Consumers are becoming ever more eco-conscious, expecting the food they buy to be wrapped in recyclable packaging. Manufacturers also expect the same standards in production. Expectations are high—food must still be kept fresh and at a reasonable price point but also packaged in environmentally-friendly materials. In this article, METTLER TOELDO specialists look at the top three trends in sustainable packaging, their impact on food manufacturing, and how product inspection can adapt to these trends to help food manufacturers keep up with demand and remain flexible.
According to the 2023 Guide to Global Markets by the Association for Packaging and Processing Technologies, sustainable packaging can be defined as "recyclable, compostable, or reusable packaging, and made from responsibly sourced materials." Many consumers now expect packaging to have minimal negative impact on the environment. A high number of manufacturers are investing time and money into increasing the sustainability of their packaging to reduce carbon dioxide emissions, support their social and environmental responsibility targets, and protect their brand to encourage customer loyalty and gain a competitive advantage.
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Trend 1: Reducing the Use of "Virgin Plastics"
Virgin plastics are plastics that have been produced from natural gas or crude oil without any recycled materials and have never been processed before. They introduce brand new plastic into the environment and are a significant pollution risk. Different manufacturers have different timescales for reducing the use of virgin plastics, but it is a common theme in corporate sustainability goals in the food industry. Similarly, many manufacturers are moving away from using “problematic” packaging materials, such as polyvinyl chloride (PVC) and polypropylene (PP), which can be harder to recycle.
Trend 2: Enhancing Packaging Recyclability and Using Alternative Materials
Materials like cardboard, recyclable aluminum and glass are increasing in popularity as they are widely recycled around the world. In addition, there has been a reduction in multi-layer plastic film which is hard to recycle. This is being replaced with mono-material film that has a better recycling profile.
Alternative compostable packaging materials are also being developed, ones that are made from natural substances. These include plant-based polymers, seaweed-based, or mushroom-based packaging. In fact, the biodegradable packaging market is forecast to reach $25.3 billion by the end of 2025, with a CAGR of 17%. This sum illustrates that the drive towards sustainable packaging is not going to slow down any time soon.
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Trend 3: Collaborative Initiatives and Smart Packaging Design
Some manufacturers are working with organizations around the world to promote a "circular economy" for their packaging. This involves sharing, leasing, reusing, repairing, refurbishing, and recycling existing materials and products for as long as possible. Simply put, it means that companies will take responsibility for the entire lifecycle of their packaging. For example, manufacturers are investing in their entire infrastructure worldwide to enable widespread recycling of the packaging they use.
As for the packaging itself, more thought is going into its design to minimize environmental impact. Manufacturers stipulate that packaging designs are simple and clean, with reduced color palettes, and use as little material as possible. The era of excessive packaging is coming to a close, once again driven by consumer expectations.
How Can Product Inspection Solutions Support Food Manufacturers in Changing Packaging Trends?
The drive towards sustainable packaging and reducing metalized films means that manufacturers can have an impact on the type and placement of certain product inspection solutions. For instance, moving from metalized film to paper or cardboard packaging can mean that metal detection technology can be used on critical control points where before it may not have been possible. In the case of chocolate bars previously packed in metalized plastic or aluminized films, for example, the detection of metal can now take place after the flow wrapping process, providing quality assurance at end-of-line. Similarly, if moving to glass packaging, manufacturers may need specialized x-ray inspection systems to detect physical contaminants within curved glass jars or bottles.
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When changing packaging materials, if a food manufacturer uses foreign body detection systems after the packaging stage, it is important to re-validate the system. The packaging characteristics may have an impact on the machine’s performance, either positively or negatively.
Equally, if using recycled materials, there is a risk of contaminants being in the packaging material itself, which could lead to increased false rejects. In such cases, food manufacturers may need to consider moving the Critical Control Point (CPP) to factor this in.
Packaging types are not the only factor to consider when selecting product inspection technology. Manufacturers should consider the properties of the product being inspected and the likely physical contaminants that could be present. Also, consider whether integrity and quality checks are required as well as contamination detection or fill level control.
Future-Proof Production
To keep up with demand and remain competitive, manufacturers must adapt to these packaging trends and invest in solutions that grow as their operations evolve. Product inspection equipment that can be adapted for new packaging lines is essential — and if existing equipment can be modified by switching out reject bins or conveyor belts, even better!
Partner with a trusted provider like METTLER TOELDO that can help business adapt to changing consumer demands.
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