for Food Products Dairy and Dairy Products Date: 27 th Feb 17 Slide No: 1
Dairy and Dairy Industry Date: 27 th Feb 17 Slide No: 2
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 2015-16: Press Information Bureau, Government of India, Ministry of Finance, 26-February-2016 Date: 27 th Feb 17 Slide No: 3
11.9 13 9.7 12 9.4 11 20 24 14.6 17 Milk Production in Million Tonnes 33.7 36 34.5 38 33.8 38 48.2 60 91.8 103 137.7 148.9 158 166 Milk production projected to grow to 160 +Million Tons by 2021 2013-14 2021 180 160 140 120 100 80 60 40 20 0 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
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 5800 BN @ 2015 Category growth @ 15% Organized growth @ 22-24% Un Org. 80 % Total 5030 BN @ 2014 Source:http://www.dairyreporter.com/Markets/India-s-organized dairy-sector-anticipates-rapid-growth-in-next-three-years Date: 27 th Feb 17 Slide No: 5
Packaging in Dairy Industry Date: 27 th Feb 17 Slide No: 6
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) http://www.marketsandmarkets.com/pressreleases/food-packaging.asp Source: http://www.businesstoday.in/magazine/co ver-story/indian-dairy-market-is-on-a-teardue-to-new-players/story/232545.html Date: 27 th Feb 17 Slide No: 7
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
Product innovations have always led Food FMCG. Packaging Led Innovations gaining importance Consumer Habits & Demands Date: 27 th Feb 17 Slide No: 9
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
Enhance shelf life through Packaging Poly Pack Pouch Process: Pasteurization Shelf Life - 2 Days Pasteurized Milk ESL Pouch Process: UHT Shelf Life - 30 60 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
Extra shelf life Milk Raw milk UHT Process Heating (142-146 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
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 ) 1650 1.6 Condition : 20 C-65% RH (out)/65% RH (in) Date: 27 th Feb 17 Slide No: 13
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 30-90 days Convenience Reclosability, Handle for holding Present Emerging Trend Likely Future Trend Convenience + Food safety Date: 27 th Feb 17 Slide No: 14
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
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
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
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
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
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
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