Food packaging is a packaging system specifically designed for food. It is one of the processes that make up the food system, having the role of providing protection from chemical, biological and physical alterations while the food travels from producers to the consumers. The main goal of food packaging is to provide a practical means of protecting and delivering food goods at a reasonable cost, while meeting the needs and expectations of both consumers and industries. Additionally, current trends like sustainability, environmental impact reduction, and shelf-life extension have gradually become some of the most important aspects in designing a packaging system.
Functions Packaging and the package's labeling have several objectives: Physical protection - The food enclosed in the package may require protection from shock, vibration, compression, temperature, bacteria, etc. Barrier protection - A barrier from oxygen, water vapor, dust, etc., is often required. Permeation is a critical factor in design. Keeping the contents clean, fresh, and safe for the intended shelf life is a primary function. Modified atmospheres or controlled atmospheres are also maintained in some food packages. Some packages contain desiccants, oxygen absorbers, or ethylene absorbers to help extend shelf life. Containment or agglomeration - Small items are typically grouped together in one package to allow efficient handling. Liquids, powders, and granular materials need containment. Information transmission - Packages and labels communicate how to use, transport, recycle, or dispose of the package or product. Some types of information are required by governments. Marketing - The packaging and labels can be used by marketers to encourage potential buyers to purchase the product. Aesthetically pleasing and eye-appealing food presentations can encourage people to consider the contents. Package design has been an important and constantly evolving phenomenon for several decades. Marketing communications and graphic design are applied to the surface of the package and (in many cases) also to the point of sale display. The colour of the package plays a significant role in evoking emotions that persuade the consumer to make the purchase. Security - Packaging can play an important role in reducing security risks for shipments. Packages can be made with improved tamper resistance to deter tampering, and can also have tamper-evident features to help indicate tampering. Packages can be engineered to help reduce the risk of package pilferage; some package constructions are more resistant to pilferage, and some have pilfer-indicating seals. Packages may include authentication seals to help indicate that the package and contents are not counterfeit. Packages also can include anti-theft devices, such as dye packs, RFID tags, or electronic article surveillance tags, that can be activated or detected by devices at exit points and require specialized tools to deactivate. Using packaging in this way is a means of retail loss prevention. Convenience - Packages can have features which add convenience in distribution, handling, stacking, display, sale, opening, reclosing, use, and reuse. Portion control - Single-serving packaging has a precise amount of contents to control usage. Bulk commodities (such as salt) can be divided into packages that are a more suitable size for individual households. It also aids the control of inventory: selling sealed one-liter bottles of milk, rather than having people bring their own bottles to fill themselves.
Types Packaging design may vary largely depending on the functions that are fashioned into different types of packages and containers, and depending on the food products and their functions, such as:
Packaging Type Foods Materials Aseptic packaging Primary Liquid whole eggs or dairy products Polymers, multi-layer packaging Trays Primary Portion of fish, meat, fruits, vegetable, sweets and convenience foods Polymers, cardboards, biopolymers Bags Primary Potato chips, apples, dried fruits, rice, snacks Metallized polymers, polymers, multi-layer packaging Cans Primary Can of tomato soup, beans, mais, salmon, tuna, and prawns Aluminum, tin, stainless-steel Cartons Primary Carton of eggs, milk, and fruit juice Multi-layer packaging, coated paper Flexible packaging Primary Bagged salad, potato chips, sweets and candies Polymer, biopolymer Boxes Secondary box of cereal cartons, frozen pizzas Cardboards Pallets Tertiary A series of boxes on a single pallet used to transport from the manufacturing plant to a distribution center Corrugated cardboard, wooden pallet Wrappers Tertiary Used to wrap the boxes on the pallet for transport Polymer, multi-layer packaging Since almost all food products are packed in some fashion, food packaging is both fundamental and pervasive. Additionally, by enabling the creation and standardization of brands, it provides the opportunity to realize significant advertising, extensive distribution, and mass merchandising. Therefore, a distinction between the various types (or levels) of packaging needs to be made.
Primary packaging Primary packaging is directly in contact with the food products, creating the ideal headspace for them, while providing protection from external alteration. Additionally, primary packaging, also known as retail packaging or consumer units, is responsible for the marketing aspects of food packaging. Typically, the packaging materials used in the primary level include cardboard cartons, plastic trays, glass bottles and multi-layered structures (Tetra Pak).
Secondary packaging Secondary packaging contains a number of primary packages into one box, being made usually out of corrugated cardboard. Thus, the secondary level is a physical distribution carrier for the primary packages, making them more easy to handle during transportation. Occasionally, it can be used as an aid in retail outlets or supermarkets for the display of basic goods.
Tertiary packaging The outermost package, known as tertiary packaging, makes it easier to handle, store, and distribute both primary and secondary packages in bulk safely, providing further protection of the product while creating an easy way to transport large quantities of materials. The most familiar type of tertiary packaging comprises a wrapped pallet of corrugated cases.
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Packaging machines A choice of packaging machinery requires consideration of technical capabilities, labor requirements, worker safety, maintainability, serviceability, reliability, ability to integrate into the packaging line, capital cost, floorspace, flexibility (change-over, materials, etc.), energy usage, quality of outgoing packages, qualifications (for food, pharmaceuticals, etc.), throughput, efficiency, productivity, and ergonomics, at a minimum.
Packaging machines may be of the following general types:
Autocoding label and date verification Blister, skin and vacuum packaging machines Capping, over-capping, lidding, closing, seaming and sealing machines Cartoning machines Case and tray forming, packing, unpacking, closing and sealing Machines Check weighing machines Cleaning, sterilizing, cooling and drying machines Conveying and accumulating machines Feeding, orienting, and placing machines Filling machines for liquid and powdered products Package filling and closing Machines Form, fill and seal machines Inspecting, detecting and checkweighing machines Palletizing, depalletizing, and pallet unitizing machines Labeling, marking, and other product identification machines Wrapping machines Converting machines
Reduction of food packaging Reduced packaging and sustainable packaging are becoming more frequent, although excessive overpackaging is still common. The motivations can be government regulations, consumer pressure, retailer pressure, and cost control. Reduced packaging often saves packaging costs. In the UK, a Local Government Association survey produced by the British Market Research Bureau compared a range of outlets to buy 29 common food items, and found that small, local retailers and market traders "produced less packaging and more that could be recycled than the larger supermarkets."
In the last decades, the growing demand from the consumers and governments for more sustainable and eco-friendly packaging design has driven the food industry to redesign and propose alternative packaging solutions. However, in designing a brand new packaging system, several variables need to be taken in consideration. As shown in the optimum packaging design chart, an ideal packaging design should only use the right amount of the appropriate materials to provide the desired performance for a specific product.
Food packaging is often necessary, or even essential, for protecting food, keeping it safe, and thus preventing substantial food losses. However, food packaging today is strongly associated with both environmental risks and health risks for consumers. To help packaging professionals address this challenge, a Responsible food packaging platform (FitNESS Food Packaging) was created in 2017 by 11 European partners, to provide both general and in-depth training courses on the design of responsible food packaging. Developed with funding from the European Union Erasmus+ programme, this platform includes learning to optimise many sometimes contradictory criteria across all aspects of food packaging, from its production and use, through to its reuse, recycling, and disposal.
End-of-use Plastic: Landfilling, burning, and recycling are all alternatives for plastic packaging at the end of their shelf-life. However, improper disposal and handling lead to higher percentages of plastic waste, which can pollute the environment in a wide spectrum of scenarios. The packaging sector accounts for 40.5% of all plastic produced in Europe, which represents the largest sector in food industry. However, the recycling of such wastege is at a critical low level of roughly 35%. Moreover, it has been estimated that over 20% of the plastic packaging does not reach any recycling process. Bioplastic: also known as biodegradable polymer or biopolymer, are usually made from renewable feedstock resources like corn, potatoes, wood pulp and sugarcane, as well as from renewable natural resources of different kind. Typical end-of-life options include the composting or the environmental degradation of bioplastics, which result in resource loss and CO2 production. Complete degradation is also only achievable under rigorous conditions that are infrequently offered by the company. Additionally, some bioplastics are processed similarly to their traditional, fossil-based counterparts, which, if improperly sorted, might cause harmful interferences in other materials' recycling processes. Paper, paperboard, and corrugated board: are composed of cellulosic fibers bonded together to form a flexible structure. These packaging materials have a long tradition as the ideal solutions for storing dry foods (such as flour, rice, and pasta) as well as being used as secondary or tertiary packaging. Paper and cardboard are often collected separately for recycling; however, some difficulties are faced in the case of the presence of a coating (e.g., plastic or aluminium) or contamination due to food residues. Alternative end-of-life options include incineration and landfill. In theory, paper and board packaging is compostable, but persistent chemicals (like PFAS) may be dispersed in the environment through this practice, thus limiting the potential benefits.