Advancements in Rigid Plastic Packaging for Shelf Stable Food

Presentation on theme: "Advancements in Rigid Plastic Packaging for Shelf Stable Food"— Presentation transcript:

1 Advancements in Rigid Plastic Packaging for Shelf Stable Food
硬塑在包装耐储食品领域的优越性 Advancements in Rigid Plastic Packaging for Shelf Stable Food Vivek A. Chougule Business Development Manager 业务开发经理 第三届食品、饮料中的塑料包装技术应用研讨会 The 3rd Plastic Packaging Technology in the Food & Beverage Industry Conference 2012年6月，广州 Guangzhou, June, 2012

2 会议议程 Agenda 普派包装简介 什么是耐储食品？ 耐储食品及其包装的发展趋势 硬塑包装的创新技术
Printpack Introduction 什么是耐储食品？ What is shelf stable food? 耐储食品及其包装的发展趋势 Trends in shelf stable food & packaging 硬塑包装的创新技术 Innovations in Rigid Plastic Packaging 灭菌和储藏对高阻隔塑料容器的性能的影响 Effects of sterilization & storage on performance of high barrier plastic containers 先进的材料技术 Advanced material technology 先进的食品加工技术 Advanced food processing technology

3 普派包装简介 Printpack Overview
创建于 1956 年 Founded in 1956 总部位于乔治亚州亚特兰大市 Headquartered in Atlanta, GA 年销售额达 13 亿美元 $1.3 billion annual sales 创始人家族企业 Privately held by founding family 专注于高阻隔软、硬塑包装 Focused on flexible and specialty rigid packaging 纵向整合，利用所有主要的薄膜材料进行制造和 工艺加工 Vertically integrated, utilizing all major film making and converting processes 提供几乎所有的食品包装和众多非食品类包装 Supplying nearly all food and many non-food categories Purpose of this slide: To give a brief overview of the size and scope of Printpack. To illustrate the diverse capabilities we have and how this gives us the tools we need to develop creative packaging designs and innovative engineering. Our expertise with multiple technologies and our manufacturing capabilities fosters creative package design and innovative engineering. Printpack began in 1956 with one employee, a used cellophane bag machine and a single purpose. Today, Printpack is one of the largest and most innovative packaging converters in the world. With a long-standing reputation for providing quality products and services to the top brands in a range of industries. 印前服务 硬包装及封盖 医用 柔性包装 标签 Prepress Services Rigid Packaging & Lidding Medical Flexible Packaging Labels

4 丰富的市场经验 Broad Market Experience
多元化的消费市场 Multiple consumer markets 独特的洞察力 Unique Insights 更胜一筹的解决方案 Better Solutions 烘焙食品 Bakery 饮料 Beverages 谷类食品 Cereal 奶酪及乳品 Cheese & Dairy 咖啡及茶 Coffee & Tea 调味品 Condiments 糖果及酒吧食品 Confectionery & Bars 曲奇及饼干 Cookies & Crackers 甜品和布丁 Desserts & Puddings 切丁水果 Diced Fruit 干杂香料及其粉末 Dry Mixes & Powders 食品服务 Food Service 新鲜农产品 Fresh Produce 冷冻食品 Frozen Food 园艺产品 Lawn & Garden 肉类 Meats 医用 Medical 营养食品 Nutritional Foods 宠物食品 Pet Food 速食 Ready Meals 小令包装纸 Ream Wrap 米饭类 Rice 腌制小吃 Salted Snacks 纸巾类 Towel & Tissue Purpose of this slide: To illustrate all the Markets we participate in and how this broad experience provides knowledge and insight that can lead to better solutions for our customer. Our experience in a wide range of consumer markets means: We have a deeper understanding of consumer trends More market knowledge about your brands it allows us to provide unique insight into challenges you face All of this leads to better solutions for you and your consumers.

5 工艺制造能力 Manufacturing Capabilities by Process
隔板共挤出 Sheet barrier co-extrusion 热成型 – 单层和共挤出隔板 Thermoforming – Mono Layer and Coex Barrier 制作带拉链的自立袋和特制包装袋 Stand-up Pouch and Specialty Bag Making with Zipper Capability 吹膜及铸膜 - 单层、三层、五层、八层共 挤出 Blown & Cast Films - Mono, 3, 5, 8 Layer Coextrusion 柔版工艺印刷 – 最多可印刷 10 种颜色 Flexographic Process Printing – Up to 10 Colors 转轮凹版印刷 – 最多可在 11 个工位进行印 刷 Rotogravure Printing – Up to 11 Stations 挤出层合 – 单螺杆串联共挤出 Extrusion Laminations – Single, Tandem, Coextrusion 粘结层合 – 10 色柔版印刷/层合机，11 色 转轮凹版印刷/层合 机，在线串联 Adhesive Laminations – 10-Color Flexo Press/ Laminator, 11-Color 内部金属喷镀、镀膜 Rotogravure Press/Laminator, Tandem In- Line 定位冷封膜 – 在线，最多 10 种颜色， 柔版或转轮凹版 Registered Cold Seal – In-line, Up to 10 Colors, Flexo or Roto 内部数字板制作和数字工作流程 In-House Digital Plate Making and Digital Workflow 收缩标签、防撕揭热收缩带和集装收缩 套 Shrink Labels, Tamper-Evident Heat Shrink Bands and Multipack Shrink Sleeves 微穿孔 OTR 控制以及经过注册的防雾 能力 Microperforation for OTR control and Registered Anti-Fog Capability 设备袋 Fitmented Pouches 多层袋备用结构 Multi-wall bag replacement structures

6 Asia: Factory in Suzhou
全球战略 Global Strategy 亚洲：苏州工厂 Asia: Factory in Suzhou 北美战略 欧洲战略 亚洲战略 Two-way interaction – “shrinking the world” to create value for our customers. Having regional capabilities will help Nestlé avoid transaction costs, reduce cycle times, increase flexibility, foster faster learning and enable innovation. Printpack is building capabilities in other/emerging regions that can support Nestlé/Gerber’s business locally and still be connected to Printpack globally.  This will reduce risk, increase the transfer of expertise and increase speed to develop new products in new regions. Printpack continues to invest in people/resources to deepen our understanding of material science and interaction with foods.  Through Printpack, Nestle/Gerber has SMEs in plastic to help drive new products, new formulations, etc. with reduced risks, less Nestle resources and increased speed. Leverage Printpack’s full capabilities and footprint to provide system solutions. Mexico: Guadalajara Querѐtaro United Kingdom: Saffron-Walden Bury Poland: Kutno Office: India: Bangalore Headquarters: Atlanta, GA USA Office: Germany: Dusselldorf Office: Thailand: Bangkok China: Suzhou

7 普派包装（苏州）有限公司 Printpack (Suzhou) Packaging Co., Ltd.
坐落在中国苏州工业园区出口加工区 Located in EPZ, SIP, Suzhou, China 拥有10,000 M2的包装设备 10,000 M2 Packaging Facilities. 塑料片材挤出线 Sheet co-extrusion 注塑成型线 Thermoforming 主要生产食品包装行业中使用的耐储塑料容器 Focus on shelf stable plastic containers for the food packaging industry.

8 耐储食品及其发展趋势 Shelf Stable Food & Trends

9 “耐储食品”是什么意思？ What does “Shelf Stable" mean?
这种食品经过加工和包装，能够安全储藏于室温下，保质期较长 This food type has been processed & packaged so that it can be safely stored at room temperature for a usefully long shelf life 降低水分活性 (aw) Deceasing water activity (aw) 提高酸度（减小 pH 值） Increasing Acidity (lower pH) 灭菌 Sterilization 蒸馏 Retort 热灌装 Hot fill 无菌净化 Aseptic Foods that can be safely stored at room temperature, or "on the shelf," are called "shelf stable." These non-perishable products include jerky, country hams, canned and bottled foods, rice, pasta, flour, sugar, spices, oils, and foods processed in aseptic or retort packages and other products that do not require refrigeration until after opening. Not all canned goods are shelf stable. Some canned food, such as some canned ham and seafood, are not safe at room temperature. These will be labeled "Keep Refrigerated."

10 无菌耐储食品的历史进程 History of Sterilized Shelf Stable Food
1795 年，法国为其军队开发出经过加热灭菌工艺（蒸馏）处理的低酸食 品罐头 Canning of low acid foods by thermal sterilization process (retort) was developed in 1795 for France military 20 世纪 60 年代，美国为其军队开发出蒸煮袋 Retort pouches were developed in the US in 1960’s for US military 接着出现了热灌装高酸度产品 This was followed by hot filling of high acid products 无菌饮料包装最初由欧洲 WHO 开发成功 – 于 20 世纪 80 年代早期进入 市场 Aseptic packaging of beverages was first developed in Europe for WHO – commercialized in early 1980’s

11 耐储食品包装的发展趋势 Trend in shelf stable food packaging
消费者的偏好推动着包装以越来越方便的形式发展，比如硬塑、盘、袋和利乐 包装。 Consumer preference is driving growth in higher convenience formats – rigid plastic, trays, pouches, Tetras. 大型食品加工厂正在寻求“彻底改进”耐储食品以吸引消费者并减少生态足印 Efforts at large food co’s are looking to “reinvent” shelf stable food to appeal to consumers & reduce environmental footprint 先进的包装技术促进了新型包装形式和质量更好的产品出现 Advanced packaging technology enabling newer formats and better product quality 新型加工技术有望变革耐储食品的质量，从而推动需求 Novel processing technologies have the potential to revolutionize shelf stable quality – driving demand 发展中及新兴市场的城市化进展促进了快速采用消费友好型包装 Urbanization in D&E markets driving faster adaption of consumer friendly packaging

12 视频 Video

13 无菌耐储食品及其包装的示例 Examples of sterilized shelf stable foods & packaging
果肉 – 果泥：玻璃包装 > 塑料包装 Fruit pulp – puree: Glass > Plastic 水果及蔬菜：罐装 > 塑料包装 Fruit & Vegetables: Cans > Plastic 汤：罐装 > 利乐包装 > 塑料包装 Soups: Cans > Tetra > Plastic 肉类及小吃：罐装 > 袋装 > 塑料包装 Meals & Snacks: Cans > Pouches > Plastic 米饭、面条、加肉意大利面、蔬菜 Rice, noodles, pasta with meat, vegetables 酱汁、面包酱：玻璃包装 > 袋装 > 塑料包装 Sauces, Spreads: Glass > Pouches > Plastic 宠物食品：罐装 > 袋装 > 塑料包装 Pet food: Cans > Pouches > Plastic 饮料 Beverages 果汁：玻璃包装/罐装 > 利乐包装 > 塑料包装 Juices: Glass / Cans > Tetra > Plastic 乳品：玻璃包装/罐装 > 利乐包装 > 塑料包装 Dairy: Glass / Cans > Tetra > Plastic 啤酒：玻璃包装/罐装 > 塑料包装 Beer: Glass / Cans > Plastic Most of these products are oxygen sensitive

14 全球各地区耐储食品市场 Global Shelf-Stable Market by Region
2010 年的数据 Units in 2010 区域 Region 增长 Growth % 中国/印度 China / India 38.2% 墨西哥/巴西 Mexico/Brazil 21.3% 东欧 Eastern Europe 14.9% 西欧 Western Europe 4.9% 美国 US 2.3% 总计: Total 1640 亿 164 bn Including Dairy – UHT milk, canned condensed milk, puddings/gels, coffee creamer 来源：Euromonitor International

15 耐储食品 = 灭菌技术 + 包装 Shelf Stable Food= Sterilization Technology +Packaging
传统的热灭菌法 Traditional Thermal 热灌装 Hot fill 巴氏灭菌 Pasteurizati on 蒸馏 Retort 无菌净化 Aseptic 剥离层 Peel layer 双氧水 Hydrogen Peroxide 蒸气 Steam 电子束 E- beam 先进的热 杀菌法 Advanced Thermal 微波辅助的 热灭菌技术 Microwave Assisted Thermal Sterilization 先进的非 加热灭菌 法 Advanced Non-thermal 高压巴氏灭 菌 High Pressure Pasteurizati on Tie in PPK’s ability to support these technologies and provide material science insights. Printpack has significant experience and knowledge in traditional sterilization methods: Packaging material sterilization: Aseptic Steam Hydrogen Peroxide Peel layer In package sterilization: Hot fill, Pasteurization, Retort Strong material science and processing experience to minimize adverse effects on polymeric packaging materials 温度辅助的高压灭菌 Temperature Assisted Pressure 压力辅助的高温灭菌 Pressure Assisted Temperature

16 无菌型灌装密封 Aseptic Form Fill Seal
切边 Trim 卷材 Rollstock 成形 Form 加热片 Contact Ovens 灭菌室 Sterile Chamber 工艺 Process 产品经过加热灭菌，冷却后进行灌装 Product is heat sterilized then cooled for fill 环境灌装温度无需使用真空板 Ambient fill temperatures eliminate vacuum paneling 机器表面经过双氧水灭菌处理 Machine surfaces are sterilized using H202 卷材及封口膜经过蒸气或双氧水灭菌处理 Rollstock & lidding are sterilized by steam or H202 产品 Product 低酸度乳品、布丁、明胶以及水果、蔬菜和肉酱 low-acid dairy, puddings, gelatins, and fruit, vege & meat purees

17 热灌装灭菌 Hot Fill Sterilization
进杯器 Denest 灌装 Fill 热密封 Heat Seal 冷却通道 Cooling Tunnel 水喷雾 Water Sprays 产品 Product 高酸度食品：pH < 4.0 High acid foods: Ph < 4.0 果酱、水果或果汁、莎莎酱和酸芝士酱 Applesauce, fruits or fruit juices, salsa dips, & acidified cheese dips 工艺 Process 通过热灌装（约 82 至 90°C）实现灭菌 Sterilization is achieved by hot product fill (~82 to 90 C)

18 蒸馏法或巴氏灭菌法 Retort or Pasteurization Process
灌装 Fill 进杯器 Denest 热密封 Heat Seal 蒸气/空气蒸馏 Steam/Air Retort 杀菌篮 Retort Baskets 耐贮存产品 Shelf-Stable Products 低酸度食品 (pH > 4.6) Low acid foods (PH > 4.6) 肉类、蔬菜、芝士酱和汤 Meats, vegetables, cheese dips, and soups 空气过压控制对于维持塑料包装完整性来说 至关重要。理想情况下，将器皿压力控制在 容器压力的 -0、+3 psi 以内 Air overpressure control is critical to maintaining plastic package integrity. Ideally control vessel pressure to within -0, +3 psi of container pressure 105°C 巴氏灭菌 Pasteurization 蒸馏 Retort 121°C

19 先进的热灭菌法 Advanced Thermal Sterilization
微波辅助的热灭菌技术 Microwave Assisted Thermal Sterilization – MATS

20 微波辅助的热灭菌技术 – MATS Microwave Assisted Thermal Sterilization
优势 Advantages: 灭菌时间短 Shorter sterilization time 改善食品品质：营养、口味 Improved food quality: nutrients, flavor 产品 Products: 肉类：意大利面、米饭、肉类和蔬菜 Meals: Pasta, Rice, Meats & vegetables 海鲜 Seafood 乳品 Dairy 经 MATS 处理 MATS Processed 传统蒸馏法 Conventional Retort

21 硬塑包装的创新技术推动着 耐储食品的发展 Innovations in Rigid Plastics Packaging Driving Growth of Shelf Stable Foods

22 使用可延长保质期的塑料包装来代替传统包装，并 在全球范围提高可持续性。
我们的工作是什么？ What we do? 使用可延长保质期的塑料包装来代替传统包装，并 在全球范围提高可持续性。 Replace traditional packages with plastic packaging that extends shelf life, and improves sustainability across the globe. Tie in customer strategy – why RPD/PPK is doing some of the thing we are doing, to support customers like Nestle

23 技术: 高阻隔层共挤出与热成型 Technology: High Barrier Co-extrusion & Thermoforming
聚丙烯 Polypropylene 回收材料 Recycle 粘合剂 Adhesive EVOH 聚丙烯 Polypropylene LDPE 粘合剂 Adhesive EVOH PS混合物 PS Blend 可包括 11 层以上 Capable of 11+ layers 各种结构布置 Various structure arrangements 各种聚合物 Variety of polymers 一般厚度：0.75 至 2.30 mm General thickness: 0.75 to 2.30 mm 同步切边热成型 Trim-in-Place Thermoforming 同心矩形密封表面 Concentric, coined seal surface 蒸馏、气密热密封的最佳选择 Best for retort, hermetic heat seal

24 技术创新 - 推动未来发展 Innovation - Driving the Future
全球市场的消费者及品牌偏好 Consumer & Brand Preference in the Global Marketplace 工艺及材料的发展 Process & Material Advancement 灭菌技术 Sterilization Technology 食品包装相互作用 Food Package Interaction 关键推动者 Key Enablers Expertise in advanced materials, effect of sterilization methods on materials and food-package interaction will drive development of package of the future. Printpack will continue to act as your Material Science subject matter expert by providing expertise across this value chain. During sterilization, through the shelf life and point of use Cleaner polymers & processes Selection of polymers, enhancements and Design of structures Developing in line leak detection technology Sensors built into package / System engineering to detect tamper

25 阻隔材料的发展 Barrier Material Advancements
被动阻隔Passive Barrier 成形性得到改进 Improved formability 光、味道和香气阻隔 Light, flavor and aroma barrier 为灭菌工艺定制的最佳阻隔层选择 Best barrier value customized for sterilization process 先进结构Structures 分层技术 Layering technology 材料使用经过优化 Optimized material usage 主动隔层Active Barrier 除湿剂：蒸馏冲击、干燥产品 Moisture scavengers: Retort shock, Dry products 除氧剂：聚合材料 Oxygen scavengers: Polymeric This is our core strength. Passive barriers are continually improved with blends of existing polymers and use of new polymers. It is not just barrier performance but help improve process ability Barrier Layer structure: Asymmetric to reduce EVOH equilibrium RH, Multi-EVOH layers Alternative barrier polymers: Equivalent barrier value, broadened forming window, improved stiffness Barrier Advancement Passive barrier polymers Ongoing evaluation of new technologies: PGA, Polyamide, NASA technologies Oxygen Scavenger technology Polymeric: In testing Activated during sheet extrusion Two component system: Significant evaluation, addressing material challenges Activated after product filling Process Technology to improve performance and expand PPK shelf stable packaging offerings beyond barrier sheet & TF containers. Feed Block technology – heart of multi-layering technology. Developed in house expertise. It optimizes structures and performance

26 氧气阻隔层对比 Oxygen Barrier Comparison
At 20°C 尼龙 Nylon EVOH（其他热成型 Other Thermoforming ） EVOH (PRINTPACK普派包装)

27 加热灭菌对 EVOH 的影响 Effect of Sterilization on Barrier Performance
121°C，25min 105°C，10min 热灌装 Hot Fill

28 普派包装的干燥技术 Printpack Desiccant Technology
最大限度降低蒸馏影响 Minimize retort shock 最大限度降低/消除永久性破坏 – 长期性能 Minimize/eliminate permanent damage – long term performance 最大限度缩短蒸馏后恢复期 – 短期性能 Minimize post retort recovery period – short term performance 专为激活高湿度蒸馏条件的技术 Technology designed to activate at high RH retort conditions 方法：将除湿化学剂加入包装结构中以“保护”隔层 Approach: Incorporate moisture scavenging chemistry within package structure to “shield” BARRIER layer 采用干燥技术的隔层 BARRIER w/ Desiccant Technology PP EVOH PP H2O

29 阻隔层在干燥条件下的改善 Barrier Improvement with Desiccant Technology
结构优化与干燥对阻隔层的影响 Effect of Structure and Desiccant on Barrier 控制品 Control 普派包装结构优化品 Printpack Structure Optimization 普派包装干燥品 Printpack Desiccant

30 产品测试 – 番茄酱腌制的金枪鱼肉 Product Testing – Tuna in Tomato Sauce
控制品 CONTROL 普派包装干燥技术 PRINTPACK DESICCANT TECHNOLOGY

31 谢谢 Thank You 我们 We are 经验丰富，值得信赖，全心投入 创新 Innovation 精诚合作，科学探讨，久经考验
Experienced. Trusted. Engaged. 创新 Innovation 精诚合作，科学探讨，久经考验 Collaborate. Scientific. Proven. 可持续发展 Sustainability 人员，工艺，产品 People. Process. Products.