The document discusses trends in flexible packaging and its applications. It notes that flexible packaging has evolved from an afterthought to a key marketing component. Global drivers include globalization, customer value, technology, and supply chain management. Flexible packaging helps reduce food waste by providing effective protection that preserves food quality and extends shelf life, as well as offering appropriate formats and serving sizes that minimize leftovers. Studies show individually packaged foods generate less waste than bulk formats. Flexible packaging is a partner in reducing food waste and supporting responsible consumption and production.

1. henkywibawa@yahoo.com
PRINCIPLE
FLEXIBLE
PACKAGING
PERFORMANCE
CHARACTERISTICS

2. Global Trends
HP Barrier Films
Trends Flex.Packaging Applications

4. Global drivers of flexible packaging

5. Globalization
Customer Delivered Value
Networked Technology
Product Life Cycle Compression
Supply Chain Management
Mass Customization
Digital Business

6. Thoughts on flexible packaging
 Global market with a value of over $200 billion
 From necessary afterthought to key marketing component
 Under pressure because of its high visibility
 Role in reducing food waste
 Lightweight = packaging efficiency
– Increasing opportunities to replace rigid materials
– Opportunity for plastics to replace traditional raw materials
 Consumer education required

7. A growing, aging global population
Over 60:
22%
Over 60:
11%
Sources: UN, WHO

8. Packaging for the middle classes
Source: Economist Intelligence Unit; World Bank
Size of the global middle class (millions of people)

9. Urbanisation fuelling retail sales boom
Source: World Bank,2014

10. Modern demand needs modern packaging
Cultural
westernization
E-commerce24/7 lifestyles

11. Asian market the global driving force
Percentage of global GDP in 2005 PPPs
Source: Long-term growth scenarios,
OECD Economics Department Working Paper No. 1000
United
States
23%
Japan
7%
Euro area
17%
Other OECD
18%
Other non-
OECD
12%
China
17%
India
6%
2011 United
States
18%
Japan
4%
Euro area
12%
Other OECD
15%
Other non-
OECD
12%
China
28%
India
11%
2030
Source: AMI Consulting, 2014

12. Asia’s wide spectrum of packaging markets
 Developed markets e.g.
Singapore; Japan; S. Korea
 Fast growing markets e.g.
China; Indonesia; Thailand
 Developing economies e.g.
Laos; Myanmar

13. Towards a smarter future?
Production Packaging Distribution Retail Consumer
Intelligent
• Printed electronics
• Sensors/RFID/NFC
• Track, Trace & Control
Active
• Nano-technology
• Security & anti-counterfeiting
• Oxygen/Gas scavenging
• Modified atmosphere
• Indicators

14. Flexible packaging today
– Greater aesthetic appeal and shelf impact
– Replacement of rigid packs by flexibles (especially pouches)
– More pack formats to satisfy a fragmenting market
 Environmental compliance driving:
– Thinner films/smaller labels
– Films with recycled material content
– Consideration of bio resins
Faster, Better, Cheaper, Greener
 Flexible packaging is growing
 Innovation continues – new materials and properties
 Brands driving change with:

15. Process Product
Material

16. High Performance Barrier Film

17. The global packaging market is huge; offering many
opportunities in barrier packaging, led by flexibles.
N. America and Europe account for roughly 55% of global packaging value,
but growing at slower rates than rapidly developing regions such as Asia
Global Packaging Market
(value of shipments-all structures)
$450 Billion
Annual
Growth
2-3%
(>5% Asia)

18. Kline’s definition for high-performance barrier
packaging films is specific, as follows.
 Film structures providing high barrier levels to oxygen, water vapor,
aromas/flavors, and/or UV light
– A barrier film is usually a coextruded, coated, or metallized substrate
– Barrier components include PVdC resin/coating, EVOH, nylon, MET films,
or Al2O3 or SiOx
– But excludes all structures that use Al foil as the barrier, paper as a
structural member, or MET films used only for graphic enhancement
 Film structures <10 mil (e.g. multilayers of printed layer, barrier & sealant)
 Includes film structure laminations (with a barrier film), or a coextrusion
containing a layer of barrier resin, or a substrate coated with a barrier
material that might also function as a sealant
A mono-structure of only barrier film is very rare; real value is created
when the barrier film is a ‘component’ that enables the final package

19. The market for H.P. barrier packaging films is
positively influenced by many factors.
Cost Reduction
Rigids to flexible; less
R.M. & lower freight
Process Improvement
CoEx & laminates
offset resin cost
High growth of
Convenience food
Home Ready - Ready to Cook
Smaller packages
More barrier needed,
Higher surface-volume ratio
Alternative Packaging
Smart, security,
reclosability, etc.
Market for
High Performance
Barrier Packaging
Films
Geo-Cultural &
Trade
Impacts
Our focus is on food packaging, with some comments on medical devices

20. Business opportunity emanates from the value chain
continuum of application, film and structure.
Barrier Film
Markets &
Applications
 Perishable Food
-Fresh meat
-Prepared food
-Processed
meat & cheese
 Dry Food
-Confections &
snack bars
-Pet food
-Snacks &
baked snacks
 Medical & others
 PVdC
 EVOH
 Nylon
 Metallized
 Specialty oxides
 CoEx. &
laminates
Package
Structure
 Bags
 Lid stock
 Stand-up
pouches
 Forming
web
 Wraps
Barrier
Film
Package
Structure
Markets &
Applications
Business
Opportunity
We use sophisticated applications model to combine film & package conversion
costs, area and package structure to determine various market size relationships

21. Markets Film Structure
PVdC is the leading barrier film used for perishable food.
In dry-food, PVdC-coated PP leads.
Perishable food
($950 MIL)
Perishable food
($950 MIL)
Dry food
($250 MIL)
PVdC, 45%
EVOH, 25% Nylon, 25%
Other, 5%
Dry food
($250 MIL)
PVdC coated PP, 50%
MET PP, 35%
MET
PET, 10%
EVOH, 5%
Shrink films
primarily for fresh &
processed meats
Modified
Atmospheric
Packaging (MAP)
Snacks, clear-packs
& pillow-packs
Films vs. coated films; e.g. PVdC does both

22. Markets Film Structure
High-growth expected in perishable foods for EVOH &
Al2O3-PET films (8%+); in dry-foods PVdC-PET (9.2%).
10
9
8
7
6
5
4
3
2
1
0
Overall
market, 4.8%
Averageannualgrowth,%
Perishable food Dry food
PVdC
45%
EVOH
25%
Nylon
25%
PVdC-
coated
PET
Total
Perishable Food
($950 MIL)
Al2O3-
coated
PET
MET
nylon
SiOx-
coated
PET
PVdC-
coated
PP
PVdC-
Coated PP
50%
MET-PP
35%
MET-PET
10%
PVdC-
coated
PET
EVOH
Total
Dry-Food
($250 MIL)
MET
PETFresh &
Processed
Meats
FFrreesshh FFooooddss,,
MeMaetsat&s T&ray
LaLmid-dTirnagys
Retort; Japan
& Europe
interest
High-growth,
but small
market today
Snacks &
Baked
Displacing
PVdC
SUP Clarity

23. Markets Film Structure
Barrier packaging films for lid stock & standup pouches
in the food sectors forecast to grow at above rates.
Lid stock
4
2
0
-2
-4
6
8
10
Overall
market, 4.8%
Averageannualgrowth,%
Perishable food Dry food
Lid
stock
Bags
Standup
pouches
Wraps Total
perishable
food
segment
Bags Wraps Total
dry-food
segment
Forming
web
Standup
pouches
Abovinetearveesrtrage
growth

24. Markets
Bags continue to be the major
Film
flexible
Structure
barrier
packaging structure, growing at average rates.
 Bags are extensively used in packaging dry foods — most are pillow packs & bag-
in-box type, supplied as rollstock to end users to run on form/fill/seal lines
 Square-bottom bags, used to package coffee, becoming popular for other dry
food with improved graphics, reclosability & overall cost reduction vs. bag-in-box
 Increases in oil prices will continue to fuel growth in 1 gal foodservice bags as
replacements for #10 metal cans
 The use of barrier shrink bags for packaging case-ready & processed meats
growing at about 3-4%, led by convenience products - fresh meat & cooked

25. Markets Film Structure
Standup pouches are being introduced into every
category of dry-foods to differentiate products.
 Standup pouches with zippers offer reclosability, improved barrier & material
savings in a one-component flexible package vs. multi-component rigid
containers they are replacing for packaging dry food
 Rising fuel prices drive the trend toward metal can replacement with standup
pouches; one truckload of flat bags/pouches equals 25 truckloads of cans
 Sales of shelf-stable foods in retort pouches grown 20-30% in recent years,
reaching $100 MIL in pouches. Many are foil laminates with clear barrier films
 Standup pouches are also gaining popularity for packaging processed meats
like bacon bits and pre-cooked bacon.

26. Markets
In addition to Standup pouches,
Film
other
Structure
growth
structures include forming web and lid-stock.
 Forming Webs: largest use is packaging processed meat and cheese, which
continues to grow exceeding 3%/year
– Case-ready products will drive double-digit growth in forming webs
laminated to trays for low-oxygen MAP packaging of fresh meat
– Thermo-formed film as an alternative to pouches and trays for retort
 Lid-stock: the trend toward case-ready fresh meat packaged in trays under
low-oxygen MAP to drive growth in barrier film lid stock
– Barrier film forming webs & lid stock combinations grow for perishables
– Lid stock providing tamper evidence to replace domes for home meals
– Clear barrier film lid stock withstanding pressure & temperature of retort,
provides microwaveability; recently commercial, but double-digit growth

27. To summarize, opportunities are created when your
solution meets the unmet needs of end users.
Adhesive &
Ink
Producers
Specialty
Film
Producers
Resin
Producers
o
n
v
e
r
t
e
r
s
C
Increasing difficulty of communication
Packagers/
Brand
Owners/
Retailers
Packagers/
Brand
Owners/
Retailers
Materials
Suppliers
T
echn
o l
ogies
:
Lamination
Coextrusion
Adhesion
Printin
g
Conversion
Materials/
Resin
Influencers
Materials:
PET
EVOH
Nylon
Polyolefins
Captured
value
Needs-based
analysis is difficult
due to
communication /
business-related
industry barriers…
Technology
Influencers

28. TRENDS FLEXIBLE
PACKAGING APPLICATIONS

29. Imagine,
◦ you have a refrigerator, which counts the content
everytime you close it, then it compares with aminimum
load checklist and shelflife data, and then this appliance
hooks up to the Internet, shops for the best offer and
orders electronically ...

30. Proprietary&
Confidential©2014 Printpack, Inc. All rightsreserved.

31. The “IPDS”-Modell
Intelligent
Product
Delivery
System
IPDS = intelligent product delivery system
Rutgers University 1998

32. The idea of IPDS: A Paradigm Change
to use information technology to shorten
and simplify the supply chain
for the communication between the
members of the supply chain
to generate a new communicative function
of packaging
to increase the functional value of the
fillgood
(quality, safety, reliability, convenience, costs ....)

33. WHAT HAPPEN IF ...
THE PACKAGING CAN
TALK
TO THE CONSUMER ... ?

34. Imagine,
◦ you have a blister card with tablets, you feel sick, you need
medication - but you can't find the instructions; then you
place the blisters under a scanner, the scanner connects to
the drug company through Internet, and you have the
instructions right- away - more than that, you can even ask
questions to a doctor

39. • higher level of convenience &
functionality
• product differentiation
easy opening
dispensing systems
reclose options
valves
design
Add-on features and design

43. What we do?
Replace traditional packages with advanced packaging thatextends
shelf life, and improves sustainability

44. WHAT IS THE PURPOSE OF
(FLEXIBLE) PACKAGING?

45. Packaging: unnecessary waste?
Packaging often perceived as unnecessary
waste
 Unnoticed when part of the product and
performing its functions
 Visible only at the 'end of life' when separated
from the product and becoming waste

46. Packaging plays an essential role throughout
the lifecycle of the product
 It contains, preserves, protects the product
throughout the value chain and enables the
proper and safe delivery to the final user
 It enables appropriate consumption
Ease of use: handling, opening, etc.
Appropriate formats and sizes
Essential role

47. Packaging can support a responsible
consumption and production by allowing:
■ Efficient use of resources and waste
minimization
■ throughout the entire lifecycle of the product
That is where Flexible Packaging shines!
Responsible Consumption and Production

48. (Flexible) packaging saves more resources than it consumes
Representing a relative small part of the product overall impact – on
average 10%
Carbon Footprint (GWP) of Food Products – Breakdown by life cyclestage
The need of perspective
0%
10%
20%
30%
40%
50%
60%
70%
80%
100%
90%
Butter (250g) Milk Chocolate Frozen Spinach Ground coffee Instant coffee Goulash soup
food
production
retail
packaging
distribution
and selling
transport to
household
storage/use at
home
Source: EAFA/FPE LCA’s qualified as best practice by UNEP/SETAC (Nov. 2013)

49. The Perfect Fit
Flexible solutions for a more sustainable packaging industry
Animation available with subtitles in:
English, French, German, Italian, Polish,
Portuguese, Spanish and Turkish
http://www.flexpack-europe.org/the-perfect-fit-video-english.html
Thought leadership paper
on sustainability of flexible
packaging

50. HOW FLEXIBLE PACKAGING SOLUTIONS
HELP TO SAVE FOOD RESOURCES?

51. Packaging a partner to reduce food waste
One third of all food produced is wasted every year
yet 870 million people are starving
Source: FAO/Save Food

52. Source: FAO Study 2013 “Food wastage
footprint. Impacts on natural resources”
Huge social, environmental and economic stakes
■ 30% of world agricultural land
■ Equivalent to third biggest “country” for carbon emissions
 just after USA and China
■ Equivalent to GDP of Switzerland
The Food Waste issue

53. Thanks to unique combination of properties and customized
solutions, flexible packaging helps to prevent food waste at
the different stages of the value stream
 By providing effective protection
 Allowing perfect preservation of food quality
throughout the value chain
 Possibly without cold chain
 By providing appropriate format and serving
 Matching consumption needs
 Minimizing risk of leftover or discarded food
Flexible Packaging Prevent Food Waste

54. Effective Protection
Bananas
Identical bunches stored
for 7 days
Cucumbers
Shelf life extended from 3 days to
14+ days

55. Effective Protection
Shelf life extension in days

56. The conclusions from the study conducted in French canteens showed that
individually packed cheese generates 60% less food waste
than large format cheese sliced on-site
Appropriate Format
Source: IFOP study for Bel 2015; totalling nearly 60000 studied meals in 33 French schools
http://www.belfoodservice.fr/actualites/de-nouveaux-chiffres-sur-le-gaspillage-du-fromage-40.php

57. The conclusions from the study conducted in French canteens showed that
individually packed cheese generates 60% less food waste
than large format cheese sliced on-site
 Measured waste rate for individually packed cheese is 6%
= 6% leftovers on the meal tray
Appropriate Format
Example of single serve individually packed cheese portions
 As compared to 15 % for large format cheese cut on-site
= 3% left-over during preparation
+ 9% leftovers on the meal tray
+ 3% surplus thrown away at the end of service
Example of cheese sliced on site
Source: IFOP study for Bel 2015; totalling nearly 60000 studied meals in 33 French schools
http://www.belfoodservice.fr/actualites/de-nouveaux-chiffres-sur-le-gaspillage-du-fromage-40.php

58. The case of a cup of coffee
Life Cycle Analysis of the Complete
Food Supply and Consumption
Chain for a coffee cup

59. The case of a cup of coffee
g CO2-eq Cup of coffee from
500 g bag (PET12/alu7/PE100) Cup of coffee from
2 g stick (PET12/alu7/PE55)
Carbon Footprint of a cup of coffee …

60. The case of a cup of coffee
…and the importance of food wastage…
and packaging format
g CO2-eq

61. HOW FLEXIBLE PACKAGING SOLUTIONS
SAVE PACKAGING RESOURCES

62. Flexible Packaging:
The resource efficient solution enabling
more sustainable consumption

63. Lightweight solution
e.g. The advantages of flexible packaging for 326g coffee
Minimized Use of Material
326g Coffee packed in
Flexible
packaging
(pouch)
Metal can with
plastic lid
Plastic can
with lid
Weight of packaging 11.3g 96.4g 59.5g
Product/Packaging Ratio 29:1 3:1 5:1
Packaging per 100g Product 3.5g 29.6g 18.3g
Source: PTIS forFPA
Same functionality but with 5 x less packaging

64. From packaging supplier to filling
location:
• Flexibles = 1 truck
• Rigids = up to 26 trucks
Efficient Transport
A comparison of a 0.2L stand-up pouch vs. 0.2L glass bottle
From Filler to Retailer
Minimized Use of Energy

65. Waste Prevention
Because of very light weight, flexible packaging solutions
generate less waste and contribute to waste prevention
Example: Which packaging is more resource efficient?
– A rigid pack (weight 50 g) with 80% recycling rate?
 Material loss is 10 g
– Or a flexible pack (weight 5 g) with 0% recycling rate?
 Material loss is 5 g

66. SO IT IS NOT ONLY A MATTER OF
RECYCLING?

67. Scientific Study with Two
Scenarios
40% non-flexible
packaging
flexible
packaging
60%
Food Packaging Situation
(in units)
in EU today
(except beverages)
Source: ifeu 2014, verified/reviewed by Carbotech 2014
Substitution of
all flexible packaging
with non- flexible packaging
 “Focus on recycling”
1
2
Substitution of
all non-flexible packaging
with flexible packaging
 “Focus on Prevention”

68. 2- Scenario focusing
on Prevention
26 26
0
82
68
114
0
66
0
20
40
60
80
100
120
Non-flexible and Flexible
with today's end-of-life
rates
Non-flexible with 100%
recycling rate / Flexible
with today's end-of-life
rate
substitution of flexible
with non-flexible (100%
recycling rate)
substitution of non-
flexibles with flexibles
(today's end-of-life rate)
CO2 Footprint
Source: ifeu 2014, verified/reviewed by Carbotech 2014
- 13 %
- 40%
+6 %
1- Scenarios focusing onrecyclingToday
CO2 Footprint of Food Packaging in Europe (Million tons CO2-eq) Source: ifeu

69. Defining and assessing packaging
resource efficiency
Ifeu has developed a relative model
to assess/compare the resource
efficiency of packaging in the
context of circular economy
Waste to disposal
(not recycled)
Cumulated Energy Demand
(throughout lifecycle)
Cumulated Material Resources
Demand (throughout lifecycle)
Resource Efficient Packaging combines the minimized use of
material and energy throughout its lifecycle with the minimized
amount of material leaving the cycle.

70. Comparing packaging
Resource Efficiency
Pouch v Steel Can
Baseline is aligned to 100%
Energy
84 % of baseline
Material
55 % of baseline
Steel can
(70% = current
recycling rate)
Laminated pouch
(assumed material recycling
rate = 0%)
Pouch v Glass Jar Pouch v
Baseline is aligned to 100%
Energy
66 % of baseline
Material
42 % of baseline
Glass jar
(73% = current recycling
rate)
Plastic Pot
Baseline is aligned to 100%
Energy
65 % of baseline
Material
85 % of baseline
Plastic pot
(35% =current recycling rate)
Waste tofinal
disposal:
59 % of baseline
Waste tofinal
disposal:
13 % of baseline
Waste tofinal
disposal:
38 % of baseline
Long life 400-460 ml pasta sauce: Flex pouch vs alternativesolutions

71.  Although highly resource efficient, flexible packaging is
generally less easy to recycle than rigid packaging.
 Nevertheless, solutions exist or can be further developed.
 example (MTM): https://www.youtube.com/watch?v=x9rXCPlRF78
 We are seeking to increase the recycling & recovery
rates for flexible materials by supporting initiatives and
encouraging the development of technologies (e.g.
CEFLEX initiative)
 A precondition for progress: Collect all packaging
 avoid the cherry picking of only the easy recyclables
 preventing from leaking into the environment
 pre-cursor to countries investing in infrastructures
Closing the Collection Gap
to further improve Resource Efficiency
Source:PwC

72. WHAT ARE THE KEY POINTS?

73. Summary
 Economic/environmental stakes of food waste are
much higher than packaging waste
 (Flexible) packaging is part of the solution to
prevent food waste…and also packaging waste
 Flexible packaging is more Resource Efficient than
alternative formats … even with zero recycling!
 Flexible packaging can be recycled/recovered
It is already in several countries!
However, it first needs to be collected.

74. henkywibawa@yahoo.com
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