Title: Tomorrow is a New Era for Food Packaging
1Tomorrow is a New Era for Food Packaging
- Food and the Environment The Costs, Benefits and
Consequences of Modern Food Production - University of California, Berkeley
- Aaron L. Brody
- PACKAGING/BRODY, INC.
- Food and Food Packaging Consultant,Adjunct
Professor, University of Georgia, USA - 23 September 2002
2Packaging and the Food Environment
- A brief perspective to demonstrate the key roles
played by food packaging in meeting consumer food
and nutrition needs and desires better than at
any time in history, at lower cost and with less
environmental insult and disruption
3Packaging
- Packaging separation of the product from an
environment attempting to return products to
their original states - indispensable to the
distribution of all consumer and most industrial
goods - Without packagingindustrialized society could
not exist - With packagingconsumer and industrys goods are
delivered
4Packaging
- A holistic system comprehending
- The productalways the primary consideration for
packaging - Protection against an always hostile natural
environment - Physical structure
- Equipment to marry the package structure to the
product - Consumer/customer use
- Distribution channels
- Safety
- Minimization of environmental insult
- All at an economic price
5Food Packaging
- Food packaging protection for safety, quality
retention - Without food packagingindustrialized society
could not eat - With food packagingindustrialized society
- Less than 4 of the population is employed in
agriculture - Delivering the safest, highest quality food
supply in world history - Broadest variety of food imaginable
- Convenience for consumers to prepare, serve and
eat
6Food Packaging
- Food today is at its lowest cost in world history
- Less than 11 of disposable income
- Even with away-from-home eating
- Packaging costs less than 7 of retail price of
food - And we strive to continuously reduce the cost of
food and its packaging
7Food Packaging
- And, despite the consumer desire for more
convenience, the weight of packaging per unit of
food contained is the lowest in history - As heavier-weight glass, metal, and high-caliper
paperboard structures decline - And lightweight plastic and flexible structures
grow
8Food Packaging
- Nearly 60 of all packaging is used to protect
our food supply - 40 of packaging is paper and paperboard and
static in growth - More than half is recaptured
- Most is recycled
- Returns to become new packaging
- A recycling infrastructure has been operational
for gt 100 years - 20 of packaging is plastic and growing
9Food Packaging
- Purpose of Food Packaging
- Protectionagainst natural environment
- Oxygen
- Moisture
- Water
- Microorganisms
- Light
- Dirt
- Odors
- Animals
- Humans
- Without this protection, food waste would be over
50
10Food Packaging
- Purpose
- Protectionagainst distribution environment
- in-plant trucks, rail cars, ships, in-store,
etc. - Impact
- Vibration
- Compression
11Food Packaging
- Purpose
- To ensure microbiological and chemical product
safety - To retain initial product quality
- Nutritional value
- Sensory characteristics
- In conjunction with distribution, to deliver the
product intended by the food processor/marketer - To permit commercial shelf life
12Food Packaging
- Microbiological safety
- Despite the headlines, our food supply is the
safest in world history and becoming safer - But, too many people die/become ill
- Food science and technology strive to ensure food
product safety in conjunction with - Processing
- Packaging
- Distribution
13Food Packaging
- Further purposes
- Communication
- Mandatory
- Marketing in a competitive environment
- Portioning
- Dispensing
- Unitizing
- Meet legal and regulatory requirements
14Why Food Packaging?
- The guidelines for food packaging
- Safety
- Protect the contents
- Consumer convenience, ease of access and use
- Facilitate finding on 100 000 self service retail
outlets - Attractive to a diversity of consumers
- Also applicable for away from home eating half
of all food consumption - And to minimize insult to the environment
15Plastics and Packaging
- To reduce the mass of material to protect the
contents - Intimate marriage of materials for functionality
- Polyethylene plus plastic and/or paperboard
- Ethylene vinyl alcohol (EVOH) oxygen barrier
- Polyester (PET) for carbonated beverage packaging
displaced glass - Hot-fill high acid fluid foods, e.g., tomato
paste, into laminated flexible pouches displaced
metal cans - Retortable plastic trays and cans for low acid
foods, e.g., macaroni and cheese - Microwavable and dual-ovenable packaging
- High technology food packaging
16A 20th Century Technology Aseptic Packaging
- Aseptic packaging
- Product sterilized with little heat package
sterilized independently and assembled in sterile
conditions to deliver higher quality product - Composite paperboard bricks
- Juice
- Milk
- Barrier plastic cups
- Puddings, apple sauce and juices
- Light weight packaging
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20Plastic Bottles
- Introduced in 1977 for carbonated beverages
- Lightweight
- Non-breakable
- Hot-filling into polyester and multilayer plastic
bottles/jars - Temperature-resistance through heat setting
- Collapsing panels for vacuum
- Limited shelf life
- Lightweight/nonbreakable
- Today displacing glass for fruit beverage
packaging and has begun for jars of jam and
tomato sauce
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23What Began Just Yesterday?
- Beer in plastic packaging
- Linerless composite paperboard canisters snacks,
etc. - Film-laminated paperboard cartons
- Combined with plastic elements ice cream,
coffee cartons - Case-ready fresh red meat
- Modified-atmosphere packaging
- Fresh-cut ready-to-dress produce
- Consumer convenience
- Microwaveable barrier plastic cans
- Microwave susceptors to permit crisping and
browning
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28Heat and Cool
- Extended shelf life (ESL)
- Ambient temperature for high-acid foods, e.g.,
tomato, apple - Refrigerated temperature distribution
- Prepared foods home meal replacement 2 weeks
shelf life - High-acid foods juices 60-70 days shelf life
- Despite the business-driven reduction in
distribution time - To reduce microbiological safety problems
- To better retain quality
- In lighter-weight packaging
- Reduction in thermal inputs for heat
sterilization - To reduce heat damage
- To deliver higher-quality foods
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30Fresh Cut Vegetables
- Gas-permeable packaging
- To reduce respiratory anaerobiosis resulting in
off-flavors in fresh vegetables/fruit - To permit distribution of fresh-cut vegetables
- Two weeks shelf life under refrigeration reduced
waste and spoilage - An entirely new industry and consumer product
category - Consumer convenience
- Safe quality food
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32New To Delight Consumers
- Shaped metal cans
- Home meal replacement
- Another major new consumer convenience
- Quality/safety are key
- Refrigerated preprepared imitations of restaurant
cuisine - Consumer convenience
- And away from home eating has soared to nearly
half of food in value and 40 of volume
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342002
- Plastic beer bottles
- Require excellent oxygen control
- Oxygen scavengers in or within plastic
- High-oxygen barrier coatings in or on plastic
- Produce/meat packaging
- Purge/drip controllers
- Retort pouches re-enter consumer markets
- Tuna fish and salads
- Pet foods
- Lower mass of package materials
- Higher quality food due to lower heat input
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372000-2002
- Controlled-water-activity food products pasta,
rice - Extended shelf life
- Beverages
- Solid foods
- Aseptic packaging for low-acid particulate foods
approved in United States - Limited applications
- Each product requires specific approval
- Shaped aluminum bottles
- All aimed at safety, quality, fitting the
distribution system, convenience for a wide
variety of consumers, economics and reducing
solid waste
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42Food Packaging 2002
- To deliver more than 30 000 food items per store
for 270 million consumers children, seniors,
multi-cultural, cost-conscious, and more - Most food packaging is
- Paperboard cartons with internal liners
- Cereals
- Dry mixes
- Corrugated fiberboard for distribution
- Aluminum cans and polyester bottles for beverages
- Oriented polypropylene film for snacks and bakery
goods - Polyethylene bottles for sirups and toppings
- Polyester bottles for carbonated beverages, water
and more
43Food Packaging 2002
- Flexible lamination and monolayer pouches 17
of food packaging - Reduced mass of packaging
- Truncated distribution channels
- Protection for the new channels
- Increasing with consumer acceptance of flexible
formats - Reducing glass static metal static paperboard
44Food Packaging 2002
- But much food packaging is high technology to
meet specific consumer and/or retailer demands
and desires - Packaging in polyester (PET) bottles
- Aseptic and hot fill
- High-acid
- Fruit beverages
- Isotonic beverages
- Low-acid
- Dairy products increased consumption of milk
- Water
- Extended shelf life (ESL) refrigerated
- Contribute to changing consumer eating patterns
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47Food Packaging 2002
- Stand-up flexible pouches
- Substituting for lined paperboard cartons
- Dry foods
- Less expensive
- Reclosable
- Better protection
- Often more economical
- Now often offered with reclosure zippers or
slides to meet consumer desire for multiple
accessability
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49Food Packaging 2002
- Stand-up flexible pouches
- Dry granular foods
- Dry solid foods
- Fruit-flavored beverages
- Largest single application
- Hot-fill
- Retorted
- Pet foods
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52Food Packaging 2002
- Retortable packages heated after sealing to
sterilize contents - Metal cans
- Full-panel easy-open ends
- Tin-free steel
- Cylindrical
- Shaped
- Plastic-lined cans
- Two-piece aluminum cans
- Glass jars
- Shaped
- Pouches
- Flat
- Stand-up
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54Food Packaging 2002
- Retortable packages
- Consumer friendly alternative for metal can
- Trays
- Alternative targeted at a more diverse and
demanding consumer market - Quality
- Convenience
- Assume safety
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56Food Packaging 2002
- Refrigerated/frozen food production/distribution
option - Tube packaging
- Yogurt
- Apple sauce
- Pudding aseptic and ESL
- Convenience for youngsters
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58Food Packaging 2002
- Multiple packaging formats for same product
- Snack foods/cereals
- Pillow pouches
- Composite paperboard canisters
- Gabletop paperboard cartons
- Lined paperboard cartons
- Stand-up pouches
- Blow-molded bottles
- Thermoformed cups
- To meet protection requirements
- To satisfy the demands of a diverse consumer base
- Demographic
- Psychographic
- Event and occasion
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64Food Packaging 2002
- Microbiological safety
- More chilled foods - subject to pathogens
- Longer distribution times
- Enhanced quality retention
- Reduced oxygensubject to anaerobic pathogens
- Under refrigerated distribution
- Modified atmosphere
- Reduced oxygen
65Food Packaging 1990s-2002
- Consumer convenience
- Ready-to-eat
- Ready-to-heat-and-eat
- The package itself serves as
- Processing aid
- Protection during distribution
- Marketing tool
- Consumer preparation tool
- Serving dish
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68Food Packaging Yesterday and Today
- Food packaging is more than protection and
communication - Process the product in the package
- Protection specifically for the targeted
distribution channel - Prepare, for example, reheat, in the package
- Serve in the package
- Consume from the package
- Ease of disposability
- Microwaveable popcorn
- Microwaveable multilayer plastic barrier cans
- Home meal replacements
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72Food PackagingThe New Tomorrow
- Intelligent packaging
- Content history
- Price
- Counter counterfeiting
- Theft deterrent
- Temperature/time integration
- To suggest quality condition
- To help control distribution
- Internal gas
- Seal integrity
73Food PackagingThe New Tomorrow
- Active Packaging
- Senses environmental change and modifies package
properties - Gas
- Moisture
- Oxygen
- Carbon dioxide
- Microbiological status
- Quality situation
- Temperature
74Food PackagingThe New Tomorrow
- Active packaging
- Microwave susceptors
- To crisp and brown surfaces
- To aid popcorn popping
- Self-heating
- Self-cooling
- Sense temperature and increase gas permeation
- Fresh-cut vegetables
- Antimicrobials slow or destroy microorganisms
- At a distance
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76Food PackagingTomorrow
- Total systems
- Convert intelligence to action
- Begin with process
- Reduce thermal input on terminal sterilization
and hot fill - Accelerate internal cooling
- To control thermal processes
- To control non-thermal processes
- Integrate with projected distribution integral
- Total thermal input optimized
77Food PackagingTomorrow
- Shelf life
- Prolongation of shelf life is equivalent to
higher quality at any specified time - Reduce entire system thermal input
- Distribution temperature reduction can
- Virtually ensure against microbiological safety
problems - Maximize quality retention
78Food PackagingTomorrow
- Oxygen
- Contributor to most food deteriorations
- Reduced oxygen generally extends quality
retention - Must reduce oxygen in product
- Must reduce oxygen in package
- Must block entry of oxygen
- Proposed to preserve foods for astronauts
traveling to Mars in 2009
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81Food PackagingTomorrow
- Marriage of multiple active packaging
technologies - Temperature history plus active cooling
- Temperature and internal gas environment
- Temperature plus
- Oxygen removal
- Antimicrobial release
- Odor control
- Relative humidity
- Microbiological status and antimicrobial release
82Food PackagingTomorrow
- Hurdle technology
- Integration of preservation technologies
- pH
- Water activity
- Modified atmosphere
- Thermal pasteurization
- Non-thermal microbiological destruction
- Temperature control
- Passive packaging
- Active packaging
- Holistic when quantitatively integrated
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85Food PackagingTomorrow
- Marriage of passive, intelligent and active
technical functionality - Passive
- Controlled separation from exterior environment
- Enhanced passive
- Total product content history
- Control product quality
- Modulate temperature
- Internal macroenvironment
- Marketing signal/inform consumer
- Light/sound/aroma
86Food PackagingTomorrow
- Contained product is the primary concern
- Safety of contents is first
- Quality of entering product is critical
- Food packaging will be corollary to distribution
control - Distribution should be optimized
- Time
- Temperature
- Passive barriers should be optimized
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88Food PackagingTomorrow
- Sense the product and its surroundings and use
the input to control the product environment - Retain the quality
- Ensure the safety
- Respond to the individual consumer desire
- Delight the target consumers
89Food PackagingTomorrow
- Integrate food preservation technologies with
packaging and distribution - Goal is to deliver food nearly identical to
freshly prepared - Maintain the cost proportion at lt7 of retail
price - Reduce the solid waste contribution
- Satisfy the growing food service market
90Food PackagingTomorrow
- Example of the future of food being here today
non-thermal ultra high pressure processing to
deliver chilled guacamole dip in flexible pouches
imitates freshly mashed avocado.
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93Tomorrow is a New Era for Food Packaging
- Food and the Environment The Costs, Benefits and
Consequences of Modern Food Production - University of California, Berkeley
- Aaron L. Brody
- PACKAGING/BRODY, INC.
- Food and Food Packaging Consultant,Adjunct
Professor, University of Georgia, USA - 23 September 2002
94A Brief History of Food Packaging
- In the beginning, packaging was
- Leaves
- Skulls
- Animal skins
- Pottery
- Amphorae
- Glass
- And so, little food was packaged
- And farming was mans and womans principal
activity - And, under the stresses, humans did not live well
or long
95The Nineteenth Century for Food Packaging
- Appert, Durand, Kensett were key to the emergence
of canning - Pasteur related microorganisms to spoilage
- Underwood, Prescott developed the scientific
basis of thermal processing to sterilize foods
valid today - Linkages were established among
- Product
- Process
- Package
96The Nineteenth Century for Food Packaging
- Appert, Durand, Kensett were key to the emergence
of canning - Pasteur related microorganisms to spoilage
- Underwood, Prescott developed the scientific
basis of thermal processing to sterilize foods
valid today - Linkages were established among
- Product
- Process
- Package
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99Food Packaging 50 Years Ago
- Rausings development of tetrahedral packaging
- Combined paperboard with other materials
- Reduced weight of paperboard
- Enabled packaging of liquids
- Complete system with equipment
- Offered ambient temperature shelf stability for
foods in territories with little refrigerated
distribution - Was the ancestor of the Tetra Pak Brik Pak
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101Food PackagingTomorrow
- Marriage of multiple active packaging
technologies - Moisture plus oxygen control
- Moisture plus odor control
- Moisture plus oxygen plus odor control
- Moisture plus antimicrobials
- Moisture plus oxygen plus antimicrobials
102Food Packaging Compare 1952 to 2002
- Oriented polypropylene film
- Metallized polyester and polypropylene film
- Paperboard cartons with easy open dispensing
closures - Milk in polyester bottles
- Corrugated fibreboard with microflutes and even
plastic cores - Two-piece steel and aluminum cans
- With easy-open ends
- Light weight
- Barrier plastic cans for microwave reheating
for pouches
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104Food Packaging 50 Years Ago
- Cellophane for wrapping and pouches
- Varied with climate
- Aged and lost properties
- Nitrocellulose coated papers for pouches
- Glass bottles and waxed gabletop paperboard
cartons for home-delivered milk - Three types of corrugated fiberboard A, B and C
- And all cans were three-piece soldered side-seam
steel requiring mechanical openers
105Pre-World War II
- Metal cans
- Three-piece steel
- Soldered side seam
- Heavy weight
- Glass bottles/jars
- Heavy
- Fragile
- Required lined steel closures
106Pre-World War II
- Metal cans
- Three-piece steel
- Soldered side seam
- Heavy weight
- Glass bottles/jars
- Heavy
- Fragile
- Required lined steel closures
107Food Packaging 2002
- Stand-up flexible pouches
- Largely preformed pouches
- Some form/fill/seal
- Many with zipper reclosures
- Output rates 60-120 per minute
108Pre-World War II
- Paperboard
- High caliper
- Moisture-sensitive
- Required flexible overwraps or internal liners to
function - Packaging operationsmanual and slow
109Mid-Twentieth Century
- Converting
- Blowing/casting of plastic films
- Laminating of plastic films/other materials
- Barrier structures
- Paperboard
- Extrusion blow molding of thermoplastics
Stopette deodorant squeeze bottle - Extrusion coating of paperboard cartons with
thermoplastics - Rotogravure printing
- Polypropylene
- Orientation to enhance properties
110Food Packaging 2002
- Packaging in polyester bottles
- A vigorous competition between
- Aseptic
- Hot-fill
- Ambient-temperature shelf-stable
- Extended refrigerated shelf life
- Sizes
- Shapes
- Bottle labeling
- Bands
- Full-body shrink film
111Food Packaging 2002
- Packaging in polyester bottles
- And the fastest-growing application
- Water
- Replacing glass, PVC and HDPE
- Convenience carry-with/drink-from on the run
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115Food PackagingTomorrow
- Concept of zero oxygen
- Can zero oxygen be achieved and measured?
- How much can zero oxygen contribute to shelf
life/quality prolongation? - Value to consumers?
- Sensory qualities
- Nutritional value
- Other sources for oxidative reactions
- Non-oxidative reactions
116Food PackagingTomorrow
- Marriage of multiple active packaging
technologies - Moisture plus oxygen control
- Moisture plus odor control
- Moisture plus oxygen plus odor control
- Moisture plus antimicrobials
- Moisture plus oxygen plus antimicrobials
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118Food PackagingTomorrow
- Specific materials and structures will not be
nearly as important as function - Paperboard and plastic will continue to dominate
as materials but in dynamic new formats - More than ever before, the materials will be
synergistically married to each other - And in close harmony with the product, process,
consumer use and environment
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120Food PackagingToday for Tomorrow
- Today
- Food package materials and structures are passive
- Food package materials and structures are
integral to product processing and
distributionand preparation - Aseptic
- Extended shelf life
- High-quality chilled
- Hot fill
- Extended chilled shelf life (1-6 months)
- Truncated ambient-temperature shelf life (1-6
months) - Ultra-clean processing/packaging
- Chilled processing/packaging operations
- Food package materials and structures
intelligent and active
121Food PackagingToday for Tomorrow
- Today
- Food package materials and structures are passive
- Food package materials and structures are
integral to product processing and
distributionand preparation - Aseptic
- Extended shelf life
- High-quality chilled
- Hot fill
- Extended chilled shelf life (1-6 months)
- Truncated ambient-temperature shelf life (1-6
months) - Ultra-clean processing/packaging
- Chilled processing/packaging operations
- Food package materials and structures
intelligent and active
122Food Packaging
- We shall establish an unbroken continuum from
the past through today into the future for - food and food packaging.
123Food Packaging 2002
- Multiple packaging formats for same product
- Dry cereals, etc.
- Lined paperboard cartons
- Gabletop paperboard cartons
- Composite paperboard canisters
- Paperboard tubs
- Stand up flexible pouches
- Thermoformed plastic tubs
124Food Packaging 2002 and Beyond
- Food packaging is indispensable to delivery of
food to consumers - Food packaging integrates
- Product
- Process
- Distribution
- Consumer use
- Economics
- Disposal
- Integration of all elements must be seamless
125Food PackagingThe New Tomorrow
- Today
- Active packaging
- Oxygen removal
- To complement oxygen barrier
- To prolong quality retention
- Moisture control
- Dryachieve and maintain
- Relative humidity
- To retard moisture change
- To help control microbiological growth
- For fresh meats, produce
126Food PackagingThe New Tomorrow
- Today
- Active packaging
- Oxygen removal
- To complement oxygen barrier
- To prolong quality retention
- Moisture control
- Dryachieve and maintain
- Relative humidity
- To retard moisture change
- To help control microbiological growth
- For fresh meats, produce
127Food PackagingTomorrow
- Extension of todays technologies
- Antimicrobials
- Light activated
- Microbial status sense the presence and respond
- Cell itself
- End-products of cellular action
- Temperatureheat
- Self-heating
- Susceptors
- Nutritional status
- Signal consumer to take preventive or therapeutic
dose
128Food PackagingTomorrow
- Extension of todays technologies
- Temperature control
- Self-cooling
- Moisture triggers for
- Oxygen scavengers
- Antimicrobials
- Gas control
- Temperature actuated
- Oxygen scavengers
129She who knows history is destined to benefit from
it.
130Nineteenth Century
- Canning heat to sterilize destroy all
pathogenic and spoilage microorganisms in
hermetically sealed packages - Concept
- Scientific basis
- Ambient temperature shelf stability
- Can making
- Paperboard cartons developed
- Invention of corrugated fiberboard
- Glass bottles manually blown
- All high cost
131Early Twentieth Century
- Frozen foods Birdseye
- Waxed paperboard wrapped in waxed paper
- Brandenburgcellophane
- Flexible and transparent barrier
- Carruthersnylon the first true plastic for
packaging - Reynoldsaluminum foil
- Mechanical glass bottle and jar making
- And Uneeda biscuit waxed paper lined paperboard
carton - Visionary, daring innovators drove the future
that is our today
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133Pre-World War II
- The birth of thermoplastics
- Polyethylene
- Water and water vapor barrier replaced wax to
protect paper - In United Kingdom
- Originally not for packaging
- Polyester
- Polyvinylidene chloride (saran)
- Barrier to water vapor and air
- Applied to protection of munitions
- Eventually alland morewere applied for packaging
1342000-2002
- Aseptic packaging in two-piece aluminum cans
- Shaped aluminum bottles
- United States energy drinks
135Mid-Twentieth Century
- Basic thermoplastic materials became package
structures - Sheet formation
- Thermoforming
- Injection molding
- Extrusion
- Film blowing
- Bottle blowing
- Low cost and mass
-
136Mid-Twentieth Century
- Aseptic packaging independent sterilization of
food and package structure to reduce heat input
to permit any package material to be used Ball
and Martin in U.S.A. Rausing in Sweden - U.S.A. for metal cansfor milk, soups
- Commercialized as the Dole system still in use
- Sweden Paperboard composites Tetra Pak
tetrahedron - Still commercial for beverages
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1381960s
- The beginnings of
- Aseptic packaging in composite paperboard/foil/pol
yethylene bricks - Retort pouches to replace metal cans with light
weight packages - Oxygen barrier plastic bottles displacing glass,
paper and cellophane - Two-piece aluminum cans
- Food packaging that we employ today - 2002
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1401960s
- The beginnings of
- Steel can welding to replace soldered side seam
- Stand-up flexible pouches
- Zipper reclosures for pouches
- Easy-open can ends
- Glass and plastic bottle and jar screw closures
- Oxygen scavenging absorb from inside the package
- High-density polyethylene bottles
- Kitchen, clothes washing, garden, and bathroom
products - Reduce injury due to glass breakage/shards
- Packaging that is common today
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1431970s
- More conversions from glass, metal and paperboard
to plastic bottles, tubs, trays and jars
lightweighting, non-breakable, shorter shelf
lives to meet new distribution - Film metallization weightless barrier
enhancement - Bag-in-box film structures milk, tomato products
- Aseptic packaging in thermoformed plastic cups
- Concern for the environment
- Reduce weight of package materials
- Increase recycling of package materials
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1461990s
- Application of aseptic technologies
- Extended shelf life for milk, juices 60 days
chilled - Flavor barrier paperboard cartons for juices
- Addition of easy open reclosures
- Prepared foods
- Active packaging the beginnings
- Oxygen absorbers in packages
- Moisture controllers in packages
- Consumer satisfaction
- Concern for environment
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149Food PackagingTomorrow
- The future depends on applying the technical and
marketing principles to help feed an expanding,
increasingly diverse and demanding society - The future is an extension of today and yesterday
- By the bold and the visionary
- The future of food packaging depends on those who
dare to reach beyond conventional wisdom