PA CKAGING INTELLIGEN CE BRIEF

PACKAGING TRENDS
Forces that will influence packaging through the end of the decade

About the Packaging Intelligence Brief Series

Packaging plays a critical role in our global economy and touches the lives of everyone. For 75 years, the PMMI has been the leading global resource for packaging manufacturers to learn about industry trends, obtain training and get involved in networking events. PMMI is proud to introduce the Packaging Intelligence Brief series which focuses on trends that are shaping the future of the industry. Over the next year, PMMI will regularly release Packaging Intelligence Briefs to address various topics that are significantly impacting packaging and outlining how suppliers and manufacturers are responding to market needs.

PACKAGING TRENDS
Forces will influence packaging through the end of the decade

TABLE OF CONTENTS

Executive Summary ..................................................................................................................... 4 Introduction ................................................................................................................................. 4 Automation ................................................................................................................................. 7

More Robots ................................................................................................................ 7 More Software and Integration ...................................................................................... 8 More RFID .................................................................................................................... 9
Sustainability ............................................................................................................................. 10

Source Reduction ....................................................................................................... 11 Replacing Non-Renewable Resources .......................................................................... 12 Conserving Water and Energy ..................................................................................... 13 Waste Reduction ........................................................................................................ 14 Recycling and Recycled Content .................................................................................. 14
Consumer Convenience ............................................................................................................. 15 Product Safety ........................................................................................................................... 16 Health and Wellness .................................................................................................................. 17

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Executive Summary Building on familiar demands, package design and packaging lines will evolve to address the need for automation, sustainability, consumer convenience, product safety and rising consumer interest in health and wellness.

likely to be in single-serving packs because these designs couple convenience with healthy portion control.

Recalls, problems with tainted foods and drugs and the prevalence of counterfeit products worldwide are spurring packagers to scrutinize their supply chains, process con-

Reliance on automation will increase throughout the 20082010 time period to increase efficiency and quality and cut costs. Packagers will automate more manual operations and update and upgrade older automated operations to boost productivity, while cutting costs and labor requirements.

trols and quality assurance practices with new intensity.

With obesity seen as a major health problem in much of the developed world, skyrocketing healthcare demand and costs and the aging baby boomer population, interest in products that can improve well-being continues to rise,

Environmental concerns, often discussed under the banner of sustainability or climate change, have not yet peaked. As a result, between now and 2010 well see continued attention on source reduction, conservation of energy, water and nonrenewable resources, minimization of greenhouse gas emissions and waste and rising levels of recycling and recycled content.

driving demand for better-for-you formulations, portioncontrol packaging, more product information, greater emphasis on fresh products and reduction in the use of artificial additives and preservatives. There also is interest in products that simplify preparation of balanced meals and improve the nutritional profile of grab-and-go foods/beverages.

Recent product introductions show how strong the demand for convenience is with products like Healthy Choice Caf Steamers entrees from ConAgra Foods, Omaha, NE, in steam-generating, cook-in packaging; Lean Cuisine panini sandwiches from Nestle USA, Glendale, CA, in microwaveable susceptor trays; organic coffee beans from Celestial Seasonings, Boulder, CO, in resealable, zippered stand-up pouches; and Pringles Minis potato crisps from Procter & Gamble Co., Cincinnati, OH, in single-serving pouches. As cook-in packaging becomes even more functional, it should remain in favor, as will package designs that are easy to open and reclose. However, the greatest action is

Although packagers may want to increase automation, and deliver products that appeal to consumers desire for sustainability, convenience, healthfulness, economics ultimately will determine changes are made in packaging designs and equipment. Introduction Building on familiar demands, package design and packaging lines will evolve to address the need for automation, sustainability, consumer convenience, product safety and rising consumer interest in health and wellness.

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The importance of sustainability, convenience, and health and wellness to todays consumer is clearly demonstrated by products listed in the top 20 Most Memorable New Product Launches of 2007. Sustainable products listed by consumers queried in a survey sponsored by Schneider Fresh Fit Meals from Subway Restaurants, Milford, CT; Diet Pepsi Max from PepsiCo North America, Purchase, NY; and microwaveable Oscar Meyer Deli Creations sandwiches from Kraft Foods, Northfield, IL.

Associates, Boston, MA; New Products magazine, Deerfield, IL; and Information Resources, Inc., Chicago, IL; include Tide 2X Ultra concentrated laundry detergent from Procter & Gamble Co., Cincinnati, OH, which contains less water and features a smaller bottle/closure than the non-concentrated formula. Food safety also is a top-of-mind concern. With high-profile U.S. recalls in 2007-2008 related to lead paint, melamine-tainted petfood, C. botulinum-contaminated hot dog chili sauce, E. coli-contaminated beef and Salmonellacontaminated pot pies and peanut butter, consumers want to know whats in a product and where it came from.

Product safety concerns are not limited to food or to the United States. Tainted products have been implicated in recent deaths and illnesses in China and Japan. In 2006, Winners falling under the health and wellness and/or convenience banners include portion-controlled Hostess 100 Calorie Pack Cup Cakes from Interstate Bakeries Corp., Kansas City, MO; Alli weight loss capsules from GlaxoSmithKline, Research Triangle Park, NC; Diet Coke Plus and Coke Cherry Zero soft drinks from Coca-Cola Co., Atlanta, GA; DanActive Yogurt Drinks from Dannon Co., North Tarrytown, NY; Although packagers may want to increase automation, and deliver products that are sustainable, convenient Packagers are scrutinizing their supply chains, process controls and quality assurance practices with new intensity. Cadbury Schweppes, London, UK, recalled more than 1 million chocolate bars from UK stores due to Salmonella contamination, and dozens died in Latin America after ingesting diethylene glycol-tainted cough syrup.

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and healthy, economics ultimately will determine the level of investment in package design and packaging line equipment.

ments, especially for smaller companies planning to spend less than $800,000 in 2008.

However, since the tax breaks relate primarily to equipAccording to Manufacturing Barometer: Business Outlook 4Q 2007, a survey by PricewaterhouseCoopers, New York, NY, senior executives in U.S.-based companies are far more positive about the world economy than the U.S. economy with 64% expressing optimism about the performance of the world economy during the next 12 months. For consumers, gasoline and other rising costs will put a squeeze on spending. With gas expected to hit $3.40 per gallon by mid-2008, consumers will be making increasingAttitudes about the U.S. economy have slipped considerably with only 29% of those surveyed feeling optimistic about prospects for the next 12 months, a substantial decline from the 45% who felt optimistic in the third quarter of 2007 and less than half of the 64%, who were feeling positive in the fourth quarter of 2006. The top four barriers to growth cited by the executives include oil/energy prices (66%), lack of demand (61%), competition from foreign markets (44%) and monetary exchange rate (44%). ly tough choices between filling the tank and other purchases. According to a Nielsen Homescan Survey done in December 2007 by The Nielsen Co., New York, NY, consumers are trying to make their dollars go farther by shopping more on the internet, eating out less, staying home more, buying more store and budget brands, reducing shopping trips and shopping more at supercenters. Manufacturers and retailers need to be alert to the fact that consumers are looking to save by altering where they shop, how they shop and what products and brands they Although the Federal Reserve cut interest rates to forestall or shorten a recession early in 2008, it appears likely the US economy will slow during 2008-2009, before accelerating in 2009-2010. However, with the dollar low versus the Euro and other major currencies, U.S. businesses should see a rising amount of revenue derived from exports. Higher oil prices are impacting consumers elsewhere in the world. In Europe, higher oil prices are boosting the cost of natural gas and electricity, as well as gasoline and raising At home, the Economic Stimulus Act of 2008, signed by President Bush in February 2008, should help offset a slowing economy through tax breaks for capital investfears of inflation. According to estimates from Luxembourg-based Eurostat, the annual inflation rate for the Euro area (15 member states) was 3.2% in January buy, says Todd Hale, senior vice president of Consumer Shopping & Insights at Nielsen, adding, Value, convenience and competitive pricing will be more important than ever in the year ahead. ment purchased and installed in 2008, its imperative to place orders early, especially for equipment with longer lead times.

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2008, significantly higher than the 2% target set by the European Central Bank, Frankfurt am Main, Germany. and machine-to-enterprise integration, use of software to collect and analyze production data, and e-machine features that permit remote access for operation, trouAt the global level, economic growth will slow from the 4.9% registered in 2007 to 4.1% in 2008, according to projections from the International Monetary Fund, Washington, DC. Pressure on growth is coming from slowing economies in the United States, western Europe and Japan, fallout from the subprime mortgage problems in the United States and moderating growth in emerging and developing economies. Automation Reliance on automation will increase throughout the 20082010 time period to address needs to increase efficiency and quality and cut costs. Respondents to the survey classify robotics as the most noteworthy development in packaging technology, and a On the packaging line, manual operations are being automated, and automated operations are looking for ways to boost productivity, while cutting costs and labor requirements. This wish list is translating into a strong interest in entry-level equipment to help packagers automate manual operations to reduce or control labor costs, improve working conditions and eliminate ergonomic hazards. significant number would like to install more. More Robots Although many packagers install new lines or upgrade existing lines to meet changing needs, theres also a strong interest in outsourcing, especially in the food industry. According to a 2007 Food Packaging Trends Study by Food Engineering magazine, 32% of respondents rely on contract packagers to reduce time to market for new products, double the percentage using this strategy in 2003. bleshooting and/or repair.

For operations that have already made the transition to automated equipment, the need to increase productivity and control costs is spurring demand for flexible machines that are easier to clean, change over, operate and maintain. Its also prompting greater use of servos, networks (especially wireless), radio frequency identification (RFID) and robotics and spurring more interest in machine-to-machine Palletizing is the most common packaging application for robots, followed by case/carton packaging and pick-andplace activities. However, the units continue to add to their

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repertoire of packaging functions. According to a study by the PMMI, Arlington, VA, robot use has grown rapidly since 2004 with a 28% jump in the number used for primary packaging and a 17% increase in units performing secondary packaging tasks. Survey respondents predict palletizing will continue to dominate, but use of robots for primary packaging tasks will experience more rapid growth.

the majority of packaging machinery companies selling robotic equipment also offer maintenance services.

More Software and Integration

Increasingly, the enabler on packaging lines is software. Not only does it govern machine action, but it also controls setup and interaction -- with other machines, the network

With 77% of the packagers surveyed planning to use more robots, penetration on packaging lines should double from about one-fourth in 2007 to roughly one-half by 2012 with all segments participating Food, Beverage, Chemical, Pharmaceutical/Medical, Durable Goods and Other. A growing number of these new units will be equipped with vision to reduce the need for fixturing, increase flexibility to accommodate different products and expedite changeover.

and beyond to other enterprise systems and even to systems run by supply chain partners. Software also is starting to be used to measure productivity and manage performance with the goal of reducing unplanned downtime,

The top three reasons packagers cite for adding robotics to packaging lines include reduced costs/higher efficiencies (35%), reduced labor (30%) and manufacturing flexibility (21%). Other influences include employee safety, ergonomics, speed, product quality and space constraints.

When adopting a robot, there also are hurdles to overcome. The most frequently cited by robot users surveyed include the skill level needed to operate and maintain the units, downtime, cost and the need for human intervention. However, costs are expected to drop 10-20% by 2012. In addition mean time between failures is now measured in increments approaching 100,000 hours, and improved software and controls simplify setup and operation. Finally,

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boosting output, improving work methods and increasing maintenance efficiency. of incoming goods by Wal-Mart Stores, Bentonville, AR, and other retailers. Other drivers include the ability to meet requirements of Californias e-pedigree law, which Whatever its purpose, software makes it possible to collect, store and organize packaging machine and line data and convert it into useful, retrievable and actionable information. Increasingly, this information is available remotely via a web portal. Some packagers have been quietly experimenting with the technology for several years. Others have been sitting on At the machine or line level, for example, the Proficy Historian tool that resides in Proficy HMI/SCADA Cimplicity visualization software from GE Fanuc Automation, Charlottesville, VA, records all process data such as temperatures, filling levels, added ingredients and raw material codes and also provides access to this information via a web-based portal. Other tools can provide real-time alerts if preset parameters are exceeded. Meanwhile, vendors have been joining forces to provide one-stop shopping for systems that include the hardware, software and systems integration needed to implement the Performance management software from companies like Informance International, Northbrook, IL, and Parsec Automation Corp., Brea, CA, monitor packaging lines, calculate overall equipment effectiveness, pinpoint problems and help identify solutions. Production data and metrics also are the focus of an Efficiency Improvement Tool, EIT 5.0, from Sidel Group, Octeville, France. For drug makers, 2008 will be spent preparing to meet Californias e-pedigree law. To prevent counterfeiting and diversion and simplify authentication, the California law More RFID requires marking each primary package with a unique code and reading and recording this item-level code at each RFID, a technology that automates product identification and enables item-level serialization for supply chain, track and trace and other purposes, will continue its steady expansion due to an unwavering commitment to tagging step in the supply chain to create an electronic chain-ofcustody record. Although the serialized code could be carried by a bar code or even manually entered, the industry seems to have narrowed its choices down to RFID or twotechnology to meet compliance requirements or in-house data collection needs. As is typical with virtually all electronics-based products, hardware prices are declining as functionality increases. the fence. However, the heel dragging appears to be at an end since further delays in implementing the technology is going to cost suppliers to Wal-Mart and Metro AG, Dsseldorf, Germany. Both retailers plan to charge a penalty for each untagged pallet received. takes effect on 1 January 2009, and its success in discouraging counterfeiting and diversion of drugs and other high-value goods.

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dimensional bar codes with RFID given an edge because a bar code has to be in the readers line of sight for data to be captured. However, RFID tags and bar codes probably will be used together, especially initially, so one can serve as a backup to the other.

Another indication of how far RFID technology has evolved is the availability of turnkey, plug-and-play systems that have eliminated the trial-and-error and read rate challenges that plagued early deployments of the technology. One system targeted for case and pallet coding, the selfcontained, 32-tag-per-minute system from Diagraph, St. Charles, MO, costs $9,500. It consists of a SATO Lt408 printer integrated with a PA/4600 label applicator, RFID TampTenna, reject module, warning tower and stand. Unlike most systems that perform the encoding step in the print engine, Diagraph prints the label and feeds it to the patented TampTenna device, which encodes the tag, checks that the code is good, applies the label and checks

Drug makers relying on RFID to meet e-pedigree requirements may be able to eliminate a separate tagging operation by using source-tagged containers. At least one firm, Rexam plc, London, UK, embeds RFID tags during the injection molding process. Indicative of how close we are to large deployments of source-tagged containers is the development of a bottle inspection system to ensure the tag is viable. Positioned at the outfeed of an injection molding machine or unscrambler, the Lomax RFID system from CIVision, Aurora, IL, inspects, encodes and verifies at a rate of 240 containers per minute. Capturing item-level RFID information on the packaging line makes it possible for pharmaceutical companies to authenticate products at the filling stage. Information from source-tagged bottles also can be used to initiate an action like labeling. At later stages in the distribution chain, RFID tags provide the opportunity to continuously gather data about a products travels, update its pedigree and confirm authenticity.

the tag again as it retracts. Sustainability Environmental concerns, often discussed under the banner of sustainability or climate change, have not yet peaked. As a result, between now and 2010 well see continued attention on source reduction, conservation of energy, water and nonrenewable resources, minimization of greenhouse gas emissions and waste, and rising levels of recycling and recycled content.

There will be an especially high level of activity related to source reduction such as lightweighting containers and closures, eliminating secondary packaging, and replacing rigid packaging with flexible packaging. Source reduction makes an easy target because it not only consumes less material, but also helps cut energy costs throughout the supply chain by reducing shipping weight.

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The potential for energy savings also makes the use of materials with recycled content attractive since virgin materials require more energy to process. Thus, well see slowly rising percentages of recycled content across all types of packaging materials -- glass, aluminum, steel, paper, paperboard, corrugated, plastic -- with the most significant gains in plastics like PET where efforts to increase collection rates seem likely to bear fruit. One of the most frequently employed tactics to shrink a products environmental footprint is source reduction. Generally accomplished by lightweighting or downgauging, source reduction involves using less material in the first place. As a result, it almost always helps packagers cut costs or offset price increases. Source Reduction

Interest in packaging materials derived from renewable resources will grow, particularly in the area of bioplastics where commercial-scale production facilities are coming online and functionality is improving.

A host of source-reduced products are coming on the market including lightweighted PET containers, short-skirt closures, and dispensers from Nordson Corp., Duluth, GA, that foam adhesive or apply it in an intermittent rather than continuous bead.

We also can expect growth in flexible packaging and aseptic products, which hold a high volume of product relative to the amount of packaging required. In addition, aseptic products offer the added benefit of reducing the need for energy-intensive refrigeration. Nestl Waters North America,

Greenwich, CT, for example, relies on Sidels Flex technology to produce its lightweight Eco-Shape bottle. Weighing in at 12.5 grams, about 30% less than

Although packagers may be paying more attention to the environmental impact of their operations and products, the driving force behind these green efforts is not an altruistic save the planet mission, but a cost-reduction strategy. Sustainability initiatives that are not cost-effective are not sustainable and will falter and die. Finally, it should be noted that packagers need to publicize their sustainability efforts. Environmental activities that arent verifiably quantified and publicized dont earn any sales from consumers or support from socially minded investors.

the average half-litre (16.9-ounce) PET water bottle, the Eco-Shape container is commercial for the Arrowhead, Ozarka and Poland Springs brands and eventually will be used throughout the Nestle Waters North America system.

Short-skirt closures typically reduce total container weight by a gram or two. Not only does the closure itself weigh less, but the designs reduce the amount of resin needed in the fin-

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ish area of the container. A number of closure makers have added shirt-skirt options to their product lines including Rank Groups Closure Systems International (formerly Alcoa CSI), Indianapolis, IN, with the Xtra-Lok mini for carbonated soft drinks and the MB-Lok mini for malt beverages; SuperShorty closures from Bericap GmbH and Co. KG, Budenheim, Germany; the PCO closure from Corvaglia, Eschlikon, Switzerland; and designs from the Obrist division of Global Closure Systems, Paris, France.

describe materials that are not biodegradable, compostable or 100% derived from renewable resources. As a result, its necessary for a packager to carefully define its requirements and verify the renewable packaging being purchased meets or exceeds specifications. U.S standards like ASTM D6400 for compostable plastics and ASTM D6868 for compostable packaging, European standards like EN13432 for biodegradability/compostability and certification systems established by the Biodegradable Products Institute, New York, NY, can help ensure the packaging purchased performs as expected.

When multiplied by millions of containers and closures, even small weight reductions add up to a significant amount of resin and can help control or even reduce packaging and distribution costs. In addition, if the lighter weight results in a denser cube, it also can generate savings in distribution packaging and shipping and handling costs due to more efficient transportation utilization and reduced handling.

There also are several certification systems for fiber used in paper, paperboard and corrugated. Programs like the Sustainable Forestry Initiative, Inc., Arlington, VA, or Forest Stewardship Council U.S., Reston, VA, for example, confirm fiber comes from sustainably managed sources.

Packagers have a growing number of bioplastic options to choose from for both rigid and flexible packaging. Functionality is rapidly evolving too. In addition, theres a

Replacing Non-Renewable Resources

continuous effort to improve the environ-

Most packaging is made from nonrenewable resources. Although some metal, glass and plastic packaging is recycled and more could be recycled, packaging derived from renewable resources like wood fiber or corn is viewed by many as more environmentally friendly. Bioplastics are seen as especially appealing because they offer a way to reduce reliance on oil.

mental profile of bioplastics. Recent

developments include the production of conventional polyethylene from ethanol derived from sugar cane. Work also is proceeding on producing bioplastics from food waste or waste agricultural material

However, it should be noted that definitions of terms like bioplastic and biopolymer are not standardized and may 12

such as bagasse (residue from sugar cane processing) rather than using food crops like corn.

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Although the concept of compostable and/or biodegradable films is appealing, it should be noted that at present very little of the material will actually be composted. A widespread composting infrastructure simply doesnt exist in the United States. In Europe, the European Unions Landfill Directive restricts landfilling of biodegradable waste. As a result, some countries have a well-established composting infrastructure, others do not. In Japan, a Food Recycling Law passed in 2001 has had a positive effect on the availability of composting facilities and rates. A-B ranks as the worlds largest user of Bio-Energy Recovery Systems. Installed at nine out of 12 of the comAs interest in packaging from renewable sources has grown, visual carded packaging, long the province of plastic clamshells, is seeing a shift toward designs with a higher level of fiber content, recycled content and/or bioplastics. Suppliers of whats described as environmentally friendly visual carded packaging like Colbert Packaging Corp., Lake Forest, IL; Dot Packaging Group, Inc., Batavia, IL; or CardPak, Inc., Solon, OH; also control or eliminate emissions of volatile organic compounds from coatings and ink and work with customers to fine-tune designs for optimum cube. In England, Scottish & Newcastle plc, Edinburgh, Scotland, plans to install two biomass-fueled heat/power plants built by Wrtsil, Helsinki, Finland, at breweries in Manchester. Reportedly the first units in the world to produce both electricity and heat using spent grain, a brewing byproduct, as Conserving Water and Energy fuel, the plants will burn a mixture of spent grain and wood chips from local sources, and will begin producing steam With energy costs rising, water increasingly viewed as a finite resource and socially aware investors asking hard questions about impact on the environment, packagers are paying more attention to energy and water conservation measures. and electricity for the breweries in 2009. Excess electricity will be exported to the local grid. The Wrtsil BioPower plants will enable Scottish & Newcastle to make more efficient use of residue from its beer production, cut down on waste handling and energy costs, as well as reducing carbon dioxide emissions, reports Tauno Kuitunen, regional Many companies are working to reduce water consumption. Since 2002, breweries operated by Anheuser-Busch
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Companies, Inc. (A-B), St. Louis, MO, have reduced water consumption 5%, a savings of about 875 million gallons.

Food and beverage companies also are converting to nontraditional power generation options. Kraft Foods, Northfield, IL, for example, provides some power for one of its plants via methane generated by adding bacteria to whey, a byproduct of cream cheese production.

panys U.S. breweries and at its facility in Wuhan, China, the system captures biogas from brewery wastewater and burns it to supply up to 15% of a locations energy needs. In 2007, biogas-derived energy supplied A-B with heat equal to that needed for 25,000 homes and reduced greenhouse gas emissions by 258 million pounds.

sales director for Wrtsil Biopower.

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Welchs, Concord, MA, is experimenting with a hydrogenfrom-waste extraction technology developed by NanoLogix, Inc., Hubbard, OH, to generate electricity from juice waste. The plant near Erie, PA, takes water used to clean juice storage tanks and adds microbes to consume the sugar from the juice. Hydrogen generated by the microbes is captured in tanks for use as an energy source. With the concept proven on a pilot-plant scale, Welchs plans to build a largescale bioreactor in Erie this spring, according to a report by Lisa Ann Pinkerton on Allegheny Front, an environmental radio station based in Pittsburgh, PA. If successful, the fullscale system could mean a substantial reduction in the $1 million the plant spends each year on electricity and wastewater treatment (about $500,000 each).

Waste Reduction

Despite a couple decades of effort to reduce packaging waste, particularly in Europe, it remains an issue and appears to be a growing concern. In global Environmental Concerns surveys done by Nielsen in May 2007 and November 2007, the number of consumers who said they were very concerned about packaging waste increased from 31% to 40%. In addition, in the November 2007 survey, the concern about packaging waste increased more than any other, outpacing worries about climate change, water shortage, water and air pollution and use of pesticides.

With more than one-third of the population very concerned Some packagers have turned to solar energy or wind power or purchase offsets to improve their carbon footprint. In Portland, OR, Lucky Labrador Brewing Co. has installed a solar hot water system to heat the water needed for the first stage of the process for brewing its Sun Beer. Other craft breweries like Anderson Valley Brewing Co., Boonville, CA, power their plants with arrays of photovoltaic panels that convert sunlight to electricity. Recycled content is commonly found in all types of packaging. Replacing virgin content with recycled saves energy, reduces waste and cuts greenhouse gas emissions. In many cases, tax credits are available for installing this type of green improvement. In most cases, higher percentages of recycled content could be used, but Improving distribution efficiency to reduce the number of trucks and miles driven is another popular tactic. A growing number of software programs are available to plan the most efficient routes. demand for recycled materials exceeds supply. Recycling and Recycled Content about packaging waste, its time to be proactive about reducing, reusing and recycling.

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Thats why Coca-Cola and other companies are working to boost collection and recycling rates. In fact Coca-Cola recently committed to recycling 100% of the aluminum bevcans and PET containers it uses. The company also supports recycling programs and has invested in a PET recycling plant operated by United Resource Recovery Corp., Spartanburg, SC, to provide food-grade recycled PET (RPET) for its containers. Consumer Convenience Although the Nielsen Global Food Packaging Survey indicates nearly half of the respondents are willing to give up convenience packaging to benefit the environment, one wonders if these good intentions are actually carried at the cash register in the mad dash to put a meal on the table Although Coca-Cola probably wont use 100% RPET bottles before the end of the decade, it is technically feasible to do so, a feat once thought to be impossible. At least two companies have commercial products on the market in 100% RPET containers. Innocent Ltd., London, UK, uses a 250-millilitre (ml) 100% RPET bottle for its ready-to-drink, refrigerated smoothies, and before Susies 7 p.m. soccer game. achieved in the United States in 2006 (the most recent year statistics are available).

GlaxoSmithKline, Brentford, UK, specifies a 500ml RPET bottle for its Ribena fruit drinks.

On the packaging line, switching from a virgin PET to an RPET container should require few, if any, adjustments. However, injection molding or sheet/film extrusion may necessitate additives to improve processability and properties as well as special drying and filtration equipment. Even then, the RPET packaging may exhibit slightly diminished physical properties like intrinsic viscosity, tensile strength, light transmission, haze and clarity. It also should be noted that widespread use of 100% RPET packaging will require substantially a higher collection and recycling rate for PET containers than the 23.5%

Food processors queried by Food Engineering magazine, Bensenville, IL, in its 2007 Food Packaging Trends Survey, believe convenience rules, ranking third behind product shelf life and food safety as the force with the greatest impact on their business.

Certainly, recent product introductions address consumer demand for convenience with newcomers like Healthy Choice Caf Steamers entrees from ConAgra Foods, Omaha, NE, in steam-generating, cook-in packaging; Lean Cuisine panini sandwiches from Nestle USA, Glendale, CA, in microwaveable susceptor trays; organic coffee beans

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from Celestial Seasonings, Boulder, CO, in resealable, zippered stand-up pouches; and Pringles Minis potato crisps from Procter & Gamble Co., Cincinnati, OH, in single-serving

attack by tainted consumer product have left consumers uneasy and consumer packaged goods companies trying to identify and mitigate risks.

In fact, food safety tops the list of concerns cited by food processors when asked what factors influence new package development in a survey done in 2007 by Food Engineering magazine.

pouches. In fact, many of these popular products have the same features, the respondents in the Nielsen survey said they were willing to give up -- packaging designed for easy stacking/storing at home (49%), packaging that can be used for cooking or doubles as a resealable container (48%) and packaging designed for easy transport (47%).

Largely ignored when package designers think of convenience is senior-friendliness. Although few design changes are likely to occur before the end of the decade, aging baby boomers and a rapidly growing over-80 population guarantee more attention post-2010 to senior-friendly features like larger type for critical information like best-by dates, and easier-to-manipulate opening/reclosure mechanisms. As a result, packagers will institute more stringent requirements for suppliers of packaging equipment, materials, containers and other components. Suppliers will be expected to certify they are shipping the highest quality product and demonstrate that they have effective measures in place to ensure their incoming goods are clean and With Braille required on European drug packaging, it seems likely its use will become universal on drug packaging and spread to other product segments. Heightened concern about product safety will prompt Product Safety A seemingly endless succession of food recalls, a significant level of counterfeiting worldwide, pedigree rules looming for pharmaceuticals and the possibility of terrorist increased use of track-and-trace technologies like serialized bar coding and RFID. It also will encourage adoption of anti-counterfeiting tools like holographic labels, microprinting and taggant-equipped packaging. contaminant-free and that their process prevents introduction of any contaminants.

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On the packaging line, greater attention will be paid to washdown compatibility and hygienic design, which eliminates areas that could collect dirt or product residue, as well as features like automated clean-in-place and easy assemble/disassemble product contact change parts. Cleanliness-enhancing design/components not only help protect product quality, but also minimize man hours needed for line changeover and cleanup. Similarly, the patent-pending ScanTrac DUO x-ray inspection system from InspX LLC, Fremont, CA, uses two x-ray beams instead of one to improve its ability to detect foreign material contaminants, underfills and packaging imperfecControl systems will be upgraded to enable proactive identification and prevention of operational glitches that could result in problems like under-processing. tions in glass bottles and jars. Dual views and advanced image processing software increase accuracy, identify smaller contaminants and reduce false-reject rates to less than 1 in 10,000 at conveyor speeds of 700 feet or 1,400 Packagers will install more quality-control equipment like X-ray inspectors, metal detectors, near-infrared inspection systems and vision systems to help minimize the chance of faulty product slipping through and entering the supply chain. There also will be increased use of rapid detection systems for contaminants like Listeria and E. coli. Concerns about food safety and the increased emphasis on fresh food will prompt greater use of labels and tags that provide a visual indicator of freshness and purity. Timetemperature indicator labels, which have been available for approximately two decades, change color as time passes Fortunately, the latest quality control equipment brings increased functionality at a lower price. One example of the expanded capabilities available and when storage temperature parameters are exceeded. Newer options include RFID tags capable of monitoring temperatures, and labels that detect the presence of spoilage organisms or pathogens. Consumers are willing to pay more for packaging which guarantees freshness, notes a survey about packaging trends by Datamonitor, London, UK. Health and Wellness With obesity seen as a major health problem in much of the developed world, skyrocketing healthcare demand and containers/minute. rienced with standard metal detectors that operate on no more than three frequencies and therefore may miss smaller pieces of metal or be unable to inspect products in metallized packaging.

today is the IQ3+ variable frequency metal detector from Loma Systems, Inc., Carol Stream, IL. It can be set at any frequency between 30 and 900 kilohertz to match the frequency of the product, overcoming the limitations expe-

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I N T E L L I G E N C E

B R I E F

costs and the aging baby boomer population, interest in products that can improve well-being continues to rise.

gories, reports Tatjana Meerman of Packaged Facts, Rockville, MD, publisher of studies like Market Trend: Low, Reduced or No Sodium or Salt Foods and Beverages

As a result, the marketplace is seeing more products with lower salt, fat and sugar levels, more single-serving, portion-controlled packs, demand for more product information, greater emphasis on fresh products and reduction in the use of artificial additives and preservatives.

in the U.S.

As a result, there has been a proliferation of single-portion snacks and side dishes in small pouches or rigid containers. Portion control is definitely something consumers want. According to data from IRI, sales of 100-calorie

In addition to limiting salt, fat, sugar, calories, preservatives and/or artificial ingredients, food and beverage makers are introducing more functional products like pre- and probiotics and developing offerings that simplify preparation of balanced meals and improve the nutritional profile of grab-and-go foods/beverages.

snacks grew 56% between November 2006 and November 2007.

Since many single-serving products rely on pouch packaging, food processors will need to increase capacity by adding vertical form-fill-seal machines and flow wrappers. Food processors also are likely to install more thermoformfill-seal units to package products like single-serving

Reduction in ingredients with preservative qualities may necessitate conversion to packaging with higher barrier properties such as barrier laminations and coextrusions, metallized or foil-based structures and smart packages with an active component like an oxygen scavenger. On fillseal and form-fill-seal machines, changes in flexible packaging materials may require adjustments in dwell time and sealing, as well as a shift to more sophisticated quality control equipment like metal detectors and leak testers.

applesauce, stick pack machines for dry mixes and liquid fillers capable of handling small bottles.

Many products also are prominently listing calorie counts on labels. Campbell Soup Co., Camden, NJ, for example, which has offered Soup at Hand in single-serving microwaveable cups for several years, now flags calorie content on Soup at Hand varieties with 100 calories or less. It also has added calorie count violators to labels on cans of its lower calorie Campbells Select and red label soups.

Todays consumer wants more nutritional information. Health and wellness are major forces in todays marketplace and are having a significant impact on consumer purchase behavior in most food and beverage cateThe demand for more nutritional information has prompted several companies to emphasize certain details on their packaging. For example, Kellogg Co.,

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PACKAGING TRENDS
Forces will influence packaging through the end of the decade
ConAgras Start Making Choices program, which provides consumers with advice on living a balanced life. Information from the product packaging can be used in program tools like the Balanced Life Index to help consumers make choices that help achieve their health goals.

With so many different formats, this deluge of nutritional information could become more confusing than useful to consumers, sparking calls for standardization and raising the specter of regulatory action. Battle Creek, has added Nutrition at a Glance banners to the front panels of cartons of its ready-to-eat cereal. The banners feature information about calorie, fat, sugar and sodium content and also state whether the cereal inside contains more than 10% of an adults recommended daily allowance of fiber, magnesium, calcium, potassium and vitamins A, C or E.

ConAgra Foods, Inc., Omaha, NE, has added a nutrition guide on packaging for products in its Healthy Choice, Chef Boyardee and Orville Redenbachers lines. Based on MyPyramid recommendations from the U.S. Department of Agriculture (USDA), Washington, DC, the label shows the amount of each key food group contained in each package, making it easier for consumers to build more healthful diets. For example, a Healthy Choice Fiesta Chicken meal that contains chicken, rice, fruit and vegetables includes a graphic indicating the product provides 15% of the grains, 30% of the vegetables, 15% of the fruit and 40% of the meat and beans that a consumer should eat per day based on a 2,000-calorie diet. The new labeling complements

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About PMMI
PMMI is a trade association with more than 540 member companies that manufacture packaging and packaging-related converting machinery, commercially-available packaging machinery components, containers and materials in the United States and Canada. PMMI's vision is to be the leading global resource for packagin, and its mission is to improve and promote members' abilities to meet the needs of their customers. Learn more about PMMI at pmmi.org.

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