Packaging Minimisation – the New Paradigm

By

Roderick A Ryan BSc FIFSTI MSc MBATechnical Manager, Batchelors

PACKAGING MINIMISATION – the New Paradigm.

The C02 Foot Print

Packaging Minimisation – the New Paradigm.

Why is there need for a new paradigm?

Definitive evidence demonstates that the damage already caused to the ozone layer by the quantity of CO2 produced since the early 1980’s will take another 50 years to repair even if we act now!

Resevoirs of fossil fuels are fast running out and energy costs are soaring.

Packaging Minimisation – the New Paradigm.

This CO2 footprint results from all kinds of activity:

The fabrication of manufacturing equipment, cars, aeroplanes etc.Generation of electricity, Heating.Transportation –sea road and air.Manufacture of containers, film, ie packaging.

Packaging Minimisation – the new paradigm

Packaging waste is now considered socially unacceptable!

Land fill is no longer an option!!

Packaging Minimisation – the New Paradigm.

What is packaging?Packaging may be defined as follows:Packaging is a coordinated system for preparing goods for transport, distribution, storage, retailing and ultimately for the consumer.put another way:A system of ensuring safe delivery of product in sound condition to the consumer.

PACKAGING MINIMISATION – the New Paradigm

Packaging falls into a number of categories:

Primary – packaging in contact with the product.

Secondary – ‘outers’ which hold a number of packed products as a unit of say 10 or 12.

Tertiary – stretch wrapped pallets which hold perhaps 100 ‘outers’ or cases.

PACKAGING MINIMISATION – the New Paradigm

What is the function of packaging?Primary packaging fundamentally:

Contains.Protects.Preserves. Informs.Delivers convenience.

Other functions of packaging: Attractive presentation assists in selling!

Packaging Minimisation – the New Paradigm.

In this presentation I am confining my remarks to packaged foods and drinks though the broad thrust of the presentation applies to considerations which apply to any packaged product.

PACKAGING MINIMISATION – the New Paradigm.

Packaging Types:

Paper – plain or waxed, card board – trays; boxes; corrugated fibre board cases.Metal packaging – tin plate; aluminium containers and foil; steel drums.Glass – bottles and jars.Plastic – film: polyethylene (LDPE / HDPE), PVC. Containers: PET, PVC, PP AND PS.Composites: Paper and plastic; steel and aluminium.

PACKAGING MINIMISATION – the New Paradigm

We need to understand:

The market.The product.Process constraintsStorage and transport hazardsPackaging materials and form, fill and seal technological considerations.

FOOD DISRIBUTION SYSTEM

FARMS CO-OPS

Primary Processors

Secondary Processors

Wholesalers

Retail outlets

Consumers

Packaging

PACKAGING MINIMISATION – the New Paradigm

Ex Farm supplies:

How are supplies delivered? Most supplies are delivered in bulk either by tractor trailer loads or in tankards.Some, supply in sacks depending on custom and practice.Others in plastic packaging to the specific processors or retailers requirements.

PACKAGING MINIMISATION – the New Paradigm

Ex Co-ops:Deliveries to primary processors are normally in bulk, usually in road tankards, palletised ‘forty footers’ etc. (This method of delivery is generally well organised with little if any negative impact on packaging utilization.(Systems are in place for return of standardised pallets etc.)

PACKAGING MINIMISATION –the New Paradigm.

Primary Processing:Packaging issues of concern here will depend on the nature of the product whether it is: Solid or liquid.

For the ambient, chilled or frozen market.

For further processing.

For export as distinct from the domestic market.

In primary processing the packaging is normally undertaken manually or semi automatically:

Shrouds on beef carcases.Cuts of beef enclosed in polythene, boxed, strapped and either blast frozen or despatched as ambient product to secondary processors or the retail trade.Washed vegetables in plastic bags.

PACKAGING MINIMISATION –the New Paradigm.

PACKAGING MINIMISATION – the new paradigm

Secondary processors.

These processors normally pack finished product for the retail trade.

It is highly mechanised and there are as many packaging systems as there are products each with its own special requirements.

Particular package types are associated with particular products though not always.

PACKAGING MINIMISATION – The New Paradigm.

The market:We need to understand the market fully!

What purpose does the product fulfill?What sizes,shapes and weights are required?What’s the nature of the channel of distribution?What type of container is required?What secondary and tertiary packaging is required?What innovative stategies can be brought to bear?

Packaging Minimisation – the new paradigm.

Metal containers and the canning of food was developed in the early 1800’s when Napoleon awarded a prize to Nicholas Appert for inventing ‘canning’ of foods process.

Appert’s first containers were made from very heavy cast iron cyclinders

Containers have come along way since then.

Still improvements are possible with emerging can making technology.

PACKAGING MINIMISATION – the New Paradigm.

Cold Rolling Mill

PACKAGING MINIMISATION – the New Paradigm.

Diagram of cold rolling mill

PACKAGING MINIMISATION –THE NEW PARADIGM

Let us take a can used for canning vegetables. For example an unbeaded can (Straight walled can).

If we reduce the steel thickness too much the can will not withstand the internal pressure build up during heat processing and on cooling the container will collapse.

PACKAGING MINIMISATION – the New Paradigm.

Unbeaded can

PACKAGING MINIMISATION – the New Paradigm.

Unbeaded can under pressure

PACKAGING MINIMISATION – the New Paradigm.

Old bead form

PACKAGING MINIMISATION –THE NEW PARADIGM

Another example: Let us take a beaded can.

If we reduce the steel thickness of this can engineers can calculate with precision the beading profile necessary to enable it to withstand the internal pressure build-up during heat processing.

Consequently, on cooling, the container will not collapse.

PACKAGING MINIMISATION – the New Paradigm.

Optimised bead form

Packaging Minimisation – the new paradigm.

Normally a can is fitted with a can end or lid which has bulit in expansion ‘rings’ This allows both ends to distort during heat processing and still retain the ability to return to the normal flat configuration after cooling.

PACKAGING MINIMISATION – the New Paradigm.

After filling

During processing

After cooling

End Expansion during procesing

PACKAGING MINIMISATION – the New Paradigm.

Optimised bead form

Packaging Minimisation – the new paradigm.

Other possibilities:The tin coating on the steel may be reduced.The overall capacity may be maintained and yet the steel quantum reduced by ‘necking in’ the can body in the area of the seam.Three piece can my be eplaced with two piece.What ever reductions are considered we cannot compromise can performance on product suitability, processing, handling, stackability, storage and transportation.This process of ‘light weighting’ requires considerable research and development.