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Packaging technologies and
value chain concepts to advance
value-added pulse-based foods
Dr Claire Sand
Spring 2017
Packaging value chain for pulses Dr Claire Sand 2
Packaging challenges from farm to fork
MANUFACTURER
• Reduce contamination
during product fill
• Assess initial microbial
load
• Reduce initial microbial
load
• Enable HACCP, etc
• Address chilled worker
conditions
DISTRIBUTOR/
RETAILER
• Enable stock rotation
• Time &Temp monitoring
system
• Oxygen level monitoring
system
• Control temperature
• Reduce microbial load at
POS
CONSUMER
• Refrigerate to Freezer
• Heat/Cook in Package
• Enable safe package reuse
• Reduce consumer contamin
from repeat use
• Expand time for safe product
use
• Enable freezer storage
Dr Claire SandPackaging value chain for pulses 3
Overview
Connecting the packaging value chain to pulses-key
technologies
Packaging value chain creates needed structure for pulse
strategies to succeed
Packaging Value Chain
Connecting the packaging value chain to pulses-sustainability
Packaging value chain for pulses Dr Claire Sand 4
Packaging value chain for pulses Dr Claire Sand 5
Packaging value chain
Packaging value chain for pulses Dr Claire Sand 6
raw materials for
packaging
converted
packaging
manufactured
packaging
components
Combined
product and
package
distributed
product and
package
sold
product and
package
discarded
product and
package
Packaging
Value
Chain
Interfaces
The Circular Value Chain
Packaging value chain for pulses Dr Claire Sand 7
Packaging evolves to a supply chain
• During Industrialization the
primary responsibility for the
transport of good shifted from
producer to the purchaser
• Ford defined packaging
• Packaging customized for different
buyers
Dr Claire Sand 8Packaging value chain for pulses
Packaging evolves to a supply chain
1950-1980s
• Post war era saw efficiencies grow
• Drucker coined the term, “knowledge worker” in 1973
• Energy crisis led to focus on bulk shipments & DCs which
reduced energy costs associated with distribution
• Global situations in operations
Dr Claire Sand 9Packaging value chain for pulses
Packaging Supply Chain – 1980s
• Mass production of packaging
increased
• Vertical integration internalized
supply chains
• External supply chains needed
management process to deliver-
• JIT
• ECR
10Packaging value chain for pulses Dr Claire Sand
Packaging Supply Chain – 1980s
• Porter’s Model of Supply Chain Management in 1985
11Packaging value chain for pulses Dr Claire Sand
Packaging Supply Chain – 1990s
• Strategic Alliances
• Price
• Fueling innovation, cost savings, sustainability
• Alliances stretch
• From Packaging to retailers
• BASF-Solvay joint venture
• Commodization
• POS information enabled continuous replenishment and then the
supply of packaging was linked directly to sales
• Essentially, once logistics were “figured out”, the focus on value
became more relevant
• Value began to be assessed down the supply chain
Dr Claire Sand 12Packaging value chain for pulses
The concept of value
• Value-
• Has Context
• Is experiential
• Has a subjective nature
• Occurs when needs are met
Dr Claire Sand 13Packaging value chain for pulses
Value has context
• The value of a quality of packaging varies with it context
• In the late 1980s within the EU, sustainable packaging had
value
• During this same time in the US, sustainable packaging had
little consumer resonance or value
• Now, with the REACH initiatives and EN standards altering
global markets, sustainability has value within developing and
developed countries
• The context changed
Dr Claire Sand 14Packaging value chain for pulses
Value is experiential
• Relationships between companies gain more traction if the
companies experience value the same way
• JL Clark and Farmaesthetics
• Price based bidding when insisting on quality, time
Dr Claire Sand 15Packaging value chain for pulses
Value has a subjective nature
• Trust of partners in the packaging value chain aligns-
• With inexperienced packaging professionals and organizations
• When economic downturns cause disruption
• When disaster management is needed
Dr Claire Sand 16Packaging value chain for pulses
Value occurs when need are met
• Needs within each link of the
value chain are met
• Retailer needs emerged as
primary in 1990s
• Post consumer needs are
emerging as primary
Dr Claire Sand 17Packaging value chain for pulses
Packaging value chain for pulses Dr Claire Sand 18
raw materials for
packaging
converted
packaging
manufactured
packaging
components
Combined
product and
package
distributed
product and
package
sold
product and
package
discarded
product and
package
Packaging
Value
Chain
Interfaces
The Circular Value Chain
Value
Chains
seek
sustainable
competitive
advantages
from
consumers
to
raw
materials
Overview
Connecting the packaging value chain to pulses-key
technologies
Packaging value chain creates needed structure for pulse
strategies to succeed
Packaging Value Chain
Connecting the packaging value chain to pulses-sustainability
Packaging value chain for pulses Dr Claire Sand 19
Packaging value chain creates
needed structure for pulse
strategies to succeed
Packaging value chain for pulses Dr Claire Sand 20
Alignment is missing
• Economic pressures
• Global competitors
• Food industry barriers
Incentives
Lack of trust/connection
• New partners
• Cost-benefits
Relationships vary within the chain
• Require different approaches
• Are assessed based on the value the relationship has to the organization and
within the entire value chain
Dr Claire Sand 21
Value Chain creates structure in relationships
Packaging value chain for pulses
Value Chain creates structure in relationships
• A strong value chain is a competitive advantage because then the entities within the
chain and the entire chain can focus on higher level goals such as innovation
• When relationships within the value chain are based on value, the footing is more solid
than price
Dr Claire Sand 22Packaging value chain for pulses
Value Chain actions for pulses
• Build Trust
• Manage knowledge
• Develop partners
• Share work
• Ensure Agility
• Adjust to reward significance in relationships
Packaging value chain for pulses Dr Claire Sand 23
Build Trust
Build Trust to increase innovation in processing and packaging-
• Trust to enable shifting the role to a packaging responsibility is needed
• Need to build trust that ___ can provide extra measure of innovation,
food safety
• Process transparency
• Align goal with food safety HACCP, FSMA, GFSI, etc processes
• Incorporate transparency to build tacit knowledge
Packaging value chain for pulses Dr Claire Sand 24
Build Trust-Manage knowledge
Dr Claire Sand 25
• SCM has refined processes for logistics data
• Knowledge not transferred
• Knowledge implies an understanding of the value of the information
• Supply chain disruptions due to disasters (economic and environmental) occur not
because of a lack information
• Data for distinct groups was available
• Knowledge was missing
Packaging value chain for pulses
Build Trust-Manage knowledge
Dr Claire Sand 26
• Human knowledge
• Seasoned packaging professionals
• Education
• Structured knowledge
• Explicit rules, behaviors, and routines of who communicates with whom
• Social knowledge
• Tacit knowledge within and with value chain members…
• 37% said they have a clear understanding of what their organization is trying to achieve
and why
• 20% said they had a clear "line of sight" between their tasks and their team's and
organization's goals
Packaging value chain for pulses
Build Trust-Refine functional relationships
27
• Functional relationships within the developing
world can be reflective of what the industrial
world needs as well
• Example- Coffee in Kenya
• Profits go to roaster after value added
consumer packaging used by roaster
• Role of packaging value chain is critical
Packaging value chain for pulses Dr Claire Sand
Build Trust-perform stress test
• To assess partner response
• To align to improve functionality
• Increased microbial load, product abused, seasonal variation in value chain
• Explore viability of safety guarantee
• Need to be involved with integration into HACCP, FSMA, GFSI, etc process and
required post pack conditions
• Stress tests define flows of information and communication needed
• By asking value chain members what would happen if ------
• We can best assess weaknesses in the value chain
• We can define new communication processes needed for each situation
Packaging value chain for pulses Dr Claire Sand 28
Packaging value chain for pulses Dr Claire Sand 29
Develop partners and shared value
• Need to stretch value chain to incorporate more members
• Researchers in ____ arena jointly funded-consortiums, foundations,
universities
• Assess distribution controls
• Explore impact on retail if shelf life extended
• Make consumer connections
• Assess sustainability in holistic manner (reuse, regeneration,
recycling, reduce)
• Nutritional waste
• Package waste
Packaging value chain for pulses Dr Claire Sand 30
Develop partners and shared value
Dr Claire Sand 31
• Focus on what’s needed
• Rapid deliveries
• Address immediate needs
• Altering priorities in distribution system from FIFO to when needed
• Blogs-Informal communication when a new priority arises
• Beyond Task Forces/Committees
• Actionable objectives from customers
• I wish we could reduce out of spec components…
• I wish we had more trust in our supplier…
• I wish they would help me optimize my retail space…
Packaging value chain for pulses
32
Shared value
Packaging value chain for pulses Dr Claire Sand
Packaging value chain for pulses Dr Claire Sand 33
Develop partners and shared value
Dr Claire Sand 34
• Shared value recognizes that externalities create internal costs for companies-
• Higher energy costs (due to dwindling supplies)
• Higher raw material costs (due to lack of reuse /recycling)
• Need for more educated work fore
• Commoditization
• Price focused competition
• Little innovation
• Unclear competitive advantage
• Profits coming at the expense of the community
• Government policies attempt to internalize externalities such as the social costs of pollution
• Business fight these initiatives and resist standards
Packaging value chain for pulses
Develop partners and shared value
Dr Claire Sand 35
• Packaging and pulses-regeneration, recycling and better technology all have shared value
• Location is refined beyond labor costs as-
• Human labor takes secondary role to robotics
• New consumer markets
• Clustering and now tierisation in automotive are mimicked in multicomponent packaging
industry
• Refined tierisation reaches inherent shared value of-
• Making profit synergistically
• Joint technology advances
• Focus on specific customer/industry
Packaging value chain for pulses
Develop partners and shared value-clusters
Clusters on packaging motivated by the-
• 5 trends
• Shift from vertical integration to relying on outside suppliers, partners, and
institutions
• Increasing knowledge and skill intensity of competition
• Globalization of markets and value chains
• Nations and regions compete to attract specific business
Dr Claire Sand 36Packaging value chain for pulses
Develop partners and shared value-clusters
Dr Claire Sand 37
Clusters Increase Productivity / Efficiency
• Efficient access to specialized inputs, services, employees, information, institutions, training
• programs, and other “public goods” (local outsourcing)
• Manage knowledge via coordination and transactions across firms
• Rapid diffusion of best practices and tacit knowledge
• Ongoing, visible performance comparisons and strong incentives to improve that align shared
value
Clusters Stimulate and Enable Innovations
• Greater likelihood of perceiving meaningful innovation opportunities (e g , unmet needs,
sophisticated customers, combinations of services or technologies)
• Presence of multiple suppliers and institutions to assist in knowledge creation
Packaging value chain for pulses
Develop partners and shared value-clusters
Dr Claire Sand 38
Clusters Facilitate Commercialization and New Business Formation
• Opportunities for new companies and lines of established business are more apparent
• Spinoffs and startups are encouraged by the presence of other companies ,
commercial relationships, and concentrated demand
• Commercializing new products and starting new companies is easier because of
available skills, suppliers, etc
Packaging value chain for pulses
Develop partners and shared value-clusters
Dr Claire Sand 39Packaging value chain for pulses
Develop partners and shared value-clusters
• Competitiveness must be a bottoms-up process in which many individuals,
companies, and institutions take responsibility
• Clusters provide a platform to address the specific barriers companies face
• in a given market, not just general challenges all companies are exposed to
Dr Claire Sand 40Packaging value chain for pulses
Develop partners and shared value-clusters
Neutral across clusters
• Enhancing productivity of multiple firms/institutions
• Facilitating/capturing linkages and externalities
• Facilitating the flow of information/knowledge across actors
• Engaging the private sector, not just government
• Preserving and enhancing market competition, not retarding it
Dr Claire Sand 41Packaging value chain for pulses
Packaging value chain for pulses Dr Claire Sand 42
Packaging value chain for pulses Dr Claire Sand 43
Ensure Agility
• Ensure agility in meeting need for package change
• Because food industry processes are not aligned to implement packaging
solutions, agility to work a different way is needed
• Realign cost-benefit within value chain members
• Development time and costs shared within value chain
• Develop solutions jointly vs “serving up” solutions
• Employ startup (mentality/physically) without internal/external
barriers
• Gain tacit knowledge
• Identify core advisory team experts to guide team
Packaging value chain for pulses Dr Claire Sand 44
Ensure Agility-VUCA
• VUCA (volatile, uncertain, complex, ambiguous) society demands agility
in packaging
• By focusing on each link’s value, packaging can uniquely offer
this agility
• Packaging’s various finished goods phases enable faster reaction time
• Example – skin graft packaging & disaster mgmt
• Packaging’s role is evolving within the value chain
• Research on increasing responsiveness, core technologies (inks,
tertiary packaging, labeling, GFSI, FSMA, REACH) have focused
innovation on finished goods flexibility
Dr Claire Sand 45Packaging value chain for pulses
Ensure Agility-Packaging for economic reshuffling
• Packaging can enable affordable choices the 4 billion+ consumers at pyramid’s base
• Packaging needs to technically leapfrog to provide product protection and a market
• Packaging can facilitate manufacturing value added goods versus raw material
exports
• Reveals opportunity to use historically indigenous materials (e g , jute)
• Research potential in facilitating leapfrogging in technology is high
Dr Claire Sand 46Packaging value chain for pulses
Ensure Agility-Packaging for urbanization
• Urban market is growing
• About 2+ million people/month become urban dwellers in Asia
• Urban households have 3 times more disposable income than rural
• Packaging can meet this market need through research on focused urban needs
• Example – optimization of aseptic pkg
Dr Claire Sand 47Packaging value chain for pulses
Ensure Agility-Packaging for urbanization
• Packaging can facilitate the distribution via alternative channels (versus traditional
models) to meet urban needs
• A future value chain defined by consumer led value will optimize packaging based
on global urban and rural consumers
• Example-Medical contract packaging & Anderson’s window walls & UHP
• Optimal packaging technology focuses on post consumer disposal in urban areas
(DSD)
• Consumer specific packaging is growing
• Kids design Legos and package
• Packaging research on predictive restocking (beyond RFID) to make consumer and
post consumer packaging seamless
Dr Claire Sand 48Packaging value chain for pulses
Ensure Agility-Packaging resource management
• The future value chain links the post consumer value of packaging with raw materials
• This moderates research to focus on raw material production-the largest energy use
in packaging
• Packaging processes are being refined to use less water and energy
• 28% of US consumers are LOHAS
• Packaging’s role is unique due to the short use of the packaging
• Packaging is also unique in that it is global since packages are made and disposed
worldwide vs products being consumed or used as durable goods
• Packaging research leads the way for regeneration of manufactured goods
• Example-reusable packaging before reusable computers
Dr Claire Sand 49Packaging value chain for pulses
Ensure Agility-Packaging resource management
• Packaging’s role in the value chain can link raw materials with post consumer
environment
• Progress mirrors the future
• Example –EU’s APEAL industry initiatives provide image of potential in packaging
• Example-KLM
• Example-Migros exceeded Switzerland’s PET recycling goal
• Future role in value chain is collaborative
• Global powerhouses (WWF, CERES, Forum for Future) are engaged
Dr Claire Sand 50Packaging value chain for pulses
Ensure Agility-Packaging innovation for pulses
Exploratory innovation within the value chain requires-
• An open culture that can absorb new ideas and abandon the status quo
• Ability to envisage a ‘new whole’ – and then work out how the various firms
might work together in the future
Dr Claire Sand 51
• Understanding that capabilities might shift along
the chain
• Value chain diagnostic systems to define
exploration innovation challenges and develop
appropriate performance measures
Packaging value chain for pulses
Ensure Agility-Packaging innovation for pulses
• Exploration closely links value chain entities with consumers to-
• Tell ‘stories’ about the packages we use to explain-
• Why it is used
• How it was produced
• Impact on the environment
• Welfare of workers involved along the chain
• Rewards accruing to the primary producers
• Commodity packaging is-
• Not able to compete on these issues
• Disadvantaged in many premium market segments
Dr Claire Sand 52Packaging value chain for pulses
Ensure Agility-Packaging innovation for pulses
• Implementation of an exploratory platform for sustainability requires incentives to-
• Absorb new ideas into organization
• Reward ideas that address how challenges could be faced
• Enable quick clearance for external entities
• Reward long term innovation at the expense of short term innovation
Dr Claire Sand 53
• Realign partners to achieve innovation
• Reward new arrangements that focus on a long term innovation need
• Reward concepts that offer opportunities to use value chain
• Reward value chain teams that make steps toward implementation of new
technology/initiative
Packaging value chain for pulses
Ensure Agility-Packaging innovation for pulses
• Enable the coordination shifting capabilities
• Reward value chain partners to skip a link in the chain
• Enable the use of loose contacts within and external to the chain
• Reward internal system of cross functional learning that employs-
• Bank of experts
• University degrees/certifications in cross disciplinary areas
• Reward knowledge transfer within organization and value chain
• Define exploration innovation challenges and develop appropriate value chain
diagnostic and performance measures
• Reward coordination of incentives and goals
Dr Claire Sand 54Packaging value chain for pulses
Ensure Agility–Align rewards
• Since food safety and reducing waste is normally the role of the food processor,
incentives to enable shifting the role to packaging is needed
• Need to provide incentives to work as a partner in food safety and waste reduction
• Assess motivation for CPG to work on ___
• Timing
• Reduce costs
• Chance to truly innovate
• Design reward system based on conversion process
• Connect with retailer on needs/signage
• Align rewards to conversion process
• Design reward system based ___ process efficacy
• Storage of ___ packaging material
• Packing of product with packaging material
Packaging value chain for pulses Dr Claire Sand 55
Ensure Agility–Align rewards
Dr Claire Sand 56
• Rewards connect to meeting specific values
• Employees motivated by difference factors than companies
• Value chain motivation often takes the form of-
• Private Education for school age children funded
• Tuition paid for college
• Health care on site
• Day care on site
• Valued food solutions on site
• Reduction in housing costs
• Access to technology (cells, computers, internet
Packaging value chain for pulses
Ensure Agility-Align rewards
Dr Claire Sand 57
For example incentives to align supplier to Pepsi’s water initiative might
take form of-
1. PET Bottle Supplier-
• R&D employees – Pepsi rewards R&D employees for developing a new
process for reduced water use at PET bottle blow molding facility
• Production employees – Pepsi rewards PET bottle production
employees for increased compliance with lower water use
2 Retailer-
• DC employees rewarded for more optimal use of water in cleaning
• Retailers rewarded for promoting recycling to consumers that will
save water in oil extraction and resin conversion
3 Recyclers-
• Employees rewarded when recycling of PET increases in community
Packaging value chain for pulses
Packaging value chain for pulses Dr Claire Sand 58
Packaging value chain for pulses Dr Claire Sand 59
Packaging Value Chain Approach
Managing for new approach requires the value chain to provide-
• Shared business culture, vision, terminology and set of practices within the value chain
• Ability to envisage how the parts add up across chain
• Ability to change internal systems
• Activities for the sake of the whole as a cooperative effort
• Dense network of contacts and trust
• Focus on team building activities
Dr Claire Sand 60Packaging value chain for pulses
Overview
Connecting the packaging value chain to pulses-key
technologies
Packaging value chain creates needed structure for pulse
strategies to succeed
Packaging Value Chain
Connecting the packaging value chain to pulses-sustainability
Packaging value chain for pulses Dr Claire Sand 61
Connecting the packaging
value chain to pulses-
sustainability
Packaging value chain for pulses Dr Claire Sand 62
Packaging sustainability-Competitive advantage
• Interviews from CEOs are telling--
• 98 % believe that sustainability issues will be critical to the future success of their
business
• 92 % believe that companies should integrate sustainability through their supply
chain; only 59% believe that their company has done so
• 51 % cite the complexity of implementation as the most significant barrier to
embedding sustainability
Dr Claire Sand 63Packaging value chain for pulses
Packaging & Sustainability-Packaging waste
increases with income
Dr Claire Sand 64Packaging value chain for pulses
Sustainability is seeking a favored option
Dr Claire Sand 65Packaging value chain for pulses
Packaging & Sustainability-Companies react in different ways
► Dannon reduced packaging waste by eliminating the plastic
cap over the peel-back foil seals on yogurt cups
► 3.6 million pounds of plastic/year
► Copied others in industry
► SunChips
► Compostable bag
► Limited compost facilities
► Noisy
Dr Claire Sand 66Packaging value chain for pulses
Packaging LCAs
Dr Claire Sand 67Packaging value chain for pulses
Measuring Package Sustainability
1. LCAs
2. COMPASS
3. Carbon Foot Print
4. Tesco and Wal-Mart Scorecards
Dr Claire Sand 68Packaging value chain for pulses
Packaging & Sustainability-Steel
Dr Claire Sand 69Packaging value chain for pulses
Packaging-LCA of Frozen and Canned Green Beans
Dr Claire Sand 70Packaging value chain for pulses
Packaging & Sustainability-Value Chain derived redesign
– Improved design is stackable, eliminates need for crates
– Eliminates need to transport, return and wash crates
– Can fit 224 jugs on a pallet instead of 180
– Reduces distribution costs by ~30%
– Reduces price to consumers by ~$ 10
Dr Claire Sand 71Packaging value chain for pulses
► Solve from Shared Value and value chain perspective
► Less packaging
► Less heat for processing
► Refrigeration
► Longer shelf life
Dr Claire Sand 72
Packaging & Sustainability-Value Chain derived redesign
Packaging value chain for pulses
• By straightening Hamburger Helper noodles-
• Product could lie flatter in the box
• Reduce the size of boxes
• Supplier- saved nearly 900,000 pounds of paper fiber annually
• Community- Reduce greenhouse gas emissions by 11 percent, by
taking 500 trucks off the road
• Retail- increased the amount of product Wal-Mart shelves by 20 %
Dr Claire Sand 73
Packaging & Sustainability-Value Chain derived redesign
Packaging value chain for pulses
Packaging & Sustainability-Value Chain derived redesign
Dr Claire Sand 74Packaging value chain for pulses
Packaging & Sustainability-Value Chain derived redesign
• Minute Maid Mango Juice in Kenya- move from external source to internal
sources for ingredients and package
• Resulted in
• Consistent quality mango supply for export and purchase by local
bottlers
• Doubled the income of 50,000 smallholder mango and passion fruit
farmers (>50% women) in Kenya and Uganda
• Need to stretch value chain to packaging and add further shared value by
• Design for Recovery
• Build recycling infrastructure
Dr Claire Sand 75Packaging value chain for pulses
More shared value oriented and value chain sustainable solutions in
Design for Recovery
• Paper & film-air float separation
• Steel-magnetic separation
• Aluminum-Eddy currents
• PE, PP, PET, PS- NIR and float density
Use of Recycled or compostable plastics
• rHDPE Envision
• rPET
Build Composting and Recycling Infrastructure
Dr Claire Sand 76
Packaging & Sustainability-Value Chain derived redesign
Packaging value chain for pulses
A packaging value chain stretches into the realm of shared value can
achieve a higher degree of sustainability
Dr Claire Sand 77
Roger’s Coffee Company
• Coffee shared value- Growers and manufacturing coffee
• Training, $, personal relationship, carbon-negative footprint
• Packaging shared value- Materials now at 97% bio-based and compostable
• Polymer source
• New profits from bio-based materials and industrial & home
composting
• Opportunities to extend shared value-
• Partnering with composters to add more industrial composting sites
• Connect down the value chain is was done with coffee growers
Packaging & Sustainability-Value Chain derived redesign
Packaging value chain for pulses
Overview
Connecting the packaging value chain to pulses-key
technologies
Packaging value chain creates needed structure for pulse
strategies to succeed
Packaging Value Chain
Connecting the packaging value chain to pulses-sustainability
Packaging value chain for pulses Dr Claire Sand 78
Connecting the packaging
value chain to pulses-key
technologies
Edible and antimicrobial
Active, intelligent, responsive
Packaging value chain for pulses Dr Claire Sand 79
Causes/ Categories
Category
Z
Category
Y
Category
X
Catgeory
W
Category
V
Category
U
Category
T
Category
S
Oxidation
Moisture Change
Microbial
Browning
Water resistance
MVTR
Antimicrobial
Reduce impact of contamin. ingredients
Reduce contamin. during product fill
Assess initial microbial load
Reduce initial microbial load
Reduce cross contamin.
Enable processing of some ingredients
Enable HACCP
Address chilled worker conditions
Time &Temp monitoring system
Oxygen level monitoring system
Control tempertaure
Measure microbial load at POS
Enable safe package reuse
Reduce consumer contamin. from repeat use
Expand time for safe product use
Enable oven/ MWmonitoring
Address eating hygiene through packaging
Enable freezer storage
Packagingand
Handling
Pkg
Prop.
Product
Degradation
Causes
Distributio
n&Retail
ConsumerUse
Value Chain solutions to food safety are focused
80
Value Chain enables innovation through focus on societal issues –
food safety
Packaging value chain for pulses Dr Claire Sand
Key technology-Edible packaging
• Focus on
• Reduce and not replace synthetic packaging
• Freezer burn
• Decreasing water loss in fresh seafood
• Enhancing product offerings
• Cook in bag
• Shaped products
• Meal kits to align with what retailers are doing
Dr Claire SandPackaging value chain for pulses 81
Key technology-Edible packaging
• Freezer burn
• Interfacial water freezes and thaws and ice crystals grow crushing
cells
• Increased degradation within cells before they burst
• Texture loss
• Water loss
• Loss from product
• Loss from package is ($$$) loss
Dr Claire SandPackaging value chain for pulses 82
Key technology-Edible packaging
• Alternative to vacuum package
• Edible barriers are a robust solution
in consumer freezers
• Many options and can be linked to
antimicrobial barriers
Dr Claire SandPackaging value chain for pulses 83
Key technology-Edible packaging
Enable venting since product is better protected
1. Perforations
• (horizontal or in a “patch”) that are coated/laminated; but,
to allow air/steam to escape through holes
2 Laser scored
• top layer that is coated/laminated; but, to allow air/steam
to escape through laser cuts that expand when heated
• steam generated from within the package bursts through the
scoring and automatically ventilates the package
3 Channels that vent air/steam through fin seal area
• Consumer slit bag to vent before microwaving
4 Tray in colander
Dr Claire SandPackaging value chain for pulses 84
Key technology-Edible packaging
• Upscale frozen/fresh Surimi seafood
• Impart texture
• Lower fat content by reducing oil uptake
• Bite size
• Decrease product waste
Dr Claire SandPackaging value chain for pulses 85
Key technology-Edible packaging
• Keep water within separate foods
with reduced synthetic packaging
Dr Claire SandPackaging value chain for pulses 86
Key technology-Antimicrobial packaging
Market need for Antimicrobial is increasing due to increase in-
1. Resistance of microbes to standard processing technologies
2. Food safety outbreaks
• Foodborne disease reaches 30% of the population
• Vibrio increased 115% since 2006
3. Need for controlled temperature conditions to inhibit microbial growth
4. Global food distribution in various stages of processing
5. Increase in consumer interest in fresh and multicomponent prepared meals
6. Inability of MAP/CAP technology to accommodate lack of controls in distribution,
processing, product
7. Growing urban population in need of food they can not produce
8. High potential for cross contamination
• Processing facilities often manufacturer more than one product
• Distribution systems between products are often linked
Packaging value chain for pulses Dr Claire Sand 87
Key technology-Antimicrobial packaging
1. FOOD PROCESSING
CONDITIONS
• Food pH, and stability
after pH changes
• Inactivation by food
enzymes
• Interaction with food
additives/ingredients
2. FOOD SHELF LIFE
FACTORS
• Food storage
temperature
• Limited stability during
food shelf life
3. MICROBIAL FACTORS
• Microbial load
• Microbial diversity and
the target bacteria
• Microbial interactions in
the food system
• Physiological stage
(growing, resting,
starving or viable)
4. BARRIERS
• Protection by physico-
chemical barriers
(microcolonies,
biofilms, slime)
• Barriers enrobing
Antimicrobials
5. DEVELOPMENT OF
RESISTANCE/ADAPTATION
• Predicted to be an issue
of concern
Packaging value chain for pulses Dr Claire Sand 88
Key technology-Antimicrobial packaging
Packaging value chain for pulses Dr Claire Sand
within a structure
as a coating
through headspace
89
Key technology-Antimicrobial packaging
ORGANIC ACIDS
• Benzoic acid and
benzoates
• Sorbic acid and
sorbates
• Acetic acid
• Propionic acids and
propionates
• Lysozyme
SOME OTHERS
• Chlorine dioxide
• Triclosan
• Silver zeolite, nitrate
• Bacteriophages
• Maillard reaction end
products
BACTERIOCINS
• Nisin
• Pediocin
POLYMERS
• Chitosan
NATURAL EXTRACTS
• Cinnamaldehyde
• Eugenol
• Allyl isothiocyanate
• Green tea extract
• Various extracts
Packaging value chain for pulses Dr Claire Sand 90
Key technology-Intelligent packaging
• Focus on-
• TTI
• Degradation sensors
• No-Fraud assurance packaging
• Responsive packaging
Packaging value chain for pulses Dr Claire Sand 91
Key technology-Intelligent packaging-
TTIs
Packaging value chain for pulses Dr Claire Sand 92
• L5-8 Smart Seafood
• irreversible color
change from the
hydrolysis of
triglycerides
• CoolVu
• aluminum
layer thins
causing a
reaction
• FreshCode, Varcode
andTempix, Tempix
• fading barcodes
• FreshMeter
• turns from blue to
gray via
benzopyridine
photoactivation
Key technology-intelligent degradation
sensors
Packaging value chain for pulses Dr Claire Sand 93
Degradation sensors are advancing rapidly
• Direct connection to food deterioration
• More sophisticated sensors that convert biochemical
signals to electrical responses that show remaining shelf
life from manufacturer to consumer
Key technology-Intelligent authenticity
sensors
Packaging value chain for pulses Dr Claire Sand 94
Intelligent packaging expands brand image potential
Current solutions
• Thermochromatic inks change color and reveal images
when the product is at the proper temperature to eat or
drink
• NFC OpenSense package sensor is tapped with a
smartphone
• Polymark fluorescence based detection for sorting food-
contact PET
Packaging value chain for pulses Dr Claire Sand 95
Key technology-Intelligent authenticity sensors
Packaging value chain for pulses Dr Claire Sand 96
Using the Packaging Value Chain for Pulses-checklist
 Set goals
 Assess market opportunity
 Define what the product-package needs to do
 Identify key social issues that are important
 Align
 Identify key partners to address these social issues and meet goals
 Continue to expand issues to guide relationships within the Value Chain
 Determine which Value Chain members align
 Define value (context, experiential, subjective, meeting needs)
 Build trust and agility into organizational frameworks so that new Value Chain initiatives are
achievable
Checklist-Bringing in your Innovations using the Packaging Value
Chain
Packaging value chain for pulses Dr Claire Sand 97
Food science and packaging expertise-
• Coaching
• Consulting
• Technology
• Strategy
www PackagingTechnologyandResearch com
Dr Claire Sand
CEO, Packaging Technology & Research, LLC
Adjunct Professor, Michigan State University
Packaging technologies and
value chain concepts to advance
value-added pulse-based foods

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Spring 2017- Packaging Technologies and Value Chain Concepts to Advance Value-Added Pulse-Based Foods

  • 1. Packaging technologies and value chain concepts to advance value-added pulse-based foods Dr Claire Sand Spring 2017
  • 2. Packaging value chain for pulses Dr Claire Sand 2
  • 3. Packaging challenges from farm to fork MANUFACTURER • Reduce contamination during product fill • Assess initial microbial load • Reduce initial microbial load • Enable HACCP, etc • Address chilled worker conditions DISTRIBUTOR/ RETAILER • Enable stock rotation • Time &Temp monitoring system • Oxygen level monitoring system • Control temperature • Reduce microbial load at POS CONSUMER • Refrigerate to Freezer • Heat/Cook in Package • Enable safe package reuse • Reduce consumer contamin from repeat use • Expand time for safe product use • Enable freezer storage Dr Claire SandPackaging value chain for pulses 3
  • 4. Overview Connecting the packaging value chain to pulses-key technologies Packaging value chain creates needed structure for pulse strategies to succeed Packaging Value Chain Connecting the packaging value chain to pulses-sustainability Packaging value chain for pulses Dr Claire Sand 4
  • 5. Packaging value chain for pulses Dr Claire Sand 5 Packaging value chain
  • 6. Packaging value chain for pulses Dr Claire Sand 6 raw materials for packaging converted packaging manufactured packaging components Combined product and package distributed product and package sold product and package discarded product and package Packaging Value Chain Interfaces The Circular Value Chain
  • 7. Packaging value chain for pulses Dr Claire Sand 7
  • 8. Packaging evolves to a supply chain • During Industrialization the primary responsibility for the transport of good shifted from producer to the purchaser • Ford defined packaging • Packaging customized for different buyers Dr Claire Sand 8Packaging value chain for pulses
  • 9. Packaging evolves to a supply chain 1950-1980s • Post war era saw efficiencies grow • Drucker coined the term, “knowledge worker” in 1973 • Energy crisis led to focus on bulk shipments & DCs which reduced energy costs associated with distribution • Global situations in operations Dr Claire Sand 9Packaging value chain for pulses
  • 10. Packaging Supply Chain – 1980s • Mass production of packaging increased • Vertical integration internalized supply chains • External supply chains needed management process to deliver- • JIT • ECR 10Packaging value chain for pulses Dr Claire Sand
  • 11. Packaging Supply Chain – 1980s • Porter’s Model of Supply Chain Management in 1985 11Packaging value chain for pulses Dr Claire Sand
  • 12. Packaging Supply Chain – 1990s • Strategic Alliances • Price • Fueling innovation, cost savings, sustainability • Alliances stretch • From Packaging to retailers • BASF-Solvay joint venture • Commodization • POS information enabled continuous replenishment and then the supply of packaging was linked directly to sales • Essentially, once logistics were “figured out”, the focus on value became more relevant • Value began to be assessed down the supply chain Dr Claire Sand 12Packaging value chain for pulses
  • 13. The concept of value • Value- • Has Context • Is experiential • Has a subjective nature • Occurs when needs are met Dr Claire Sand 13Packaging value chain for pulses
  • 14. Value has context • The value of a quality of packaging varies with it context • In the late 1980s within the EU, sustainable packaging had value • During this same time in the US, sustainable packaging had little consumer resonance or value • Now, with the REACH initiatives and EN standards altering global markets, sustainability has value within developing and developed countries • The context changed Dr Claire Sand 14Packaging value chain for pulses
  • 15. Value is experiential • Relationships between companies gain more traction if the companies experience value the same way • JL Clark and Farmaesthetics • Price based bidding when insisting on quality, time Dr Claire Sand 15Packaging value chain for pulses
  • 16. Value has a subjective nature • Trust of partners in the packaging value chain aligns- • With inexperienced packaging professionals and organizations • When economic downturns cause disruption • When disaster management is needed Dr Claire Sand 16Packaging value chain for pulses
  • 17. Value occurs when need are met • Needs within each link of the value chain are met • Retailer needs emerged as primary in 1990s • Post consumer needs are emerging as primary Dr Claire Sand 17Packaging value chain for pulses
  • 18. Packaging value chain for pulses Dr Claire Sand 18 raw materials for packaging converted packaging manufactured packaging components Combined product and package distributed product and package sold product and package discarded product and package Packaging Value Chain Interfaces The Circular Value Chain Value Chains seek sustainable competitive advantages from consumers to raw materials
  • 19. Overview Connecting the packaging value chain to pulses-key technologies Packaging value chain creates needed structure for pulse strategies to succeed Packaging Value Chain Connecting the packaging value chain to pulses-sustainability Packaging value chain for pulses Dr Claire Sand 19
  • 20. Packaging value chain creates needed structure for pulse strategies to succeed Packaging value chain for pulses Dr Claire Sand 20
  • 21. Alignment is missing • Economic pressures • Global competitors • Food industry barriers Incentives Lack of trust/connection • New partners • Cost-benefits Relationships vary within the chain • Require different approaches • Are assessed based on the value the relationship has to the organization and within the entire value chain Dr Claire Sand 21 Value Chain creates structure in relationships Packaging value chain for pulses
  • 22. Value Chain creates structure in relationships • A strong value chain is a competitive advantage because then the entities within the chain and the entire chain can focus on higher level goals such as innovation • When relationships within the value chain are based on value, the footing is more solid than price Dr Claire Sand 22Packaging value chain for pulses
  • 23. Value Chain actions for pulses • Build Trust • Manage knowledge • Develop partners • Share work • Ensure Agility • Adjust to reward significance in relationships Packaging value chain for pulses Dr Claire Sand 23
  • 24. Build Trust Build Trust to increase innovation in processing and packaging- • Trust to enable shifting the role to a packaging responsibility is needed • Need to build trust that ___ can provide extra measure of innovation, food safety • Process transparency • Align goal with food safety HACCP, FSMA, GFSI, etc processes • Incorporate transparency to build tacit knowledge Packaging value chain for pulses Dr Claire Sand 24
  • 25. Build Trust-Manage knowledge Dr Claire Sand 25 • SCM has refined processes for logistics data • Knowledge not transferred • Knowledge implies an understanding of the value of the information • Supply chain disruptions due to disasters (economic and environmental) occur not because of a lack information • Data for distinct groups was available • Knowledge was missing Packaging value chain for pulses
  • 26. Build Trust-Manage knowledge Dr Claire Sand 26 • Human knowledge • Seasoned packaging professionals • Education • Structured knowledge • Explicit rules, behaviors, and routines of who communicates with whom • Social knowledge • Tacit knowledge within and with value chain members… • 37% said they have a clear understanding of what their organization is trying to achieve and why • 20% said they had a clear "line of sight" between their tasks and their team's and organization's goals Packaging value chain for pulses
  • 27. Build Trust-Refine functional relationships 27 • Functional relationships within the developing world can be reflective of what the industrial world needs as well • Example- Coffee in Kenya • Profits go to roaster after value added consumer packaging used by roaster • Role of packaging value chain is critical Packaging value chain for pulses Dr Claire Sand
  • 28. Build Trust-perform stress test • To assess partner response • To align to improve functionality • Increased microbial load, product abused, seasonal variation in value chain • Explore viability of safety guarantee • Need to be involved with integration into HACCP, FSMA, GFSI, etc process and required post pack conditions • Stress tests define flows of information and communication needed • By asking value chain members what would happen if ------ • We can best assess weaknesses in the value chain • We can define new communication processes needed for each situation Packaging value chain for pulses Dr Claire Sand 28
  • 29. Packaging value chain for pulses Dr Claire Sand 29
  • 30. Develop partners and shared value • Need to stretch value chain to incorporate more members • Researchers in ____ arena jointly funded-consortiums, foundations, universities • Assess distribution controls • Explore impact on retail if shelf life extended • Make consumer connections • Assess sustainability in holistic manner (reuse, regeneration, recycling, reduce) • Nutritional waste • Package waste Packaging value chain for pulses Dr Claire Sand 30
  • 31. Develop partners and shared value Dr Claire Sand 31 • Focus on what’s needed • Rapid deliveries • Address immediate needs • Altering priorities in distribution system from FIFO to when needed • Blogs-Informal communication when a new priority arises • Beyond Task Forces/Committees • Actionable objectives from customers • I wish we could reduce out of spec components… • I wish we had more trust in our supplier… • I wish they would help me optimize my retail space… Packaging value chain for pulses
  • 32. 32 Shared value Packaging value chain for pulses Dr Claire Sand
  • 33. Packaging value chain for pulses Dr Claire Sand 33
  • 34. Develop partners and shared value Dr Claire Sand 34 • Shared value recognizes that externalities create internal costs for companies- • Higher energy costs (due to dwindling supplies) • Higher raw material costs (due to lack of reuse /recycling) • Need for more educated work fore • Commoditization • Price focused competition • Little innovation • Unclear competitive advantage • Profits coming at the expense of the community • Government policies attempt to internalize externalities such as the social costs of pollution • Business fight these initiatives and resist standards Packaging value chain for pulses
  • 35. Develop partners and shared value Dr Claire Sand 35 • Packaging and pulses-regeneration, recycling and better technology all have shared value • Location is refined beyond labor costs as- • Human labor takes secondary role to robotics • New consumer markets • Clustering and now tierisation in automotive are mimicked in multicomponent packaging industry • Refined tierisation reaches inherent shared value of- • Making profit synergistically • Joint technology advances • Focus on specific customer/industry Packaging value chain for pulses
  • 36. Develop partners and shared value-clusters Clusters on packaging motivated by the- • 5 trends • Shift from vertical integration to relying on outside suppliers, partners, and institutions • Increasing knowledge and skill intensity of competition • Globalization of markets and value chains • Nations and regions compete to attract specific business Dr Claire Sand 36Packaging value chain for pulses
  • 37. Develop partners and shared value-clusters Dr Claire Sand 37 Clusters Increase Productivity / Efficiency • Efficient access to specialized inputs, services, employees, information, institutions, training • programs, and other “public goods” (local outsourcing) • Manage knowledge via coordination and transactions across firms • Rapid diffusion of best practices and tacit knowledge • Ongoing, visible performance comparisons and strong incentives to improve that align shared value Clusters Stimulate and Enable Innovations • Greater likelihood of perceiving meaningful innovation opportunities (e g , unmet needs, sophisticated customers, combinations of services or technologies) • Presence of multiple suppliers and institutions to assist in knowledge creation Packaging value chain for pulses
  • 38. Develop partners and shared value-clusters Dr Claire Sand 38 Clusters Facilitate Commercialization and New Business Formation • Opportunities for new companies and lines of established business are more apparent • Spinoffs and startups are encouraged by the presence of other companies , commercial relationships, and concentrated demand • Commercializing new products and starting new companies is easier because of available skills, suppliers, etc Packaging value chain for pulses
  • 39. Develop partners and shared value-clusters Dr Claire Sand 39Packaging value chain for pulses
  • 40. Develop partners and shared value-clusters • Competitiveness must be a bottoms-up process in which many individuals, companies, and institutions take responsibility • Clusters provide a platform to address the specific barriers companies face • in a given market, not just general challenges all companies are exposed to Dr Claire Sand 40Packaging value chain for pulses
  • 41. Develop partners and shared value-clusters Neutral across clusters • Enhancing productivity of multiple firms/institutions • Facilitating/capturing linkages and externalities • Facilitating the flow of information/knowledge across actors • Engaging the private sector, not just government • Preserving and enhancing market competition, not retarding it Dr Claire Sand 41Packaging value chain for pulses
  • 42. Packaging value chain for pulses Dr Claire Sand 42
  • 43. Packaging value chain for pulses Dr Claire Sand 43
  • 44. Ensure Agility • Ensure agility in meeting need for package change • Because food industry processes are not aligned to implement packaging solutions, agility to work a different way is needed • Realign cost-benefit within value chain members • Development time and costs shared within value chain • Develop solutions jointly vs “serving up” solutions • Employ startup (mentality/physically) without internal/external barriers • Gain tacit knowledge • Identify core advisory team experts to guide team Packaging value chain for pulses Dr Claire Sand 44
  • 45. Ensure Agility-VUCA • VUCA (volatile, uncertain, complex, ambiguous) society demands agility in packaging • By focusing on each link’s value, packaging can uniquely offer this agility • Packaging’s various finished goods phases enable faster reaction time • Example – skin graft packaging & disaster mgmt • Packaging’s role is evolving within the value chain • Research on increasing responsiveness, core technologies (inks, tertiary packaging, labeling, GFSI, FSMA, REACH) have focused innovation on finished goods flexibility Dr Claire Sand 45Packaging value chain for pulses
  • 46. Ensure Agility-Packaging for economic reshuffling • Packaging can enable affordable choices the 4 billion+ consumers at pyramid’s base • Packaging needs to technically leapfrog to provide product protection and a market • Packaging can facilitate manufacturing value added goods versus raw material exports • Reveals opportunity to use historically indigenous materials (e g , jute) • Research potential in facilitating leapfrogging in technology is high Dr Claire Sand 46Packaging value chain for pulses
  • 47. Ensure Agility-Packaging for urbanization • Urban market is growing • About 2+ million people/month become urban dwellers in Asia • Urban households have 3 times more disposable income than rural • Packaging can meet this market need through research on focused urban needs • Example – optimization of aseptic pkg Dr Claire Sand 47Packaging value chain for pulses
  • 48. Ensure Agility-Packaging for urbanization • Packaging can facilitate the distribution via alternative channels (versus traditional models) to meet urban needs • A future value chain defined by consumer led value will optimize packaging based on global urban and rural consumers • Example-Medical contract packaging & Anderson’s window walls & UHP • Optimal packaging technology focuses on post consumer disposal in urban areas (DSD) • Consumer specific packaging is growing • Kids design Legos and package • Packaging research on predictive restocking (beyond RFID) to make consumer and post consumer packaging seamless Dr Claire Sand 48Packaging value chain for pulses
  • 49. Ensure Agility-Packaging resource management • The future value chain links the post consumer value of packaging with raw materials • This moderates research to focus on raw material production-the largest energy use in packaging • Packaging processes are being refined to use less water and energy • 28% of US consumers are LOHAS • Packaging’s role is unique due to the short use of the packaging • Packaging is also unique in that it is global since packages are made and disposed worldwide vs products being consumed or used as durable goods • Packaging research leads the way for regeneration of manufactured goods • Example-reusable packaging before reusable computers Dr Claire Sand 49Packaging value chain for pulses
  • 50. Ensure Agility-Packaging resource management • Packaging’s role in the value chain can link raw materials with post consumer environment • Progress mirrors the future • Example –EU’s APEAL industry initiatives provide image of potential in packaging • Example-KLM • Example-Migros exceeded Switzerland’s PET recycling goal • Future role in value chain is collaborative • Global powerhouses (WWF, CERES, Forum for Future) are engaged Dr Claire Sand 50Packaging value chain for pulses
  • 51. Ensure Agility-Packaging innovation for pulses Exploratory innovation within the value chain requires- • An open culture that can absorb new ideas and abandon the status quo • Ability to envisage a ‘new whole’ – and then work out how the various firms might work together in the future Dr Claire Sand 51 • Understanding that capabilities might shift along the chain • Value chain diagnostic systems to define exploration innovation challenges and develop appropriate performance measures Packaging value chain for pulses
  • 52. Ensure Agility-Packaging innovation for pulses • Exploration closely links value chain entities with consumers to- • Tell ‘stories’ about the packages we use to explain- • Why it is used • How it was produced • Impact on the environment • Welfare of workers involved along the chain • Rewards accruing to the primary producers • Commodity packaging is- • Not able to compete on these issues • Disadvantaged in many premium market segments Dr Claire Sand 52Packaging value chain for pulses
  • 53. Ensure Agility-Packaging innovation for pulses • Implementation of an exploratory platform for sustainability requires incentives to- • Absorb new ideas into organization • Reward ideas that address how challenges could be faced • Enable quick clearance for external entities • Reward long term innovation at the expense of short term innovation Dr Claire Sand 53 • Realign partners to achieve innovation • Reward new arrangements that focus on a long term innovation need • Reward concepts that offer opportunities to use value chain • Reward value chain teams that make steps toward implementation of new technology/initiative Packaging value chain for pulses
  • 54. Ensure Agility-Packaging innovation for pulses • Enable the coordination shifting capabilities • Reward value chain partners to skip a link in the chain • Enable the use of loose contacts within and external to the chain • Reward internal system of cross functional learning that employs- • Bank of experts • University degrees/certifications in cross disciplinary areas • Reward knowledge transfer within organization and value chain • Define exploration innovation challenges and develop appropriate value chain diagnostic and performance measures • Reward coordination of incentives and goals Dr Claire Sand 54Packaging value chain for pulses
  • 55. Ensure Agility–Align rewards • Since food safety and reducing waste is normally the role of the food processor, incentives to enable shifting the role to packaging is needed • Need to provide incentives to work as a partner in food safety and waste reduction • Assess motivation for CPG to work on ___ • Timing • Reduce costs • Chance to truly innovate • Design reward system based on conversion process • Connect with retailer on needs/signage • Align rewards to conversion process • Design reward system based ___ process efficacy • Storage of ___ packaging material • Packing of product with packaging material Packaging value chain for pulses Dr Claire Sand 55
  • 56. Ensure Agility–Align rewards Dr Claire Sand 56 • Rewards connect to meeting specific values • Employees motivated by difference factors than companies • Value chain motivation often takes the form of- • Private Education for school age children funded • Tuition paid for college • Health care on site • Day care on site • Valued food solutions on site • Reduction in housing costs • Access to technology (cells, computers, internet Packaging value chain for pulses
  • 57. Ensure Agility-Align rewards Dr Claire Sand 57 For example incentives to align supplier to Pepsi’s water initiative might take form of- 1. PET Bottle Supplier- • R&D employees – Pepsi rewards R&D employees for developing a new process for reduced water use at PET bottle blow molding facility • Production employees – Pepsi rewards PET bottle production employees for increased compliance with lower water use 2 Retailer- • DC employees rewarded for more optimal use of water in cleaning • Retailers rewarded for promoting recycling to consumers that will save water in oil extraction and resin conversion 3 Recyclers- • Employees rewarded when recycling of PET increases in community Packaging value chain for pulses
  • 58. Packaging value chain for pulses Dr Claire Sand 58
  • 59. Packaging value chain for pulses Dr Claire Sand 59
  • 60. Packaging Value Chain Approach Managing for new approach requires the value chain to provide- • Shared business culture, vision, terminology and set of practices within the value chain • Ability to envisage how the parts add up across chain • Ability to change internal systems • Activities for the sake of the whole as a cooperative effort • Dense network of contacts and trust • Focus on team building activities Dr Claire Sand 60Packaging value chain for pulses
  • 61. Overview Connecting the packaging value chain to pulses-key technologies Packaging value chain creates needed structure for pulse strategies to succeed Packaging Value Chain Connecting the packaging value chain to pulses-sustainability Packaging value chain for pulses Dr Claire Sand 61
  • 62. Connecting the packaging value chain to pulses- sustainability Packaging value chain for pulses Dr Claire Sand 62
  • 63. Packaging sustainability-Competitive advantage • Interviews from CEOs are telling-- • 98 % believe that sustainability issues will be critical to the future success of their business • 92 % believe that companies should integrate sustainability through their supply chain; only 59% believe that their company has done so • 51 % cite the complexity of implementation as the most significant barrier to embedding sustainability Dr Claire Sand 63Packaging value chain for pulses
  • 64. Packaging & Sustainability-Packaging waste increases with income Dr Claire Sand 64Packaging value chain for pulses
  • 65. Sustainability is seeking a favored option Dr Claire Sand 65Packaging value chain for pulses
  • 66. Packaging & Sustainability-Companies react in different ways ► Dannon reduced packaging waste by eliminating the plastic cap over the peel-back foil seals on yogurt cups ► 3.6 million pounds of plastic/year ► Copied others in industry ► SunChips ► Compostable bag ► Limited compost facilities ► Noisy Dr Claire Sand 66Packaging value chain for pulses
  • 67. Packaging LCAs Dr Claire Sand 67Packaging value chain for pulses
  • 68. Measuring Package Sustainability 1. LCAs 2. COMPASS 3. Carbon Foot Print 4. Tesco and Wal-Mart Scorecards Dr Claire Sand 68Packaging value chain for pulses
  • 69. Packaging & Sustainability-Steel Dr Claire Sand 69Packaging value chain for pulses
  • 70. Packaging-LCA of Frozen and Canned Green Beans Dr Claire Sand 70Packaging value chain for pulses
  • 71. Packaging & Sustainability-Value Chain derived redesign – Improved design is stackable, eliminates need for crates – Eliminates need to transport, return and wash crates – Can fit 224 jugs on a pallet instead of 180 – Reduces distribution costs by ~30% – Reduces price to consumers by ~$ 10 Dr Claire Sand 71Packaging value chain for pulses
  • 72. ► Solve from Shared Value and value chain perspective ► Less packaging ► Less heat for processing ► Refrigeration ► Longer shelf life Dr Claire Sand 72 Packaging & Sustainability-Value Chain derived redesign Packaging value chain for pulses
  • 73. • By straightening Hamburger Helper noodles- • Product could lie flatter in the box • Reduce the size of boxes • Supplier- saved nearly 900,000 pounds of paper fiber annually • Community- Reduce greenhouse gas emissions by 11 percent, by taking 500 trucks off the road • Retail- increased the amount of product Wal-Mart shelves by 20 % Dr Claire Sand 73 Packaging & Sustainability-Value Chain derived redesign Packaging value chain for pulses
  • 74. Packaging & Sustainability-Value Chain derived redesign Dr Claire Sand 74Packaging value chain for pulses
  • 75. Packaging & Sustainability-Value Chain derived redesign • Minute Maid Mango Juice in Kenya- move from external source to internal sources for ingredients and package • Resulted in • Consistent quality mango supply for export and purchase by local bottlers • Doubled the income of 50,000 smallholder mango and passion fruit farmers (>50% women) in Kenya and Uganda • Need to stretch value chain to packaging and add further shared value by • Design for Recovery • Build recycling infrastructure Dr Claire Sand 75Packaging value chain for pulses
  • 76. More shared value oriented and value chain sustainable solutions in Design for Recovery • Paper & film-air float separation • Steel-magnetic separation • Aluminum-Eddy currents • PE, PP, PET, PS- NIR and float density Use of Recycled or compostable plastics • rHDPE Envision • rPET Build Composting and Recycling Infrastructure Dr Claire Sand 76 Packaging & Sustainability-Value Chain derived redesign Packaging value chain for pulses
  • 77. A packaging value chain stretches into the realm of shared value can achieve a higher degree of sustainability Dr Claire Sand 77 Roger’s Coffee Company • Coffee shared value- Growers and manufacturing coffee • Training, $, personal relationship, carbon-negative footprint • Packaging shared value- Materials now at 97% bio-based and compostable • Polymer source • New profits from bio-based materials and industrial & home composting • Opportunities to extend shared value- • Partnering with composters to add more industrial composting sites • Connect down the value chain is was done with coffee growers Packaging & Sustainability-Value Chain derived redesign Packaging value chain for pulses
  • 78. Overview Connecting the packaging value chain to pulses-key technologies Packaging value chain creates needed structure for pulse strategies to succeed Packaging Value Chain Connecting the packaging value chain to pulses-sustainability Packaging value chain for pulses Dr Claire Sand 78
  • 79. Connecting the packaging value chain to pulses-key technologies Edible and antimicrobial Active, intelligent, responsive Packaging value chain for pulses Dr Claire Sand 79
  • 80. Causes/ Categories Category Z Category Y Category X Catgeory W Category V Category U Category T Category S Oxidation Moisture Change Microbial Browning Water resistance MVTR Antimicrobial Reduce impact of contamin. ingredients Reduce contamin. during product fill Assess initial microbial load Reduce initial microbial load Reduce cross contamin. Enable processing of some ingredients Enable HACCP Address chilled worker conditions Time &Temp monitoring system Oxygen level monitoring system Control tempertaure Measure microbial load at POS Enable safe package reuse Reduce consumer contamin. from repeat use Expand time for safe product use Enable oven/ MWmonitoring Address eating hygiene through packaging Enable freezer storage Packagingand Handling Pkg Prop. Product Degradation Causes Distributio n&Retail ConsumerUse Value Chain solutions to food safety are focused 80 Value Chain enables innovation through focus on societal issues – food safety Packaging value chain for pulses Dr Claire Sand
  • 81. Key technology-Edible packaging • Focus on • Reduce and not replace synthetic packaging • Freezer burn • Decreasing water loss in fresh seafood • Enhancing product offerings • Cook in bag • Shaped products • Meal kits to align with what retailers are doing Dr Claire SandPackaging value chain for pulses 81
  • 82. Key technology-Edible packaging • Freezer burn • Interfacial water freezes and thaws and ice crystals grow crushing cells • Increased degradation within cells before they burst • Texture loss • Water loss • Loss from product • Loss from package is ($$$) loss Dr Claire SandPackaging value chain for pulses 82
  • 83. Key technology-Edible packaging • Alternative to vacuum package • Edible barriers are a robust solution in consumer freezers • Many options and can be linked to antimicrobial barriers Dr Claire SandPackaging value chain for pulses 83
  • 84. Key technology-Edible packaging Enable venting since product is better protected 1. Perforations • (horizontal or in a “patch”) that are coated/laminated; but, to allow air/steam to escape through holes 2 Laser scored • top layer that is coated/laminated; but, to allow air/steam to escape through laser cuts that expand when heated • steam generated from within the package bursts through the scoring and automatically ventilates the package 3 Channels that vent air/steam through fin seal area • Consumer slit bag to vent before microwaving 4 Tray in colander Dr Claire SandPackaging value chain for pulses 84
  • 85. Key technology-Edible packaging • Upscale frozen/fresh Surimi seafood • Impart texture • Lower fat content by reducing oil uptake • Bite size • Decrease product waste Dr Claire SandPackaging value chain for pulses 85
  • 86. Key technology-Edible packaging • Keep water within separate foods with reduced synthetic packaging Dr Claire SandPackaging value chain for pulses 86
  • 87. Key technology-Antimicrobial packaging Market need for Antimicrobial is increasing due to increase in- 1. Resistance of microbes to standard processing technologies 2. Food safety outbreaks • Foodborne disease reaches 30% of the population • Vibrio increased 115% since 2006 3. Need for controlled temperature conditions to inhibit microbial growth 4. Global food distribution in various stages of processing 5. Increase in consumer interest in fresh and multicomponent prepared meals 6. Inability of MAP/CAP technology to accommodate lack of controls in distribution, processing, product 7. Growing urban population in need of food they can not produce 8. High potential for cross contamination • Processing facilities often manufacturer more than one product • Distribution systems between products are often linked Packaging value chain for pulses Dr Claire Sand 87
  • 88. Key technology-Antimicrobial packaging 1. FOOD PROCESSING CONDITIONS • Food pH, and stability after pH changes • Inactivation by food enzymes • Interaction with food additives/ingredients 2. FOOD SHELF LIFE FACTORS • Food storage temperature • Limited stability during food shelf life 3. MICROBIAL FACTORS • Microbial load • Microbial diversity and the target bacteria • Microbial interactions in the food system • Physiological stage (growing, resting, starving or viable) 4. BARRIERS • Protection by physico- chemical barriers (microcolonies, biofilms, slime) • Barriers enrobing Antimicrobials 5. DEVELOPMENT OF RESISTANCE/ADAPTATION • Predicted to be an issue of concern Packaging value chain for pulses Dr Claire Sand 88
  • 89. Key technology-Antimicrobial packaging Packaging value chain for pulses Dr Claire Sand within a structure as a coating through headspace 89
  • 90. Key technology-Antimicrobial packaging ORGANIC ACIDS • Benzoic acid and benzoates • Sorbic acid and sorbates • Acetic acid • Propionic acids and propionates • Lysozyme SOME OTHERS • Chlorine dioxide • Triclosan • Silver zeolite, nitrate • Bacteriophages • Maillard reaction end products BACTERIOCINS • Nisin • Pediocin POLYMERS • Chitosan NATURAL EXTRACTS • Cinnamaldehyde • Eugenol • Allyl isothiocyanate • Green tea extract • Various extracts Packaging value chain for pulses Dr Claire Sand 90
  • 91. Key technology-Intelligent packaging • Focus on- • TTI • Degradation sensors • No-Fraud assurance packaging • Responsive packaging Packaging value chain for pulses Dr Claire Sand 91
  • 92. Key technology-Intelligent packaging- TTIs Packaging value chain for pulses Dr Claire Sand 92 • L5-8 Smart Seafood • irreversible color change from the hydrolysis of triglycerides • CoolVu • aluminum layer thins causing a reaction • FreshCode, Varcode andTempix, Tempix • fading barcodes • FreshMeter • turns from blue to gray via benzopyridine photoactivation
  • 93. Key technology-intelligent degradation sensors Packaging value chain for pulses Dr Claire Sand 93 Degradation sensors are advancing rapidly • Direct connection to food deterioration • More sophisticated sensors that convert biochemical signals to electrical responses that show remaining shelf life from manufacturer to consumer
  • 94. Key technology-Intelligent authenticity sensors Packaging value chain for pulses Dr Claire Sand 94
  • 95. Intelligent packaging expands brand image potential Current solutions • Thermochromatic inks change color and reveal images when the product is at the proper temperature to eat or drink • NFC OpenSense package sensor is tapped with a smartphone • Polymark fluorescence based detection for sorting food- contact PET Packaging value chain for pulses Dr Claire Sand 95 Key technology-Intelligent authenticity sensors
  • 96. Packaging value chain for pulses Dr Claire Sand 96 Using the Packaging Value Chain for Pulses-checklist  Set goals  Assess market opportunity  Define what the product-package needs to do  Identify key social issues that are important  Align  Identify key partners to address these social issues and meet goals  Continue to expand issues to guide relationships within the Value Chain  Determine which Value Chain members align  Define value (context, experiential, subjective, meeting needs)  Build trust and agility into organizational frameworks so that new Value Chain initiatives are achievable Checklist-Bringing in your Innovations using the Packaging Value Chain
  • 97. Packaging value chain for pulses Dr Claire Sand 97 Food science and packaging expertise- • Coaching • Consulting • Technology • Strategy www PackagingTechnologyandResearch com Dr Claire Sand CEO, Packaging Technology & Research, LLC Adjunct Professor, Michigan State University Packaging technologies and value chain concepts to advance value-added pulse-based foods

Notas do Editor

  1. Indian consumers were ready to pay a premium of 10-15% for branded and packed pulses, provided the same was able to deliver some unique value              Further, it is also seen that branding has a significant effect on the distribution of margins across the value chain with the ‘brand propagator’ getting a higher share in gross margins and retailers losing out their margins on account of strong brand pull
  2. Porter conjectures that companies have missed the mark with customers and suppliers- How else could companies overlook the wellbeing of their customers, the depletion of natural resources vital to their businesses, the viability of key suppliers, or the economic distress of the communities in which they produce and sell? How else could companies think that simply shifting activities to locations with ever -lower wages ( …reducing personnel, restructuring ) was a sustainable “solution” to competitive challenges?
  3. Global investments have changed focus from universal design to global packaging solutions Chinese investors have enterprises in 200+ countries (in 2012; in 2005 <5) Investors guide solutions Packaging suppliers are globally integrating by solutions versus product Example-BASF and competitors linked Research focus can provide global solutions and switch from universal design to global design Example-Japan’s senior market and low income market in USA
  4. BRIC (Brazil, Russia, India, China) face packaging struggles Brazil’s recent legislation suggests that Brazil will emerge and a environmentally focused country Will exceed G7 economies in 30-40 years China imports most of world’s recycled pulp, steel, and PET driving prices up for recycled pkg and making pkg valuable and sometimes more costly than non-recycled pkg Environmental jumping is growing