packaging of milk and milk products

packaging of milk and milk products

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2. PACKAGING OF MILK AND MILK PRODUCTS SPEAKER NEHA TANDON INSTRUCTOR DR. ANUJ GAUTAM RGSC, BHU RAWE (0+4) 9/29/2016 2

3. Milk is a liquid and so requires a container at every stage. Packaging of milk is the technique of using appropriate containers to protect, carry , and merchandise any milk product. V ital link between the manufacturer and consumer. Necessary for delivering fresh, sound and convenient form of milk. INTRODUCTION 9/29/2016 3

4. 9/29/2016 4 MILK PRODUCTION (2015-2016) PER CAPITA MILK AVAILABILITY (2015-2016) INDIA 155.5 million tones 337 grams per day UTTAR PRADESH 25198.36 (‘000 tones) 335 grams per day DAIRY INDUSTRY OF INDIA Source: Press Information Bureau

5. 9/29/2016 5 TOP 5 MILK PRODUCING COUNTRIES OF THE WORLD (2014-2015) RANK COUNTRY AMOUNT OF MILK (MILLION TONNES) 1. India 146.31 2. USA 93.5 3. China 45 4. Pakistan 42 5. Brazil 35.7 TOP 5 MILK PRODUCING STATES OF INDIA (2014-2015) RANK STATE AMOUNT(‘000 TONNES) 1. Uttar Pradesh 25198 2. Rajasthan 16934 3. Gujarat 11691 4. Madhya Pradesh 10779 5. Punjab 10351 Source: Press Information Bureau

6. 9/29/2016 6 STATES WITH THE HIGHEST PER CAPITA MILK AVAILABILITY (2015-2016) RANK STATE PER CAPITA MILK AVAILABILITY (gram/day) 1. Punjab 1032 2. Haryana 877 3. Rajasthan 704 4. Himanchal Pradesh 505 5. Andhra Pradesh 475 Source: Press Information Bureau

7. ‘‘A tool that protects and contains our goods with the aim of minimizing the environmental impact on our consumption.” “A technology of enclosing or protecting products for distribution, storage, sale, and use.” WHAT IS PACKAGING 9/29/2016 7

8. At early stages-cow's udder was the basic container. Development of containers in 1860-70 for distribution. These were metal cans of up to about 80L First significant development in milk packaging- process for sterilized milk ( end of last century) In the third decade of this century- bottling of pasteurized milk developed Development and introduction of plastic materials for packaging in the dairy industry (initially polyethylene) in 1940. HISTORY OF MILK PACKAGING 9/29/2016 8

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10. MILK PACKAGING IN THE PRODUCTION CHAIN RECEPTION COOLING CLARIFICATION PREHEAT PASTEURISATION PROCESSING FINISHED PRODUCT PACKAGING STORAGE/ DISTRIBUTION 9/29/2016 10

11. PRESENT STATUS AND SCOPE OF MILK PACKAGING 9/29/2016 11

12. In 1995, money spent on packaging materials nearly Rs. 29,000 million. Packaging activities engage about 60% of the 5 million labour force in the food industry. 46 % of the total milk production in the country consumed as fluid milk Only 15% of milk is packed. Of this, the flexible pouch accounts for approximately 94 % . 89 % of the households in India consume loose milk Only 9 % households use packaged milk. STATUS IN INDIA 9/29/2016 12

13. Penetration of packaged milk high amongst towns having a population of more than 10 lakh Production of tinplate containers 0.46 MT Use of tinplate containers for packaging 0.4 MT About 0.3 million tinplate containers are exported Alluminium cans accounts to 0.035 MT The production of glass bottles for packaging 0.9 MT Plastics used in the milk industry in the form of containers as well as films & laminates Contd.. 9/29/2016 13

14. The glass bottle for milk introduced in USA in 1884 Plastic containers, i.e. single-service HDPE containers were introduced in 1964. Milk also sold in LDPE pouches, but not popular Paperboard industry in USA introduced a new twin pack comprising two-half gallon containers ( Goyal , 1986). PACKAGING TRENDS ABROAD 9/29/2016 14

15. In German Federal Republic pasteurized milk packaged in cartons. In UK, plastic bottle weighing 23 g was made from a 50/50 blend of high and low density PE. Liquid milk in Berlin packed in plastic bags placed in returnable plastic crates. The Rhineland Milk Supply of Germany marketed pasteurized milk in ‘Tetra King’ one litre packs. CONTD.. 9/29/2016 15

16. Paper and paper based products Glass bottles Tin plate Aluminium foil Timber Plastics a. Low polymer b. High polymers 7. Laminates 9/29/2016 16 BASIC PACKAGING MATERIALS USED

17. PRODUCT PACKAGING MATERIAL Liquid milk Glass bottles Paper laminate for tetra paks Flexible pouches Milk powder Tin plate containers Metalized alluminium foils Lined cartons Bag-in-box: Powder filled in laminates Butter Duplex board with parchment paper Tin plate containers Alluminium foil Cheese/Cheese spread Tin plate containers Alluminium foil in duplex board carton Ghee Tin plate container Flexible p ouches Ice cream Plastic containers Duplex board cartons Laminates 9/29/2016 17

18. Containing the product Selling the product Safety of the product Facilitating the handling & storage Protecting against biological, chemical and distribution damages Providing convenience Information Security ROLE OF PACKAGING MATERIAL 9/29/2016 18

19. Product image Increasing the shelf-life Marketing and advertising tool. Attractive to the consumer. Easy to open, store and dispose. Economical Helps in portion control CONTD.. 9/29/2016 19

20. Specific sensitivities Factors changing the contents Weight and shape of the container Filling and sealing speeds Contamination of food Storage conditions Bio-degradability and recycling potential. Transportation Perishiblity Product range Market Consumer needs SELECTION CRITERIA FOR PACKAGING MATERIAL 9/29/2016 20

21. PACKAGE DESIGN CONSIDERATION FOR MILK AND MILK PRODUCTS 9/29/2016 21

22. MARKET RESEARCH PLANNING PACKAIGNG SPECIFICATION PACKAGE DESIGN PACKAGE MODELING TEST PRODUCTION EVALUATION PRODUCTION SALE MARKETING MAIN FACTORS GUIDING PACKAGE DESIGN 9/29/2016 22

23. LIQUID MILK Flexible pouches 92 %, glass bottles 7% and aseptic packaging 1%. Plastic materials in aseptic packaging of milk product are polyethylene , polypropylene, polystyrene etc. P opular commercial systems available are Tetra pak , Combi block, Pure pak , Hind pak , etc. Economic saving realized 9/29/2016 23

24. GLASS BOTTLES INDIVIDUAL PACK TETRA PACK FLEXIBLE POUCHES 9/29/2016 24

25. 2. CREAM Shelf life of refrigerated creams 1-2 days Packaging consists of PE coated paperboards. In India, cream generally packaged in 250 ml glass bottles, individual pack or consumer’s own container Tin plate containers also used for larger sizes . Whipped creams sold in AEROSOL cans and PE tubs Imitation cream packed in wax-coated paperboard cartons. 9/29/2016 25

26. 9/29/2016 26 WHIPPED CREAM TETRA PACKS INDIVIDUAL PACK

27. 3. WHOLE MILK POWDER Produced either by roller or drum process. Rapid flavour deterioration due to oxidation. General procedure is to remove oxygen by subjecting the product to vacuum within 24 hours of drying. Less than 2% final oxygen considered satisfactory. Coating with an impermeable material or the addition of antioxidants also done. 9/29/2016 27

28. Upon prolonged storage, ghee undergoes lipid deterioration. Tin plate container: Protects the product against tampering and being sturdy, can be transported to distant places. Semi Rigid Containers: Provides a moderately long shelf life, lightweight , economical and transport-worthy. Flexible Films/Pouches: Limited quantities of of less than 1 kg packed. Most economical. 9/29/2016 28 4. GHEE

29. TIN PLATE CONTAINER FLEXIBLE GHEE POUCHES WHOLE MILK POWDER POUCHES MILK POWDER SACHETS 9/29/2016 29 PAPER CARTONS

30. 5. PANEER Short shelf life of about 7 days at refrigeration storage and less than 24 hours at room temperature . Sachdeva et al .(1991) vacuum packaged paneer blocks of 10x4x6 cm size in polyethylene bags using a vacuum packaging machine. The body and texture of paneer improves on vacuum packaging No deterioration observed upto 30 days at 6 ±10 °C in vacuum VACUUM PACKAGED PANEER FROZEN PANEER CUBES 9/29/2016 30

31. 6. KHOA Limited shelf life of 5 days at room temperature Hot filling (80-90° C) of khoa in tin cans increases shelf life to 14 days at 37° C Recently, high barrier structures/laminates based on polyester/ethylene vinyl alcohol (EVOH)/polythene being developed ( 10 days at 37°C and 60 days at refrigerated ) Tin cans and rigid plastic containers of 15 kg capacity can be used. 9/29/2016 31

32. MILK SWEETS BURFI AND PEDA Currently , packaged in paper cartons or duplex board boxes with or without butter paper lining. Recently, packaged in HDPE/polypropylene boxes and cartons of 500g and 1 kg size. They observed the shelf life of 52 days at 30 ° C in vacuum packaged samples against 16 days without vacuum packaging PAPER CARTONS POLYPROPYLENE BOXES 9/29/2016 32

33. b. GULABJAMUN AND RASOGOLLA Rasogolla preserved in sugar syrup, in tin cans of 500 g and 1 kg capacity. Proportion of rasogolla and syrup is 40:60 ( stays good for 6 months ) Gulabjaman largely packaged without syrup in paper cartons or polyester boxes Though lacquered tin can most suitable, it is very expensive. 9/29/2016 33

34. 8. FERMENTED PRODUCTS Dahi , Misti dahi and Shrikhand most popular. Dahi and Misti dahi are sold in earthen pots and PE containers. Drawbacks: H eavy in weight B reakable Expensive , C annot be covered properly S hrinkage of product Polystyrene (PS) and polypropylene (PP) cups of 100, 200 and 500 g used. 9/29/2016 34

35. 9 . BUTTER Pat of butter: Most commonly used Manual- moulded butter: Hand-packaged Machine- moulded butter: Automated version of hand-packaged butter Butter in a dish: Most popular for reduced-fat Mini butter: For markets with limited buying power and high demand Jar of butter: For larger quantities. 9/29/2016 35

36. PAT OF BUTTER MACHINE-MOULDED BUTTER ROLL OF BUTTER DISH OF BUTTER MINI BUTTER JAR OF BUTTER 9/29/2016 36

37. 11. CHEESE Cheese is coated with a wax layer to protect from contamination Cheese may be packaged in plastic film as slices Also packed as cubes or whole pat in aluminum or tin foil Primarily transported in cartons 9/29/2016 37 CHEESE SLICES IN PLASTIC FILMS CHEESE TINS

38. Creates MSW Plastics non-biodegradable Some materials (PVC) contains chlorine and other harmful elements Difficult to separate from other recyclable waste Release of harmful neurotoxins Production of greenhouse gases Scarring of landscape Contributes to climate change Bio-magnification Increased amount of landfill space Pollutes groundwater and other water bodies Energy consumed for incineration Depletion of raw materials 9/29/2016 38 EFFECT OF PACKAGING MATERIALS ON ENVIRONMENT AND HUMAN HEALTH

39. MILK PACKAGING TOMORROW 9/29/2016 39

40. THERMOFORM BOTTLE Made from Poly Lactic Acid ( PLA) PLA derived from natural corn starch. Advantages of PLA Degrades within weeks High stability Transperency Wide temperature range UV resistance Convenient Carbon footprint of PLA 2.16gm as compared to 720gm/ 500ml of serving of polyethylene FUTURE PROSPECTS 9/29/2016 40

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42.   Self-heating and self-chilling. Shelf-life time temperature indicators Micro-oven able containers Edible films and coatings Resource efficiency and light weight packaging. Bio-degradable materials Shrink wrapping Modified atmospheric packaging (MAP) Oxygen Scavengers. Better sealing techniques Bioplastics NEW CONCEPTS 9/29/2016 42

43. 9/29/2016 43 CONCLUSION Packaging necessary for extended shelf life of milk product Containers have evolved from cow’s udder to convenient and sturdy ones Packaging of milk has innumerable roles and benefits Various factors concerning package design needs to be kept in mind Packaging material differs from product-to-product Negative impact of packaging materials needs to be checked Thermoform bottles or bioplastics- future packaging material New concepts and innovations in packaging need to be developed constantly

44. THANK YOU 9/29/2016 44