In a recent global survey conducted by Industrial Physics, pioneering insights into the world of food packaging innovation have emerged. The study, encompassing professionals from the food and beverage packaging industry, showcases a concerted effort to meet sustainability demands and cater to evolving consumer preferences through groundbreaking material choices and production processes.
Industrial Physics, a leading authority in packaging, product, and material testing and inspection, casts a wide net, gathering input from packaging professionals spanning diverse industries with a primary focus on food and beverage. The survey exposed the most influential drivers propelling innovation in this sector, which include:
- Ensuring the Quality of Packaging (69%): A significant majority of respondents emphasized the paramount importance of maintaining packaging quality.
- Ensuring Product Quality and Safety (63%): Concerns for product integrity and safety were high on the list of priorities.
- Enhancing Consumer Usability (56%): Simplifying consumer interaction with packaging garnered significant attention.
- Supporting Sustainability Initiatives (50%): Sustainability remains a pivotal motivation, with many striving to reduce the environmental footprint of packaging solutions.
Toby Lane, Product and Applications Manager at Industrial Physics, commented on the findings, stating, “Sustainability is driving material advancements, catalyzing the global drive to eliminate plastic. However, we must consider the broader context, including material transportation weight, production energy, testing capabilities, food safety approvals, and related challenges.”
Despite the challenges posed by material costs, with 60% of respondents grappling with this issue, investment in novel material development is still a prevailing trend. The reduction of plastic usage remains a central goal for 43% of respondents, with biodegradable materials (58%) and organic alternatives (51%) emerging as promising frontiers for exploring new packaging mediums.
Lane further remarked, “Discussions surrounding material selection often pivot on the question: Can the chosen material meet the required standards of quality and safety? For instance, plastic remains a staple in food storage due to its efficacy in sealing food and providing a lightweight, durable barrier with versatile sealing options. Opting for less effective materials to fulfill sustainability or cost objectives could inadvertently lead to negative consequences, such as increased food waste—a contradiction to the broader waste reduction goals highlighted in our research.”
The survey also brought to light significant investments in recyclability (60%) and waste reduction (59%) by professionals in the food and beverage packaging sector.
The report delves into the realm of manufacturing processes, revealing that over one-third (37%) of food and beverage packaging professionals are exploring lightweighting techniques to bolster waste reduction across the supply chain. Lightweighting involves reducing the amount of material used in metal packaging while preserving durability and performance. Modern cans, for example, can now be manufactured with a wall thickness as thin as 0.097 mm, equivalent to a human hair’s width. By using fewer materials in production, professionals can cut costs and optimize raw material usage.
Lane elucidated, “Lightweighting presents food can manufacturers with an opportunity to reduce production costs and material waste while enabling the transportation of more cans using the same amount of fuel. However, practitioners must tread carefully, ensuring that material reductions don’t compromise quality and that cans continue to meet stringent regulatory standards, including food-grade coatings, seam closures, and tamper-evident features.”
Regarding testing practices, the survey revealed that while packaging decision-makers overwhelmingly favour new developments (96%), food and beverage industry professionals are grappling with challenges related to material and process testing. These challenges include:
- High Cost of Expertise (63%): Testing new packaging materials can be cost-prohibitive due to specialized knowledge requirements.
- Limited Testing Facilities (50%): Adequate testing facilities are often lacking.
- Lack of In-House Expertise (44%): Insufficient in-house expertise hampers the testing process.
In closing, Lane emphasized, “Contrary to perceptions, the testing equipment and methods remain relevant today. There are cases, such as recycled polymers, where materials may exhibit different behaviours, necessitating the construction of new datasets. Collaboration within the industry can expedite data collection. Furthermore, the automated nature of today’s equipment means that specialized knowledge is not always a prerequisite for conducting the required tests.”