Artificial and intellegent packaging by Maks

vo l u m e 9 i s s u e 7 15 M a r c h 2 011

p i r a i n t e r n at i o n a l

active & intelligent packaging world News RFID-based systems boost healthcare efficiency Spanish team tackles food spoilage US food firm adds QR labels to packs Israel University develops killer paper BASF extends OnVu range Reports Fresh ideas

active & intelligent pack world is published 10 times a year. Each issue includes consultancy-level articles that provide independent analysis and exclusive primary market data on active, intelligent and other shelf life-enhancing packaging technologies, as well as news reporting on R&D activity, pilots and launches of active and smart packaging technologies.

Vol Nine Issue Seven 15 March 2011

active & intelligent pack world

RFID-based systems boost healthcare efficiency

ealthcare efficiency and patient treatment have taken a step forward with the launch of two medication monitoring packaging systems. In the US, a San Diego hospital is testing an RFIDbased drug management system developed by MEPS Real Time, a US-based RFID solutions provider. The system, known as Intelliguard, uses standard EPC Gen two ultrahigh-frequency passive RFID tags and readers, including a tabletop reader for commissioning the tag attached to each drug’s packaging. There are also RFIDenabled drug-dispensing cabinets and bedside patient trays. Every time one of the cabinet’s drawers is opened

and then closed, the system reads the tags of drugs stored within, and can verify that the correct item was removed. Jay Williams, vice president of marketing and business development of MEPS Real Time, says: ‘We have developed the system to not only offer benefits for hospitals looking to improve upon their systems and processes – expiration date control, lot number control, medication error prevention – but to offer a solution for the entire healthcare supply chain. ‘In time, we would like to see the pharmaceutical supply chain adopt RFID for high-value, critical dose, controlled medications, to tag and encode at the point of manufacture.’ The company anticipates

Using conductive ink and a cellular module, the Pharma DDSi Wireless system can transmit when pills have been taken

Source: Stora Enso

that the pilot project will end in September 2011. Meanwhile in Paris, Stora Enso made its Pharma DDSi Wireless available to the healthcare and pharmaceutical industry at the Pharmapack 2011 exhibition in February. The system is based around conductive ink on a carton board-based blister inlay, which is connected to a cellular module embedded in the package. The technology allows the tracking of one pill at the time on removal from the blister. Data is sent to the cellular module and then forwarded wirelessly, using GSM or GPRS, to electronic health record systems. Patients can have the data provided to relatives, pharmacists, physicians and healthcare providers for more effective treatment. The blister inlay connected to the cellular module is made of recyclable carton board with no metal components. The cellular module is equipped with a rechargeable battery. Juha Maijala, project manager at Stora Enso, says: ‘Pricing at a general level is a one-time cost for the GSM module – reusable for up to two years – which is in the range of a few tens of US dollars. The package with functional printing and converting is much lower compared to high-frequency and ultra high-frequency-

Intelliguard installed in drugdispensing cabinets verifies that the correct item is removed

Source: MEPS Real Time

based applications. ‘One of the ideas in addition to the wireless functionality was to drastically decrease the unit price per package per patient, and to enable the wider spread of this medication compliance and adherence technology in the market.’

Spanish team tackles food spoilage

panish technology centre Gaiker-IK4 and the company Inkoa have launched MIPFood, a project to discover new methods to entrap and detect biomolecules using molecularly

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The project will analyse biotic and abiotic parameters, together with freshness indicators

Feiraco, Percaldia and Nutreco. Research began during September 2011, and is scheduled to last until December 2013.

US food firm adds QR labels to packs

U Source: Gaiker-IK4

imprinted polymers (MIPs), to guarantee food quality. The project will analyse biotic and abiotic parameters, together with freshness indicators. The goal of the project is to develop active packaging and smart labelling to increase the lifetime and quality of packaged goods. The research will examine various methods for implementing the technology: in reactive strip or similar formats; smart labelling, including a signal to visually evidence the presence of the analyte; MIP incorporation in active packaging for gradual and controlled release of molecules. A spokesperson says: ‘Similar research has been carried out in food, pharmaceutical and environmental applications. Research in this area is increasing every year, but the research is focused in the detection of new contaminants in food.’

At present, the focus is on the use of the technology on chicken, milk, beer and fish. However, it could be extended to beef, veal, seafood, dairy products and sausages. The project is funded by the Ministry of Science and Innovation. It is led by MahouSan Miguel and Gaiker-IK4 as technical coordinator; and consists of six companies and research centres in Basque Country, Galicia, Madrid, Cataluña and Toledo. The project’s partners are: Grupo Mahou-San Miguel, Fundacion Gaiker, Universidad de Santiago de Compostela, Universidad Complutense de Madrid, Instituto de Investigación y Tecnología Agroalimentarias, Amcor, Pescaldia, Feiraco, Nutreco España and Inkoa. Already, the project has attracted the attention of retailers, including Mahou,

S food producer Tanimura & Antle has introduced scannable quick response (QR) codes on to the packs of its Artisan Lettuce packs, to enhance engagement with consumers. When scanned with a smartphone, the code gives shoppers recipes and shopping lists that are designed to drive additional sales in stores The company, which started using QR codes in January 2011,

says there is no incremental cost for including it on its packaging. Diana McClean, director of marketing at Tanimura & Antle, comments: ‘There are websites available to create a QR code from which you can download the file to include in the packaging artwork. The big difference to the various uses of QR codes by different companies is what information is provided on the target URL. We have chosen to be very strategic – rather than provide a simple link to our product website, we are directing consumers to a selection of recipes specific to our promotion.’ The product’s consumerfocused microsite has been updated with healthy recipes and living tips.

The QR labels take consumers directly to recipes and advice on healthy living

Source: Tanimura & Antle

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McClean adds: ‘We decided to include a QR code, as the trends speak clearly regarding the use of smartphones by consumers in making purchasing decisions. We wanted to capitalise on that trend and be a leader in our industry regarding that innovation. ‘We can track visits to the QR URL as we would track website analytics. ‘We do see that this has been an effective element to our consumer branding and engagement efforts. ‘I cannot speak for the entire US market, but I can speak with confidence that we are one of the first produce companies to use the QR code on individual unit consumer packages.’ The company also prints a QR code on the display cartons of its Tanimura & Antle Artisan Onions.

Israel University develops killer paper

cientists at Israel’s Bar-Ilan University have developed a packaging material that uses anti-bacterial nanoparticles to extend the shelf life of foods. The research team of Professor Aharon Gedanken, Ronen Gottesman and Nina Perkas developed the ‘killer paper,’ which contains a coating of silver nanoparticles, a powerful antibacterial agent. Having been used in surface cleaners and clothing, scientists have recently been exploring the use of silver nanoparticles

as germ-fighting coatings for plastics, fabrics and metals. It is believed they could overcome the problem of antibiotic resistance, in which bacteria develop immunity to existing antibiotics. In laboratory experiments the team demonstrated the coated paper’s potent antibacterial activity against E coli and S aureus, the two main causes of food poisoning. According to the team, the scientists use high-frequency ultrasound waves to deposit the silver nanoparticles on the surface of paper. The technique allows the thickness of the coating and the particle size of the nanoparticle to be controlled to a great extent. The final product will be coated with colourless ZnO, which is also antibacterial. The researchers believe that the silver nanoparticles could also potentially help overcome the growing problem of antibiotic resistance by bacteria. The next stage of development will involve testing the paper on vegetables and fruits, which frequently spoilt as a result of bacteria. Gedanken says: ‘Once the paper proves itself as a superior wrapping, a factory can start operating within 6-12 months. We have already built a prototype that can coat 50m of any material that can be rolled – namely textile, paper and polyethylene supermarket bags.’ Three supermarkets and food producers from the US, two from Israel and one from the UK have

shown interest in using the paper, Gedanken adds.

BASF extends OnVu range

ASF has added an additional temperature indicator for frozen foods to its OnVu range of labels, which monitor freshness and shelf life. OnVu time temperature indicators are intelligent labels on food packaging that monitor the cold chain for chilled and deep-frozen food. The label changes colour depending on temperature - the darker its colour, the better the cold chain has been maintained. OnVu uses temperaturesensitive ink, which is used to print a thermometer symbol on the product label or even, in the packaging line, directly on the packaging. The indicator at the centre of the thermometer is activated for use by UV light, which causes it

to turn a dark blue colour. From this moment on the indicator monitors the cold chain – while a thermometer on the outer portion of the indicator, which is a lighter shade of blue, acts as a point of reference. As long as the centre is darker than or the same as the reference colour, there has not been any significant interruption in the cold. Martin Angehrn, project manager for time temperature indicators at BASF Future Business, says: ‘When used as a logistics tool between producers and retailers, OnVu enhances or replaces RFID and data loggers currently used to monitor chill and cold chains. ‘Using RFID or data loggers, you need special technical equipment for analysing the stored data. OnVu helps all involved persons to visually monitor the chill or frozen chain at a glance.’

The OnVu range changes colour to reflect any changes in temperature

Source: BASF

Consumers and brand owners are both demanding increased shelf life from products. A&I World reports

Fresh ideas

ne of the foundations of active and intelligent (A&I) packaging is to extend the shelf life of products. The commercial need to allow a range of products to stay fresh on a retailer’s shelf has spawned many technologies that aim to remove components within the packaging that could adversely affect shelf life. What was once a supply chain issue is now a consumer concern, as freshness coupled with sustainable packaging has become an important buying factor. Research from foodproductiondaily.com published in June 2010 has indicated that freshness indicators on packaging will become critical to consumer choice over the next few years.

What is more, A&I packaging is set to expand at a rate of over 5% a year within the food and drinks market that will be worth e5.3 billion by 2015, of which the vast majority will comprise of active packaging. Consumers are certainly asserting their desire for sustainable packaging solutions that also perform shelf life-extending duties, but brand owners also understand the commercial advantages that A&I technology can deliver to their products. With oxygen scavengers, moisture absorbers and barrier films to name just a few technologies being explored, any business within a supply chain will be able to enhance the shelf life of its products.

Condition Neil Farmer of Neil Farmer Associates comments: ‘Consumers want packaging that keeps products in good condition. They want packaging that keeps products clean and ready to be eaten. They want longer shelf life, product security and, in the current downturn, value for money.

Figure 1 Neil Farmer of Neil Farmer

‘The speed of take up of packaging innovation will depend on the pace of the economic recovery. Innovations in packaging for extending shelf life will be a key driver over the next five years for manufacturers. Enhanced technical performance qualities of materials will fuel market growth.’

Associates Source: Neil Farmer Associates

‘

Jonathan Quinn, business development representative for food and beverage

Consumers are certainly asserting their desire for sustainable packaging solutions that also perform self lifeextending duties, but brand owners also understand the commercial advantages that A&I technology can deliver to their products

’

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7 packaging at Multisorb says: ‘From both the consumer and the manufacturer perspective, shelf life is very important. From the manufacturer side, it is important to maintain product integrity including: colour, flavour, texture, and aroma. ‘Additionally, shelf life is the indicator to the point at which the manufacturer will see product markdowns on the retail shelf, as well as returns from the retailer, all of which will affect the bottom line. From the consumer side, as the world we live in is changing and evolving, the general consumer more often than not buys their products in bulk. They will be looking to maintain the product quality for longer.’

– it is hoped the new product could help keep food fresh for long periods of time (see ‘Israel University develops killer paper,’ p.4).

Choice of technology

The packaging technology that Hefestus uses enables fresh cut fruit and

As the supply chain that retailers are a part of includes many distinct product lines, technology to improve shelf life has divided across product ranges. Bikash Chatterjee of Pharmatech Associates says: ‘One of the most rapidly growing areas is the application of nanotechnology in packaging materials. As the food market has expanded to a worldwide marketplace, food in particular is requiring a longer shelf life. New materials incorporating nanoparticles have been able to reduce or eliminate the transmission of oxygen, as well as block the transmission of moisture from the product. ‘The result is food that is nearly hermetically sealed and does not spoil easily. These new materials can also be embedded with nanosized sensors, which are reactive to toxins, viruses and so on, and can fundamentally determine a priori if the food has been contaminated. Pharma is looking at these materials for secondary packaging applications where the packaging is not a required component for stability.’ Research has also taken place at Bar-Ilan University in Israel that has developed what the research group calls ‘killer paper.’ The paper has been coated with silver nanoparticles via ultrasonic radiation. Silver has long been used as an anti-bacterial

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Figure 2

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Modified atmosphere

vegetable manufacturers to

Hefestus, also based in Israel, has been developing its Shelf Life Booster (SLB) technology for several years. As a developer of modified atmosphere packaging (MAP), the company has made rapid progress with its SLB product.

extend the shelf life of their

Says Oded Shtemer, president and CEO: ‘SLB technology allows our customers to reduce the cost of packaging materials and improves our environmental profile by using environmentally friendly packaging.’ Another innovative technology is the microwave sterilisation process. Packaged food is submerged in pressurised hot water while heating it with microwaves at a frequency of 915 MHz. This results in the removal of microorganisms that could spoil the food, and the elimination of any other food pathogens that might be present. The whole process typically takes 5-8 minutes. Juming Tang, professor in the WSU Department of Biological Systems Engineering that lead the team developing the new process notes: ‘New processes for producing shelf-stable, low-acid foods must pass rigorous reviews by FDA to ensure that the technology is scientifically sound and the products will be safe. Our team patented system designs in October 2006 after more than 10 years of research. We spent another three years developing a semi-continuous

products by up to 14 days Source: Hefestus

8 Figure 3

Tetra Pak produces shelf life-extending products for the dairy industry.

Tetra Pak intends to expand the use of its

‘Extended shelf life [ESL] technology is used primarily for dairy liquids. ESL seeks to ensure that the product is free from bacteria, by using a holistic approach to the processing and packaging supply chain, from the cow’s udder to the retailer’s fridges,’ Tetra-Pak adds.

aseptic technology in a range of packaging materials aimed at the beverage markets in China Source: Tetra Pak

‘With Tetra Pak’s unique position as the only single-source company able to supply all processing and packaging facilities for the dairy industry, it has developed the most comprehensive and rigorous ESL system, called 3SL. The 3SL programme combines technology and intelligence, to provide the only system on the market that offers measurable and significant results compared to other ESL solutions.’ system, collecting engineering data, and microbiologically validating the process before receiving FDA acceptance.’ Another burgeoning industry that is developing technology to enhance shelf life is bioplastics. Farmer of Neil Farmer Associates adds: ‘The qualities of some bioplastics, in being able to provide longer shelf life, means that they have great growth potential. More brands and retailers are introducing products comprising conventional polymers made from sugar cane and molasses, and new plastics, such as home compostable film made from wood pulp. Whilst these materials can be more expensive than all-petroleum derived materials, they will become more costeffective as economies of scale develop.’ The liquid products market has traditionally been a focus for shelf life extension, as a Tetra Pak spokesperson notes: ‘Tetra Pak pioneered the use of aseptic technology in the 1960s, and changed the way the liquid food industry approached packaging and shelf life issues. ‘There are many benefits to aseptic packaging: food retains its taste, texture, colour and nutrition for at least six months – all without refrigeration or preservatives. For branding purposes, aseptic packaging has a great variety of shapes and sizes of carton, with the vast majority of the surface area available to display printed material.’

Indicating shelf life From a consumer’s perspective the technology that delivers ESL is usually invisible. However freshness indicators are now available that offer retailers the opportunity to indicate accurately the freshness of some product ranges. Temperature sensing is one area that many companies are actively developing technologies for. Companies including ShockWatch and PakSense Labels are working in this field. Meat has traditionally been the main focus of ESL technologies, but as Multisorb’s Jonathan Quinn explains, other product categories also need shelf life enhancement. ‘Fruit and meat are the main products where shelf life extension is being aimed. Meat is and always will be at the top of everyone’s list of products in need of shelf life assistance, which is being done successfully today. As of right now the world is becoming more conscious of what we are putting into our bodies – the natural and organic product market is a dramatically growing segment, with no sign of slowing down, which has significant need for shelf life extension,’ he comments. Multisorb has a range of technologies that

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9 allows food manufacturers to extend shelf life. FreshPax has been proven to allow meat packers to extend the shelf life of case-ready meats. The low oxygen MAP solution can maintain meats in shelf condition for up to 30 days. The technology has also proven highly success in the bakery and processed foods sectors.

Figure 4 Multisorb’s FreshPax is a proven innovation for meat packers looking to extend the shelf life of their caseready meats Source: Multisorb

Also available is FreshMax, an oxygen scavenging self-adhesive patch designed to work with small gas-flushed packages.

Supply chain Freshness indication is also a vital component of the supply chain, particularly when transporting chilled products. A joint development project between US food distributor FreshPoint and chemicals firm Ciba has developed the OnVu Time-Temperature Indicator (TTI) label, which indicates the freshness of chilled products (see ‘BASF extends OnVu range’, p.4) With new printing technologies it will soon be possible to print a colour-changing label directly onto packaging, eliminating one stage in the packaging process. International Paper has recently announced

the development of its ClimaShield product for poultry, which uses moisture barrier technology to offer suppliers a 100% recyclable material. Jimmy Fielding, International Paper poultry segment business manager says: ‘International Paper is capitalising on more than 10 years of experience in wax replacement technology, and over the past few years we have implemented technological breakthroughs that have taken this expertise to a new level. We believe ClimaShield is the next logical step in meeting customer needs for petroleum based wax alternatives.’ From a manufacturer’s perspective any reduction in packaging volume and weight that can be coupled with ESL has a commercial platform. Farmer concludes: ‘Extended product protection and longer shelf life in oxygensensitive beverages is a key driver. The new

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generation of oxygen scavenging coating and barrier technology is an important. Combining oxygen-scavenging technology with barrier properties provides protection from oxygen ingress, carbon dioxide loss and potential product degradation.’

Convenience ‘These types of developments are driving further growth in the PET plastic container food contact market, providing ESL. Brands currently in glass or other plastic containers are under threat, as the benefits of lightweighting, improved barrier properties, ease of use and convenience have an impact.’ The commercial aspect of ESL will always be a focus for manufacturers. ‘The citizens of the world are following the course of the US public, becoming less and less likely to prepare a complete home-cooked meal,’ says Multisorb’s Quinn. ‘As consumers move towards the prepared meal market segment there will continue to be a significant need for shelf life extension. Prepared meals like the pre-made sandwich will become dramatically more apparent and in doing so, the demand for shelf life extension will be needed. The sandwich producer will always be looking to be a step ahead of the game, as the prepared meal business segment becomes more competitive.

10 Active packaging and our ability to extend shelf life, while maintaining product quality – texture, taste, colour, and aroma – will have a significant role in giving the consumers the “freshly made today” perception of the product that may have been made 3-5 days earlier.’

Freshly made Tetra Pak also outlined how it enhances shelf life with its Recart product: ‘The Tetra Recart is a new and unique non-aseptic addition to the Tetra Pak range – the world’s first retortable carton-based solid food package. Tetra Recart packages allows foods such as vegetables, beans and tomatoes to be sterilised by retorting inside the package, and stay fresh for up to two years. ‘Retorting heats the product in-container to temperatures up to 130ºC for anything up to three hours. Tetra Recart is a more spaceefficient alternative to cans, glass jars or pouches, and is suitable for vegetables, beans, tomatoes, pet food, soups and sauces. Tetra Recart weighs in at just 18g and uses 33% less space than a can.’ Trefor Owen, environmental manager at Sharpak, notes that a wide variety of the company’s products are in use for shelf life enhancement: ‘There are a number of technologies already in use, and shelf-ready packaging that by its very description reduces labour costs and additional display packaging. Some are extending shelf life through improved MAP in meat products, or creating packaging that allows better transpiration of air, such as SPSAir. ‘Some are cutting down condensation, even when in transit, through lateral sloping base vents, and reducing material content through Sharplok+. This eliminates the use of an absorbent pad in the base of the meat tray, through an integral reservoir feature in the base of the tray.’ The issue of shelf life extension has created an industry that is actively researching new process and materials that can have a profound affect on the freshness of the products the packaging contains. The mechanism by which shelf life is eroded is

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Figure 5

now well understood, with conclusive research into biochemical reactions, enzyme and microbiological growth, particularly their effects on fresh food

OnVu displays a visual summary of the elapsed time-temperature history of the product to which it is attached. A time-

Value

temperature indicator

For consumers looking to enhance the value of their purchases, by buying larger qualities of what can often be highly perishable goods, shelf life now has a significant impact on buying habits. Brands have become acutely aware that they must innovate to meet this consumer demand.

can be used on any product that is sensitive to temperature Source: BASF

And those in the supply chain are clearly appreciating that shelf life extension can offer them commercial gains that are impossible to ignore ■

active & intelligent packaging world provides independent analysis and exclusive primary market data on active, intelligent and other shelf life-enhancing packaging technologies Pira International is a leading consultancy business with major publishing and conference activities, serving retail supply chain technologies. © Pira International 2011 ISSN 1476-6795 Published by Pira International Cleeve Road Leatherhead Surrey KT22 7RU, UK

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