Name: Flexible Packaging Innovation and Trends
Uploaded: 2022-09-08
Duration: 13 min 1 s
Description: Flexible Packaging Innovation and Trends. 9 -SEPT-2022.

Flexible Packaging Innovation and Trends. 9 -SEPT-2022. 

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Flexible Packaging  Innovation and Trends

Outline. 1. Introduction / Opening Meeting 15 mins (9:30am -9:45am) 2. UGEC Presentation 15 mins (9:45am-10:00am) Company Profile Capability and Capacity Product lines Packaging design, Trends and UGEC New technology 20 mins (10:00am-10:20am) Product Testing/ Packaging Integrity Testing 10 mins (10:20am-10:30am) Packaging Formats Retort Pouches Vacuum Pouches/ 3 Side Seal Pouch Stand Up Pouch Plant Tour 45 mins ( 10:30am-11:15am) Q &A 30 mins ( 11:15am-11:45am). 

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1. Introduction / Opening Meeting                                                 15 mins       (9:30am -9:45am)  2. UGEC Presentation                                                                           15 mins        (9:45am-10:00am)       Company Profile   Capability and Capacity    Product lines      Packaging  design, Trends   and UGEC New technology      20 mins        (10:00am-10:20am)      Product  Testing/ Packaging Integrity  Testing                     10 mins         (10:20am-10:30am)     Packaging Formats                                            Retort Pouches    Vacuum  Pouches/ 3 Side Seal  Pouch    Stand  Up  Pouch Plant Tour                                                                                          45 mins    ( 10:30am-11:15am) Q &A                                                                                                       30 mins   ( 11:15am-11:45am)

Packaging Design , Trends and UGEC New technology. 

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Packaging   Design , Trends  and  UGEC  New technology

Risk and opportunities. Packaging Design Features and Format Innovation, Environmentally Friendly and Sustainable Features Business and Cost Model Customized Business and Cost Model Design Innovation. 

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Packaging Design Features and Format Innovation, Environmentally Friendly  and Sustainable Features  Business and Cost Model Customized Business and Cost Model Design Innovation

Change Agenda for Compliances Zero Landfill on 2025   EPR Law compliances Current Barriers in complying Change agenda:  Infrastructure readiness Material / Technology Readiness Product Protection , Food Waste  Cultural Barriers / Consumer and Waste  habits Economic barriers (Business, consumers) Misinformation (Green washing )

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Packaging Relevant Functions. 0 E Active Packaging Protection Preservation Futu•tiats of Packaging Communication Marketing Intelligent Packaging. 

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0
E
Active Packaging
Protection
Preservation
Futu•tiats of
Packaging
Communication
Marketing
Intelligent Packaging

From Brand Owner’s Perspective Brand Awareness Product Identification, Preservation and Protection From Designer’ s/ Development Perspective Shape/ Format Adequate materials substrate From a Printer / Converter’ s Perspective High quality printing and converting Fast job change over Attraction Differentiation Cost Reduction/ Effectiveness Legislation/ Regulation Compliance Printing and Converting Quality and Consistency Added Value Considerations to processes High Efficiency Adaptable to end-user’s machine Waste reduction Value added processes. 

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From  Brand Owner’s  Perspective Brand Awareness Product Identification, Preservation and Protection   From Designer’ s/ Development  Perspective Shape/ Format Adequate  materials substrate From a  Printer / Converter’ s Perspective High quality printing and converting Fast job change over Attraction Differentiation Cost Reduction/ Effectiveness Legislation/ Regulation Compliance Printing and Converting Quality and Consistency Added Value Considerations to processes High Efficiency Adaptable to end-user’s machine Waste reduction Value added processes

Market Requirements & Applications :. Product Protection Machine / Packing Efficiency Zero Waste Lowest Unit Price Shelf-life Shelf-appeal Added Functions Sustainability. 

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Product Protection  Machine / Packing Efficiency  Zero Waste Lowest Unit Price Shelf-life Shelf-appeal Added Functions Sustainability

Light Weighting / Down gauging Use of Recycled Materials Recyclable Materials Bio-based / Compostable Second  Life Energy  Zero  Land fill  Excess Packaging Avoidance

Shelf- Stability Product Characteristics Mode of Deterioration Method of Preservation. 

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Shelf- Stability  Product Characteristics Mode of Deterioration  Method of Preservation

Sterilization  (UHT, Retort, Microwave Radiation)  Cold/ Frozen Storage

Chemical/ Biochemical nature Physical nature

Protection and Preservation. Tamper evident packaging Anti-counterfeit features Barrier resistance Protection from various substances against physical , chemical, biological deterioration, as well as from its environment.. 

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Tamper evident packaging Anti-counterfeit features  Barrier resistance Protection from various substances against  physical , chemical, biological  deterioration, as well as from its environment.

The protective function of packaging essentially involves protecting the contents from the environment and vice versa.

preservatve free
16 nattral ingrM0nts
Xernum wtlo•kgrans
ausralmbusn

Physical Caking Chemical Discoloration Non-enzymatic Browning Biological Microbiological Enzymatic Insect Infestation Oxidation (E.g. Rancidity) Breakage Crystallization Change in Texture. 

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Physical Caking Chemical Discoloration Non-enzymatic Browning Biological Microbiological  Enzymatic  Insect Infestation  Oxidation      (E.g. Rancidity) Breakage  Crystallization Change in Texture

Know product distribution needs. Climatic Environment Water and water vapor Physical Environment Warehouse storage Biological Environment Environment in which the package interacts with pests Distribution Light (UV) Dust Effects of Heat or Cold. 

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Climatic Environment Water and water vapor  Physical Environment Warehouse storage Biological Environment Environment in which the package interacts with pests Distribution  Light (UV) Dust  Effects of Heat or Cold

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Refill at Home Users refill their re-usable container at Home Return Packaging Returned to Business Return on the go Users return the packaging at a store or drop-off point (Eg. Deposit return machine or mail box concept) Refill on the go Users refill their reusable container away from home (Eg. At in-store dispensing system) Refills delivery thru subscription service. 

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Refill at Home Users refill their re-usable container at Home Return  Packaging Returned to Business Return on the go Users return the packaging at a store or drop-off point (Eg. Deposit return machine or mail box concept)  Refill on the go Users refill their reusable container away from home (Eg.  At in-store dispensing system)   Refills delivery thru subscription service

Re-use Design Features. Re-use Considerations Consumer Safety Cleaning/ washing environmental footprint Collection logistics Material Health. 

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Re-use Considerations Consumer Safety  Cleaning/ washing environmental footprint  Collection logistics  Material Health

Overall Environmental Impact via life cycle  analysis Disposal at End-of-Life  Recovery Process (Washing / sanitizing ) No. of Re-uses Impact on Shipping  Increased in Material Use

Convenience. “ The p ackage should be simple to hold, open and use by the end-user or consumer”. 

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“ The  p ackage should be simple to hold, open and use by the end-user or consumer”

Communication. Silent Salesman Labeling Requirements (AO #2014-0030) Controlled and efficient warehouse and distribution activities.. 

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Silent Salesman Labeling Requirements (AO #2014-0030) Controlled  and efficient warehouse and distribution activities.

“ A package must protect what it sells and sells what it protects “

100% natural
jug
Made With
Real
USDA
tsode W
quot.t,
FAT FREE REA
Heart
Healthy
NO NITRATES
NITRILES APO
s, immune supp
SUGAR FREE
0% Vitamin C

POUCHES and BAGS. PRODUCTION CONSIDERATIONS- POUCHES AND BAGS • • • • Sealing Type Machine Type Flatness of Pouch Outside Slip Inside Slip Position of Zippers/Holes Zippers Open or Closed? Bottom Gusset Opening Optimal Production Line Times & Least Wastage. 

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PRODUCTION CONSIDERATIONS- POUCHES AND BAGS
•
•
•
•
Sealing Type
Machine Type
Flatness of Pouch
Outside Slip
Inside Slip
Position of Zippers/Holes
Zippers Open or Closed?
Bottom Gusset Opening
Optimal
Production Line
Times & Least
Wastage

COMMUNICATION AND MARKETING. Branding and Communication Fails... Designs too similar to competitors • Colour inconsistencies • Poor barcode and information placement Product showing through the pouch. 

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Branding and Communication Fails...
Designs too similar to competitors
• Colour inconsistencies
• Poor barcode and information placement
Product showing through the pouch

Other CONSIDERATIONS. How Time and Temperature Impact Food When developing a flexible packaging design for a product, understanding the conditions of the products manufacture and storage are factors to consider to ensure food safety. • Heat Conditions (Hot Fill, Retort, (h)king, Storage of Product) • Cool Conditions (Fridge, Freezer safe) • Shelf Life Length Jasmine eg bles, oeen bsrle,•. 

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How Time and Temperature Impact Food
When developing a flexible packaging design for a product, understanding the
conditions of the products manufacture and storage are factors to consider to
ensure food safety.
• Heat Conditions (Hot Fill, Retort, (h)king, Storage of Product)
• Cool Conditions (Fridge, Freezer safe)
• Shelf Life Length
Jasmine
eg bles,
oeen bsrle,•

Food Behaviours and Food Safety- Examples Knowing food behaviours and following correct processes are vital to ensure none of these issues occur with products either before, during, or after packing! Delamination from oil seep Product showing through pouch after retort process Blue cracks indicate break in the SIOX after Retorting. 

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Food Behaviours and Food Safety- Examples
Knowing food behaviours and following correct processes
are vital to ensure none of these issues occur with
products either before, during, or after packing!
Delamination from oil seep
Product showing through
pouch after retort process
Blue cracks indicate break in
the SIOX after Retorting

Minimising Issues: Choosing the correct film combinations Choosing the right material density Obtaining the right gauge • Obtaining the right weight distribution • Using quality manufacturers & suppliers Quality Control and Lab Testing!! 0. 

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Minimising Issues:
Choosing the correct film combinations
Choosing the right material density
Obtaining the right gauge
• Obtaining the right weight distribution
• Using quality manufacturers & suppliers
Quality Control and Lab Testing!!
0

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Intelligent Packaging Active Packaging Smart Packaging Sustainable Packaging. 

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Intelligent Packaging  Active Packaging  Smart Packaging  Sustainable Packaging

Lower environmental impact  Can be effectively recovered and utilized in biological and         or industrial closed loop cycles

“Materials  and articles that  monitor the condition  of packaged food or the environment surrounding the food” They have the ability to  communicate  the conditions of the packaged product, but they do not interact with the  product.

Active packaging refers to the incorporation of additives into packaging systems, with the aim of maintaining or extending  freshness of the product’s  quality and shelf  life.

P ackaging  which  goes beyond the basic function  of passively containing and  protecting the product  by adding useful functionality with real benefits for the consumer

Optimizing Packaging : 8R approach. Remove Recycle Renewable Reuse Redesign Reduce Refuse Repurpose. 

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Remove Recycle Renewable Reuse Redesign Reduce Refuse Repurpose

To optimize the transport and use of the product

If possible, and if not, adapt to the end-of-the life

CONSUMER EXPERIENCE PACKAGING. LOOKING AT PACKAGING TRENDS THE CONSUMER EXPERIENCE WITH FLEXIBLES A variety of technologies and finishes for current flexibles create vibrant packaging Formats that are appealing to consumers and evoke their senses! TOUCH SIGHT SOUND SMELL. 

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LOOKING AT PACKAGING TRENDS
THE CONSUMER EXPERIENCE WITH FLEXIBLES
A variety of technologies and finishes for current flexibles
create vibrant packaging Formats that are appealing to
consumers and evoke their senses!
TOUCH
SIGHT
SOUND
SMELL

Shaped steamer pouches-
Where design meets functionality
'Vussdf

HOW IS ugec MOVING WITH THE TREND?. Swmr jupø5. 

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Ideation 1 Target Market Business Case/ Scoping 2 Segment and Scope Development 3 Development Strategy Pilot, Testing and Validation 4 Launch Production of Mock-up, Small Volume, Batch Trial Runs Existing Product Evaluation Supply Network / Studies (Supplier, Market/ Client) Anticipated Sales/ Growth Potential Client Requirements, Pain Points / Problems Minimum Viable Product (MVP) Anticipated Sales/ Potential Other Due Diligence Readiness for Commercial (RM, Timings, Sales Forecast) Standardization (Specs, ERP Set-up, BOM Finalization) QA/ QC Checks / Approved Standards (HACCP Studies, Mandatories) Final Costing Assessment Product Launch Internal Assessment of Product Quality, Process Efficiency and Productivity, Parameters and Controls for Reproducibility and Repeatability Client Reports/ Approvals Trial Protocols Resource Readiness Timings Change Management Process DOE Client Sign-offs Documented Information. 

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Ideation  1 Target Market  Business Case/ Scoping  2 Segment and Scope Development 3 Development Strategy  Pilot, Testing and Validation  4 Launch  Production of Mock-up, Small Volume, Batch Trial Runs  Existing Product Evaluation Supply Network / Studies (Supplier, Market/ Client) Anticipated Sales/ Growth Potential Client Requirements, Pain Points / Problems Minimum Viable Product (MVP) Anticipated Sales/ Potential  Other Due Diligence Readiness for Commercial  (RM, Timings, Sales Forecast) Standardization (Specs, ERP Set-up, BOM Finalization)  QA/ QC Checks / Approved Standards (HACCP Studies, Mandatories) Final Costing Assessment Product Launch Internal Assessment of Product Quality, Process Efficiency and Productivity, Parameters and Controls for Reproducibility and Repeatability  Client Reports/ Approvals Trial Protocols Resource Readiness Timings Change Management Process DOE Client Sign-offs  Documented Information

Key Results : Studies Development Directions (Capability assessment and Readiness)

Key Deliverables :  Business Case Exit Criteria  Project Feasible/ Viable

Key Deliverables :  Joint Development Strategies Exit Criteria  Agreed Development Protocols and Timeline

Key Deliverables :  Assessment and Readiness to Commercial Production Exit Criteria  Customer approvals (Final Costing, Trial run results, References/ QC Standards Internal specs/ references

Key Deliverables :  Trial Plan/ Protocols Exit Criteria  Customer approvals (Trial run results, References/ QC Standards

1 Characterize product 2 Check Available Packaging facilities 3 Characterize target market 4 Choose appropriate packaging materials 5 Optimize handling/ logistics/ supply chain processes 6 Test your packaging. 

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1 Characterize product  2 Check Available Packaging facilities  3 Characterize target market  4 Choose appropriate packaging materials 5 Optimize handling/ logistics/ supply chain processes 6 Test your packaging

Basic Steps in selecting the right packaging design

Analyze full range of packaging Are specs “one size fits all” ? Is it under or over specs? Analyze full range of products Are product testing covered? Are additional product testing done (when exposed to oxygen, light, moisture, Nitrogen, aroma) Confirming specific considerations Are product / production needs covered? Are Shelf-life and stability studies covered? Are ingredients interactions confirmed / covered?. 

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Analyze full range of packaging   Are specs “one size fits all” ?  Is it under or over specs? Analyze full range of products  Are product testing covered?    Are additional product testing done (when exposed to oxygen, light, moisture, Nitrogen, aroma)    Confirming specific considerations Are product / production needs covered? Are Shelf-life and stability studies covered? Are  ingredients interactions confirmed / covered?

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Material Feedstock Processing Methods/ Technology Sustainable/ Green Packaging. 

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Material Feedstock   Processing Methods/ Technology Sustainable/ Green Packaging

Substrates  Inks and Coatings  Laminating Adhesives

Flexographic Printing Technology    Lamination Technology   Ink Technology  Inspection Machine

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From Sustainability Implementation to Possible Food Safety Issues Unavailable EPR IRR Cost Impact. 

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From Sustainability Implementation to Possible Food Safety  Issues   Unavailable EPR IRR Cost Impact

For the use of recyclable material ingredients

Product format mix for development (Paper or Film-based laminates)  Biodegradable , Compostable and Recyclable identification and grading

Product and Environmental Safety. Challenges Ahead ……... 

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The Recycling Label Guessing Game!!!
RECYCLiNG
000

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Ideation Green Packaging for Laminates Optimized Packaging Laminates and applicable business models Business Case/ Scoping Century Pacific Products Dry and Frozen Foods Retort packaging. 

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Ideation Green Packaging for Laminates  Optimized Packaging Laminates and applicable business models Business Case/ Scoping Century Pacific Products  Dry and Frozen Foods Retort packaging

a. Lightweight Laminates/ Optimized layering b. Monomaterial Laminates (PET, PE, PP) c. High Barrier films for longer shelf-life Biodegradable Laminates/ Use of Renewable Materials Paper-based. 

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a. Lightweight Laminates/ Optimized layering b. Monomaterial Laminates (PET, PE, PP) c. High Barrier films for longer shelf-life Biodegradable Laminates/ Use of Renewable Materials  Paper-based

Set # Description Scope Set 1A Light weighting/ Optimized Laminates Set 1B Mono-material Laminates Set 1C High Barrier Films Set 2 Biodegradable Laminates/ Renewable Material Sources Bio-PET/ Bio-PE Starch-based PHA/ PLA Set 3 Paper-based Laminates. 

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Set #  Description Scope Set 1A Light weighting/ Optimized Laminates     Set 1B  Mono-material Laminates  Set  1C High Barrier Films  Set 2 Biodegradable Laminates/ Renewable  Material Sources   Bio-PET/ Bio-PE Starch-based   PHA/ PLA Set 3 Paper-based Laminates

Reduction of Plastic Foot print Higher material yield Production source of recyclable materials for repurposing. Longer Shelf-life using high barrier films. 

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Reduction of Plastic Foot print  Higher material yield Production source of recyclable materials for repurposing.  Longer Shelf-life using high barrier films

Sustainability Measures Product Performance

Functional properties need validation runs and testing   (barrier properties)  High risk for product safety, needing due diligence.  Buy back market for recycled packaging laminates is inadequate.

Set 1- Initiatives  (Light weighting/ Optimized layering  and Monomaterial Structures)

Reduction of Plastic Foot print Lower GHG emissions (109% less) , lower fossil fuel consumption (79% less) Mostly biodegradable= decrease in waste generation. 

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Reduction of Plastic Foot print  Lower GHG emissions (109% less)  , lower fossil fuel consumption (79% less) Mostly biodegradable= decrease in waste generation

Limited Functionality  Expected to have lower moisture and gas barrier properties Raw materials competes with food supply Higher Cost Vulnerability to degradation  Possible Increase in aquatic toxicity (90% more) Possible increase in water consumption (1,100% more)

Set  2 - Initiatives  (Biodegradable Laminates/ Renewable materials )

Renewable material types. Bio-PET/ PE Partially or completely bio-based, non-biodegradable; Starch-based Bio-based, Biodegradable Properties : Transparent, edible , poor mechanical properties, poor barrier; PHA Bio-based, Biodegradable PLA Bio-based, Biodegradable Feedstocks: Starch, Corn, Sugar Cane Properties : Transparent, rigid, low heat resistance, low barrier Feedstocks: Starch, Corn, Sugar, Biomass Properties: Opaque, rigid to elastomeric, good heat resistance and barrier properties , Higher production cost. Feedstocks: Starch, corn, sugar cane Feedstocks: Sugar cane, molasses, vegetables oils, Properties: Comparable to conventional plastics, easy processing.. 

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Bio-PET/ PE Partially or completely bio-based,  non-biodegradable; Starch-based Bio-based, Biodegradable Properties : Transparent,  edible ,  poor mechanical properties, poor barrier;  PHA Bio-based, Biodegradable PLA Bio-based, Biodegradable  Feedstocks: Starch, Corn, Sugar Cane Properties : Transparent, rigid,  low heat resistance, low barrier Feedstocks: Starch, Corn, Sugar, Biomass Properties: Opaque, rigid to elastomeric,  good heat resistance and barrier properties ,  Higher production cost.  Feedstocks: Starch, corn, sugar cane Feedstocks:  Sugar cane, molasses, vegetables oils, Properties: Comparable to conventional plastics, easy processing.

No Plastic Foot print Sustainably sourced materials (From protected forest) Minimum barrier property, with heat sealability .. 

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No Plastic Foot print  Sustainably sourced materials (From protected forest)  Minimum barrier property, with heat sealability .

Limited Functional Performance and Product applications & bulk weight content.   Cost of compliance is expected to be higher.

Set 3- Initiatives  (Paper-based Laminates)

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UGECORP Green Packaging Innovation Options : Ready for Test Trial Runs. 

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UGECORP Green Packaging  Innovation  Options : Ready for Test Trial Runs

1 Packaging with Recyclable plastic layers/ Optimized Layers Monomaterial film structures  (PET-based, PP, PE-based ) Alu Foil and Nylon Replacement Down gauging / Light Weighting

Metallized based or with Transparent areas It can be printed with metallic/ Matte  effect finish Doable in Rotogravure or Flexographic Printing

2 Packaging with degradable material Paper-based Biodegradable films. 

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2 Packaging with degradable material Paper-based Biodegradable films

UGECORP Green Packaging  Innovation  Options : Exploration

Home Pride - Pasta Sauce - Filipino Sweet Style - 1 KG – Sukli - Filipino  Grocery Online USA

Packaging with Optimized material structure/ layers. 

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Packaging with  Optimized material structure/ layers

Packaging with degradable additives/ Ingredients**

Commercial Terms/unique offerings Bundled Pricing Scheme Freemium vs Premium Cost offerings Sustainable Products / Service Green Packaging Formats Closed loop product offerings Cost Leadership model Flexible Pricing model VMI warehouse Customization and integrated product offerings. 

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Commercial Terms/unique offerings Bundled Pricing Scheme Freemium vs Premium Cost offerings Sustainable Products / Service   Green Packaging Formats Closed loop product offerings  Cost Leadership model Flexible Pricing model VMI warehouse  Customization and integrated product offerings

The Future :. AIP The Future of Flexibles THE BARRIER TO INNOVATION IS A LACK OF IMAGINATION. 

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AIP
The Future of Flexibles
THE BARRIER TO INNOVATION
IS A LACK OF IMAGINATION