The document summarizes emerging packaging technologies for the dairy and food sectors in India. It discusses how modified atmosphere packaging can extend the shelf life of products like Indian sweets and fresh cheeses. It also describes hot fill sterilization and hot water bath processes that can be used for high acid foods, as well as retort sterilization and aseptic packaging techniques for low acid foods. The document highlights how these advanced packaging methods open new opportunities for Indian food businesses to scale up operations and expand their reach.

1. Emerging technology platforms and
packaging needs of dairy and food sector
Sumit Saha
Market Development Manager (India)
Printpack Packaging Supplies (India) Pvt Ltd
IDEA Seminar AAU,September30, 2016

2. Agenda
• Printpack overview
• Advanced Packaging Technology
– MAP: Low moisture sweets, Cheese, Fresh Cream
– Hot water bath / pasteurization: High moisture high sugar
– Hot Fill: Processed / Acidified cheese
– Retort: Low acid products
– Aseptic : Low acid products
– Cheese slice packaging
– RnB BottleTechnology
• Path Forward

3. • Focused on flexible and specialty
rigid packaging
• Vertically integrated,utilizing all
plastic package converting processes
• Supplying nearly all food and many
non-food categories
• Founded in 1956 & still privately
owned
• Headquartered in Atlanta,GA
• $1.4 billion annual sales
• Privately held by founding family
Printpack Overview
Prepress Services Rigid Packaging
& Lidding
MedicalFlexible Packaging Labels

4. Global Strategy
Mexico:
Guadalajara
Querѐtaro
Headquarters:
Atlanta, GA
USA
China:
SuzhouOffice:
Thailand:
Bangkok
Office:
India:
Bangalore
Asia: Factory in China

5. Broad Market Experience
Multiple consumer markets
Unique Insights
Better Solutions
Bakery
Beverages
Cereal
Cheese & Dairy
Coffee & Tea
Condiments
Confectionery & Bars
Cookies & Crackers
Dairy
Desserts & Puddings
Diced Fruit
Dry Mixes & Powders
Food Service
Fresh Produce
Frozen Food
Lawn & Garden
Meats
Medical
Nutritional Foods
Pet Food
Ready Meals
ReamWrap
Rice
Salted Snacks
Towel & Tissue
©2011 Printpack Proprietary & Confidential.

6. Trusted By the MostTrusted Brands

7. Trend in Indian Demographics (2011 census)
• 56% of households in urban India now have four or
less members
• 47.1% of rural households now have four or less
members
– compared to less than 40% ten years ago.
• What this means for packaged food?
• Shelf stable, Portion packs
• Nutrition, No preservatives
• Easy to open, Heat & Eat

8. Multilayer Barrier Value Proposition
Material
Science
Consumer
Needs
Food
Science
Protects food
Light weight
Non breakable
Easy to shape
Colors and prints
Easy to open
Easy to use
Easy to recycle
Less Energy consumption
Customized and economical

9. Forces to drive change in consumer
landscape
• Middle class explosion
• Women in work place
• Urbanization
• Shrinking household sizes
• Increase in convenience
• Focus on shopping experience
• Much needed cushion for supply chain

10. ModifiedAtmosphere Process & Packaging
Denest Fill
Product
Ready meals, Dry fruits, nuts,
Low water activity dairy and
non dairy sweets, nutrition
powders, instant mix, savory
products
Process
Product is filled, package is exposed to
UV and then MAP sealed followed by UV
exposure
Package
Barrier cups & lids suitable to withstand
UV and MAP are used
Vacuum, Gas Flushing
& Sealing
UV
Tunnel
Cooling
Tunnel
(optional)

11. ModifiedAtmosphere Packaging
- Fresh Cheese, Cream & Shrikhand

12. ModifiedAtmosphere Packaging
- Indian Sweets

13. INDIAN SWEETS
• BIG BUT FRAGMENTED
• FOR GENERATIONS SWEET SHOPS HAVE HAD A
CONSTRAIN...ITSTHEIR REACH……LIMITED BY
SHELF LIFE
• CONSUMER LIFESTYLE MAKING FOOD SHELF
LIFE EXTENSION MORE IMPORTANT.

14. LACK OFTECHNOLGY IS A CONSTRAIN
• TRADITIONAL RECIPES AND ADVANCED
TECHNOLOGIES..CAN BE AWINNING FORMULA!
• CHANGEYOUR BUSINESS FROM FRAGMENTEDTO
SCALEABLE ANDWITH EXPANDED REACH.
EXAMPLE:
– CHOCOLATES,
– BAKERY PRODUCTS

15. HOT KITCHTEN PRODUCTS: REALLY HOT
• Its specially for the products where thermal sterilization
technique can’t be used.
• Food should reach where the consumer is..

16. RECENT LAUNCH OF BIG BASKET

17. PRODUCTS LEAPFROGGINGTOYOUR
PLATTER

18. POTENTIAL FOR DIPS, SAUCES AND
SPREADS
• Fizzy foodlabs sees the
opportunity and makes a B-
plan….shelf life is critical for
scalability
 Products which are a big hit
abroad but not seen in the
Indian Retail market.

19. DISRUPTIVE PRODUCTS IN INDIAN
MARKET
 Take Niche products Mainstream
 Shelf life is critical for
distribution & scalability

20. Hot Fill Sterilization
Denest Hot Fill Heat Seal
Cooling Tunnel
Product
High acid foods: Ph < 4.0 without
particulates: fruits pulps, purees &
juices, salsa dips, & acidified
cheese dips
Process
Sterilization is achieved by hot product
fill (~84 to 90 C)
Package
High barrier cups & lids suitable to withstand
filling temperature and vacuum panel are used

21. Products from Hot Fill Sterilization

22. HotWater Sterilization Process
Denest Fill Heat Seal
Product
High acid food with and
without particulates
(Ph < 4.0)
Diced fruits, acidified
vegetables
Process
Product is filled, package is sealed and
then sterilized in hot water bath at 85C
to 90C
Package
High barrier cups & lids suitable to withstand
retort are used
Hot Water
Cooling
Tunnel

23. Products from Hot Water Sterilization
Process

24. Retort Sterilization Process
Denest Fill Heat Seal Overpressure Control Retort
Retort Baskets
Air overpressure control is critical to maintaining plastic package integrity. Ideally control
vessel pressure to within 0, +3 psi of container pressure
Product
Low acid foods (PH > 4.6)
Meats, vegetables, RTE
meals, soups & dairy
Process
Product is filled, package is sealed and
then sterilized by retorting process
Package
High barrier cups & lids suitable to withstand
retort are used

25. Products from Retort Sterilization Process

26. Products from Retort Sterilization Process

27. Aseptic Form Fill Seal
Fill
SealForm
Contact Ovens
Trim
Rollstock
Process
Machine surfaces are sterilized using H202
Product is heat sterilized then cooled for fill
Package is sterilized by steam or H202
Sterile Chamber
Product
low-acid dairy,
puddings, gelatins, and
fruit, vegetable & meat
purees Package
High barrier sheet is used as bottom web
High barrier lid film is used as bottom web

28. Products from Aseptic Form Fill Seal

29. Advances inThermal
Sterilization

30. In Package Aseptic Cooking Technology
Ref: http://www.shinwa-kikai.co.jp/en_newproduct/index3.html

31. Steam Cooking – what else?

32. MATS: Mw AssistedThermal Sterilization
Faster and Uniform Heating Pattern
Conductive Heating
Mw Volumetric Heating

33. How is MATS different?
Packaged food is simultaneously heated externally by
pressurized hot water, and internally by the patented
microwave system
Food rapidly reaches sterilization temperature,
significantly reducing process times and heat damage
Provides vastly better quality and higher nutritional value

34. Heating Differentials of MATS vs Retort
Sterlization Time to Achieve Same Target Fo
PRODUCT MATS
TIME
(min)
CONVENTIONAL
RETORTING TIME
(min)
300g Mashed potato 10.1 28.8
250g Salmon & Alfredo 6.8 24.0
250g Chicken dumpling & Sauce 6.5 21.0
250g Cheese Tortellini 7.3 46.5

35. 35
Impressive results!
Microwave Sterilized
Chicken and Dumplings
Conventional Retorted
Chicken and Dumplings

36. Herd mentality in the format..

37. Reset your intuition..its business imperative !

38. Thank You