Innovations in Packaging for Convenience Traditional Foods

By

Dr. Himanish Das

General Manager- Innovation & Technology,

MTR Foods Pvt Ltd (Norway Based ORKLA Group)

Bangalore- 560099.

Email: himanish.das@mtrfoods.com

Cell: + 91 9916725625

Conference on Role of Packaging in Promoting Food Safety and Security

Organized by ILSI-India

27 – 28 Feb 2017, New Delhi

POINTS

�India’s Agriculture and Food Industry – A Snapshot

�Why Convenience Traditional Foods?

�Technologies behind Convenience Traditional Foods

�Packaging for Convenience Traditional Foods

�Trends in Packaging Developments

�Challenges & Way forward

Indian Agriculture & Food Industry- Snapshot

�India’s Agriculture – Key Indicators: India is the second largest producer of food in the

global map having no. 1, 2 & 3 position in many produces out of agriculture, horticulture and

animal husbandry, and contributes to 1.5% of overall International Trade.

�Indian Food Industry- Key Indicators:

No. 1

Fruits, Milk, Nuts, Chilli, Ginger,

Sesame, Chickpea, Pigeonpea,

Mango, Guava, Lemon, Banana,

Buffalo meat……..

No. 2

Vegetables, Wheat, Rice, Tea,

Sugar, Potato, Garlic, Onion,

Tomato, Goat meat,

Groundnut……..

No. 3

Cashew nut, Coconut,

Nutmeg, Cardamom, Mace,

Rapeseed………

Indicators Values

Rank 5th with respect to Industry output

Contribution 14% to Manufacturing GDP; 6% to Industrial investment

Business Rs 2.7 lakh Cr. Estimated to Rs 4 lakh Cr by 2018

Employment 1.6 Mn

Big consumer base About 70 Cr population buy packaged food

�Food Processing Segments, % Share:

� Greater need for packaging for storage, packaging and distribution of raw and processed

agricultural produces which will help:

1. To avoid wastage of raw and processed produces. Current wastage of wheat is

8% and that of fruits and vegetables 40%.

2. To store and distribute both raw and processed with superior product quality

and hygiene.

3. In the last decades, Milk and Oil packaging has higher achievement than other

produces, showing the extent of % packaged product in double digit.

Segments % Share

Meat, Fish, Fruits, Vegetables, Oil 40

Beverage 20

Grains, Milled Products 10

Dairy Products 5

Others 25

Indian Agriculture & Food Industry- Snapshot

� Greater Convenience –

A. Due to Changing Life style & Food habits

• Time constraint - Fast-paced life, have no/less time to cook.

• Nuclear family & Majority couples working.

B. Change in Demography & Income

• Urbanization; Unmarried youth living away from home

• Increase in income- affordability

� Food closure to heart

• Traditional food, Home-food – Comfort.

• Variety of foods in a day or week.

�Higher Food Safety –

• Increased awareness for SAFE, HYGIENIC FOOD

• Unbranded to branded packaged foods

� Availability

Big Change for Convenience Traditional Foods

Technologies behind Convenience Traditional Foods

Food Technology

•Thermal processing

•Dehydration technology

•Flaking technology

•Extrusion technology

•Dry grinding and blending

•Frying & roasting, etc……..

Ingredient Research

•Flavour, Oleoresin

•Food additives

MANY MILES TO GO…...

Packaging Technology

•Polymer science- Packaging

materials and format

•Material science

• Filling & Packing technology

Automation

• Material handling

• Front & End line automation

Others

•Advances in other Engg & Tech

•Quality analysis and food safety

Traditional Foods- Categories

SPICES

Sambar, Rasam, Puliogare, Bisibele bhat, Vangi

bhat, Garam masala, Biryani masala, Chettinad

masala, Curry powder, Paneer Tikka masala, Pav

Bhaji masala, Chhole masala, Missal Rasa,

Masala paste

BREAKFAST MIXES

Idli, Ragi Idli, Oats Idli, Vegetable Idli, Dosa,

Multigrain dosa, Poha, Umpa, Vegetable Upma,

Dhokla

BEVERAGE

RTD Badam drink, Badam drink mix

OTHERS

Vermicelli and Macaroni, Vegetable vermicelli,

Vermicelli payasam, Pickles, Frozen Breakfast

RTE SWEET AND MEALS

Sweets: Gulab jamun, Rasogulla, Rasmalai

Curries: Paneer butter masala, Dal Makhani, Dal

Fry, Chhole masala, Bhindi fry, Avial, Rajma

masala, Paneer Tikka masala

Meals: Veg Pulav, Rajma chawal, Sambar rice

RTE SNACKS

Khara boondi, Benne Murukku, Avalakki Mixture,

Cornflake mixture, Thick Sev, Banana chips, Huli

thengule, Ompudi, Onion nibbles, Kodubale

SWEET, DESERT SNACK MIXES

Gulab jamun mix, Jalebi mix, Kulfi mix, Bhaji

bonda mix

Breakfast Mixes

Total Breakfast Category- Rs 5000 cr

�Breakfast Cereals- Rs 1600 cr

� Breakfast Mixes- Rs 250 cr

• Dosa, Idli, Upma, Poha,

Kesari Bhat, Bonda, Chutney

�Branded wet batter

�Noodles

�Sweet Mixes

Product format: Ready-to-cook, Easy-to-cook

Quick/Brief/No Cooking

Product requirements:

Fresh for long time Very low moisture gain

Very low fat deterioration No infestation

Packaging Properties: Laminates good WVTR & OTR

Packaging Format:

�Pillow pouch & Standy pouch

� Bag in Box

�Cups with foil seal and lid

Traditional Sweets

Product format:

Ready-to-eat

Product requirements:

Packaging Properties:

Packaging Format:

�Tin/Glass – Long shelf life

�Retortable PP Cup/tray with top laminate

film- light wt, long life, easy peel

�Non-retortable Cup/Tray with MAP- Short

shelf life

Preparing & serving sweets – part of culture & still stands strong

Highly penetrated category

Total Estimated Category: Rs. 49000 Cr

Lion’s share un-organized: Cottage, Small scale, Local sweetmeat and bakery shops: Quality and safety

is a major concern.

Ready-to-eat

Shelf life - few weeks to year

Fresh for long

Very low fat deterioration

Very good OTR

Good seal strength

Easy peelability

Organized segment: Branded packaged, Branded shop: Quality & safety not a concern

Spices & Masala- Rs. 12500 Cr

Pure Spices Masala

Veg Non Veg

Product format:

Product requirements

Packaging Properties:

Packaging Format:

�Pillow & Standy pouch – Laminate

�Bag in box, Ceka

Ready-to-cook

Mix for dish or basePowder or paste

Shelf life - months to year

Fresh for long Less Aroma loss

Low moisture gain

Good WVTR and OTR

Very good seal

Traditional Spices & Masala

Product format

Product requirements:

Packaging Properties:

Packaging Format:

Pillow, Standy pouch with zip lock

Flow wrap

Varied shape/sizeReady-to-eat/cook

Shelf life-Few months Fried/Roasted/Extruded

Fresh for long Low moisture gain

Low rancidity Inert gas

Very good WVTR, OTR Good grease resistance

Very good seal Puncture resistance

Traditional Snacks

Majority share by un-organized: Cottage, Small scale, Local sweetmeat, Snack and bakery shops:

Quality and safety is a major concern.

Total Estimated Category: Rs. 67000 Cr

Organized segment: Branded packaged, Branded shop: 50% is Indian traditional Snacks. Quality &

safety not a concern

FLEXIBLE POUCH has replaced tin containers due to:

Retains Taste and Proven Safe; High temp resistance; High barrier – Provide longer life; Light weight;

Easy to carry; Microwavable/Non microwavable; Multilayer Pet/Foil/CPP or PET/Foil/OPA/CPP.

Breathable laminate has additional benefits.

RIGID CONTAINERS:

Multi-layer cup/tray with peelable laminate is replacing tin due various advantages.

Has advantage of easy to open, easy to carry, see-through and microwavable properties.

Ready-to-eat Traditional meals

Though a small category, it has it own importance for urban youth staying alone away from home

and having no time to cook, traveller, picnic goers, off-time companion, etc.

High degree of Convenience with literally no cooking for traditional dishes which require elaborate

cooking.

Provides high Food Safety and long shelf at ambient coupled with traditional taste are key features

Source: PlastIndia, Business Press, Research by

Tata Strategic

Countries Per Capita Plastic consumption

(Kg/Person/Year)

USA 109

Europe 65

China 45

Brazil 32

India 9.7

�Expected to double by 2020.

Plastic Production and Consumption

Countries Annual Production,

Million Ton

Global 322

Europe 58

India 12

�40% use as

Packaging

Plastics % Share in Flexible

packaging

Polyethylene 33

Polypropylene 29

PET 17

PVC 7

Others 14

Trends in Packaging Development

Change in objectives of R&D in Packaging

�Contain

�Protect

�Preserve

�Transport

�Deliver

� To meet above needs

PLUS

�Inspire

�Instruct

�Educate

�Record

�Trace

Change in Consumer Needs

�Leak-proof

�Pilfer-proof

�Safe

�Hygienic

�Fresher, Healthier

�Easier to open

�Easier to reseal

�Cleaner

�Compliant

�Environment friendly

�Recycle

Development Multi-directional:

1. Improved functionality 2. Greater convenience

3. Less cost per unit volume of food product 4. Improved printing

5. Improved machinability 6. High food safety

7. Less environmental impact 8. Easy availability

9. Smart packaging

Trends in Packaging Development

EXAMPLES

1. Reclosable pouches 2. Anti-fog pouch

3. Oxygen scavenger film 4. Time-Temp indicator

5. Plasma treatment 6. Metallocene incorporated film

7. Spouted pouches 8. Retortable cup/tray

9. Hybrid structure (Plastic + paperboard)

10. Bioplastics- renewable, compostable, degradable

11. Plastic impregnated with active compounds- Anti-oxidants, Antimicrobial, Flavours, etc:

release of synthetic phenolic antioxidants from polylactic acid film.

12. Reduced packaging: Optimise packaging solution will reduce materials consumption.

Challenges

I. Lack of Standardisation/Optimisation

A. Use of over-engineered pack by small players pose bigger impact on Environment.

B. On the other hand, use of sub-optimal by them may lead to food safety and quality.

II. Lack of awareness on packaging material quality

A. Small players don’t check for food-grade materials and migration which is a bigger safety concern.

B. Their inadequate capability to handle and use/seal will further add to safety concern.

III. Plastic Waste Management Rules, 2016

A. In absence of Collection and recycling infrastructures, it will be difficult to implement this.

B. In absence of efficient alternative, phasing out of non-recyclable alternatives laminates by 2018 will

be difficult and a stumbling block to existing plastic and processed food business as well as pull a

closing curtain on R&D going on existing plastics including flexible laminates and their formats.

Way Forward

1. Optimisation of pack: Reduce consumption. 1% reduction in packaging consumption will lead to 50000

MT reduction per year.

2. Quality check on food contact materials before use.

3. Development of collection, segregation, reuse & recycle process/infrastructure and efficient, effective

alternate solution to laminates is a prerequisite to implementation of Plastic Waste Management.

4. Private and Govt institutes to emphasize on research on recyclable laminates/degradable plastic.

5. Plastic packaging materials manufacturing units will be licensed or registered for intended use of the

materials and will be responsible to adhere to the standards, as practised in the US.

6. Standards for plastic packaging materials to be implemented at the point of manufacturing.