PACKAGING DESIGN AND PACKAGING CONCEPTS
Packaging design is the process of ideation and development of packaging combining;
- Objectives of producer/logistics and retail
- Deep knowledge of the product
- The consumers
Production chain aspects
1. Producer packaging process depends on
o The product (most importantly)
o Available equipment
o Experience
o Demands in the chain
2. Logistics
o Firmness of secondary packaging (boxes)
o Sizes of secondary packaging (fit on pallet)
3. Retail
o Shelf space
o Assortment
o Type of secondary packaging
4. Consumer
o Product choice (massive variety)
o Larger assortment
o Convenience
o Fresh & healthy
o Smaller units (portion size)
Standardisation of size
- For optimization of logistics
- Easy unpacking onto the shelves
,PACKAGING DESIGN
What is the need for packaging design?
- New product
o A new package of an existing product? Consumers may perceive this product as new
o The new product should fit in the assortment of the retail stores
- New distribution type
- Competition changes
- Consumer needs
- New tech/materials
- New legislation
It is necessary to do in-depth market research to know whether the new package will be accepted.
Change is very costly
Consider product quality: many mechanisms for quality loss
Biological: enzymatic, microbial growth, insects
Chemical: oxidation, Maillard
Physical: water migration
Therefore, the design of the packaging should reduce the rate of quality losses which is often an
integrative approach between 4 disciplines: product formulation, processing, packaging design and
chain management
Important aspect of packaging with a barrier function
- Exchange of components from/to the environment (water, oxygen, aromas)
- Depends on packaging material used and the surface area of the packaging
Calculating quality losses
1. Reaction kinetics: mathematical description of quality attributes (during storage or processing)
2. Mass transfer: mathematical description of transfer through packaging materials
3. Heat transfer: pasteurization, sterilization
4. Mass balances: Linking mass transfer and reactions
Look at the packaging as a system designed to improve the quality and/or to guarantee the safety of the
product
,Criteria to define at the start of packaging design
1. Selection of packaging materials
o Tradition of use consumer expectation
o Product freshness and protection
2. Packaging construction
o Flexible or rigid container
o Easy to handle and (re)open
3. Ease of secondary packaging
o Will shape and size favour the shipping to the retailers
4. Shelf life extension through packaging
o What is the goal shelf life?
5. Ease of storage and distribution
o Cost of secondary packaging and transportation
o Time and conditions of storage before going on display
6. Packaging materials and design drive costs
7. Pay attention to sustainability issues
8. Space to convey the messages to consumers
BIOLOGICAL: MICROBIAL GROWTH
- Inhibition of microbial growth is very important in food preservation
- Control of water activity is the main method to avoid undesired microbial growth
o Also, low temperature, low pH or antimicrobials
Food perishability as a function of water activity and pH
CHEMICAL: LIPID OXID ATION
- Major chemical route of food spoilage
- Auto-catalytic reaction, should be stopped at the very beginning by
o Oxygen barrier
o Light
o Metal chelators (coated metal container)
o Antioxidants
- Not only oils but fat containing foods can turn rancid fatty fish for example (salmon)
, PHYSICAL: MOISTURE MIGRATION
Moisture loss
- Most semi-dried foods lose moisture during storage
- Sealable packaging is effective in combination with product formulation
- Bread turns stale due to moisture loss
Moisture absorption
- Absorption of moisture to dry products results in decreased crispness/crunch
- Cookies that go soft
- Single portion packaging used to provide a more constant quality
MATERIALS
Cans: long shelf life cheap products
- Traditionally made from tin plate sheet, now aluminium is more common
- Inside of can often sheet coated with lacquers to prevent rust and reactions between can and
contents (especially acidic foods)
Plastics: versatile and convenient
Barrier properties of;
Polyeth(yl)ene:
- low density is used as a film wrapping, resistant to water
- high density is used for ‘sous vide’ cooking
- polyethylene absorbs many apolar compounds (lipids)
polyamide (nylon)
- very good barrier to oxygen
- used for vacuum packaging (especially for foods containing fat which are sensitive to oxidation)
*Barrier properties are not the only selection criterion
*other properties to consider are transparency, melting point, sound
Bioplastics
Biobased plastics made from renewable sources
1. PLA polylactic acid
2. PHA polyhydroxyalkanoaten
3. Bio PET Polyethylene terephthalate (“plant bottle”)
Bio-degradable plastics that are compostable
1. Starch based
2. Protein based
3. PLA & PHA (very slow composting)
Packaging design is the process of ideation and development of packaging combining;
- Objectives of producer/logistics and retail
- Deep knowledge of the product
- The consumers
Production chain aspects
1. Producer packaging process depends on
o The product (most importantly)
o Available equipment
o Experience
o Demands in the chain
2. Logistics
o Firmness of secondary packaging (boxes)
o Sizes of secondary packaging (fit on pallet)
3. Retail
o Shelf space
o Assortment
o Type of secondary packaging
4. Consumer
o Product choice (massive variety)
o Larger assortment
o Convenience
o Fresh & healthy
o Smaller units (portion size)
Standardisation of size
- For optimization of logistics
- Easy unpacking onto the shelves
,PACKAGING DESIGN
What is the need for packaging design?
- New product
o A new package of an existing product? Consumers may perceive this product as new
o The new product should fit in the assortment of the retail stores
- New distribution type
- Competition changes
- Consumer needs
- New tech/materials
- New legislation
It is necessary to do in-depth market research to know whether the new package will be accepted.
Change is very costly
Consider product quality: many mechanisms for quality loss
Biological: enzymatic, microbial growth, insects
Chemical: oxidation, Maillard
Physical: water migration
Therefore, the design of the packaging should reduce the rate of quality losses which is often an
integrative approach between 4 disciplines: product formulation, processing, packaging design and
chain management
Important aspect of packaging with a barrier function
- Exchange of components from/to the environment (water, oxygen, aromas)
- Depends on packaging material used and the surface area of the packaging
Calculating quality losses
1. Reaction kinetics: mathematical description of quality attributes (during storage or processing)
2. Mass transfer: mathematical description of transfer through packaging materials
3. Heat transfer: pasteurization, sterilization
4. Mass balances: Linking mass transfer and reactions
Look at the packaging as a system designed to improve the quality and/or to guarantee the safety of the
product
,Criteria to define at the start of packaging design
1. Selection of packaging materials
o Tradition of use consumer expectation
o Product freshness and protection
2. Packaging construction
o Flexible or rigid container
o Easy to handle and (re)open
3. Ease of secondary packaging
o Will shape and size favour the shipping to the retailers
4. Shelf life extension through packaging
o What is the goal shelf life?
5. Ease of storage and distribution
o Cost of secondary packaging and transportation
o Time and conditions of storage before going on display
6. Packaging materials and design drive costs
7. Pay attention to sustainability issues
8. Space to convey the messages to consumers
BIOLOGICAL: MICROBIAL GROWTH
- Inhibition of microbial growth is very important in food preservation
- Control of water activity is the main method to avoid undesired microbial growth
o Also, low temperature, low pH or antimicrobials
Food perishability as a function of water activity and pH
CHEMICAL: LIPID OXID ATION
- Major chemical route of food spoilage
- Auto-catalytic reaction, should be stopped at the very beginning by
o Oxygen barrier
o Light
o Metal chelators (coated metal container)
o Antioxidants
- Not only oils but fat containing foods can turn rancid fatty fish for example (salmon)
, PHYSICAL: MOISTURE MIGRATION
Moisture loss
- Most semi-dried foods lose moisture during storage
- Sealable packaging is effective in combination with product formulation
- Bread turns stale due to moisture loss
Moisture absorption
- Absorption of moisture to dry products results in decreased crispness/crunch
- Cookies that go soft
- Single portion packaging used to provide a more constant quality
MATERIALS
Cans: long shelf life cheap products
- Traditionally made from tin plate sheet, now aluminium is more common
- Inside of can often sheet coated with lacquers to prevent rust and reactions between can and
contents (especially acidic foods)
Plastics: versatile and convenient
Barrier properties of;
Polyeth(yl)ene:
- low density is used as a film wrapping, resistant to water
- high density is used for ‘sous vide’ cooking
- polyethylene absorbs many apolar compounds (lipids)
polyamide (nylon)
- very good barrier to oxygen
- used for vacuum packaging (especially for foods containing fat which are sensitive to oxidation)
*Barrier properties are not the only selection criterion
*other properties to consider are transparency, melting point, sound
Bioplastics
Biobased plastics made from renewable sources
1. PLA polylactic acid
2. PHA polyhydroxyalkanoaten
3. Bio PET Polyethylene terephthalate (“plant bottle”)
Bio-degradable plastics that are compostable
1. Starch based
2. Protein based
3. PLA & PHA (very slow composting)
