expanding exports with food processing technology & packaging systems thomas dunn flexpacknology...

Expanding Exports withFood Processing

Technology & Packaging Systems

Thomas DunnFlexpacknology LLC

July, 2012Central Philippine

University

Food Technology: Gearing Up for Exports

What is Success?

• WHAT: Increased exports• WHY: Increased national capital↑ Jobs↑ Wealth↑ Economic demand

• How long: Long term SustainabilityEconomicSocialEnvironmental

HOW: Food Technology!

What is that?

First: Food Science is

The study of foods’ Makeup Chemical Physical Biological/

Microbial

Decline Chemical Physical Biological/

Microbial

Processing Chemical Physical Biological/

Microbial

Food technology is the application of the following to Food Science

For the Safe Use of Food!Se

lecti

on

Pres

erva

tion

Proc

essi

ng

Pack

agin

g

Dis

trib

ution

Source: Institute of Food technologists

Beginning—Middle—End

END: Distribution

MIDDLE: PreservationProcessingPackaging

BEGINNING: Selection

Gearing up for Exports

Begin with the End in MindCovey’s Successful Habit

#2…

Literally:The distribution

system• Product Destination • Product Quality @ Destination• Product Safety @ Destination • Product Demand @

Destination • Product Itinerary to

Destination

Gives Specification to:

PreservationProcessingPackaging

Gives direction for:

Selection

Distribution: Destination

From Distribution comes Direction For Selection

US, Western Europe, Japan

• The demand for Consumer packaged goods (CPGs) is well established.

• Cultural pressures influence priorities– Convenience– Healthy Life Style– Perpetual snacking– Mix up Global cuisine

Ready for imports

Western Pacific• The growth of Middle

Class drives demand for CPGs.

• Area is the source of “exotic fare”.

Opportunity: Global exports Internal/Regional

growth Economic dynamics*Slow

growthFast

growth

* Economic opportunity:Developing Countries#

Top52% with >$8/day

Middle39% with $2-8/day

Bottom9% with <$2/day

2.7 billion people in developing countries:

• Concerned about safe & healthy food (children)

• Live in remote areas,

• Shop traditional stores

• Buy for one day

Wor

ld P

opul

ation

#TetraPak(2012) ref. Prahalad(2004)

From Selection comes Direction For others

Selection

Preservation

Distribution

Processing

Packaging

Value Addition Opportunity

Processed in the PhilippinesSelection Preservation

/Processing Packaging

Tropical Fruits

Healthy Snack

Thermally Stabilized

(Value-added)Product of the Philippines

Processing Research

• Center for Advanced Processing and Packaging Studies (CAPPs): http://fst.osu.edu/capps/index.htm

• Institute of Food Technologists– Food Technology Industrial Achievement Award

• Processing/Packaging Processing Systems (2009 and 2010)

• USDA National Institute of Food and Agriculture (NIFA)– $25Million study to strengthen food safety

• Studying human noro-viruses across the food supply chain• Design effective control measures • Reduce the number of virus-caused foodborne illnesses

Advances in Processing

• Thermal Processing– Microwave Assisted Thermal Sterilization

• Continuous Flow (North Carolina State University)*

• Prepackaged (Washington State University)*

– Pressure Assisted thermal Sterilization• Ohio State University• National Center for Food Science and Technology

• Non-Thermal Processing– High Pressure Processing (Commercial)– Pulsed Electric Field (Commercial)*IFT: Food Technology Industrial

Achievement Award

“ Fresh Prepared” Food

• Minimally processed food– Healthy life styles– Convenience– Sustainable sourcing and product life

cycle

Packaging & Sanitation Enable “Fresh Prepared” Food

• Sanitation– Good manufacturing practices– HACCP– Global Standards

• Packaging– Contain– Protect & Preserve– Distribute– Inform/Sell

Taken to new levels of excellence

Case Study: I

• Stand up pouches with fitmentsSolutions in search of a problemAvailable for decades

Gualapack CheerPack

Same food: new opportunity

• Convenience for time-poor mothers of toddlers

Traditional No glass chardsLess messProcess - Challenging

Reclosable optimized process

Same Food: Distinctive Package

Jar Cup Pouch

Material Glass jar/metal cap

Foil laminate lid/ barrier plastic

cup

Foil laminate/ plastic

fitment & capReclosable Yes Additional cap YES

Processing Thermal Thermal/Aseptic Hot fill/Thermal

Dispensing Assisted Assisted Self

Distinctive Package: Enhanced Experience

Remaining Possibilities

• Expand high acid-hot fill/low acid-thermal– Continuous Flow Microwave

– High Pressure Processing

– Pulsed Electric Field

• Develop aseptic form/fill/seal

• Tropical fruit purees

• Low price point/traditional distribution

Case Study: II

• Global Fresh Foods (US pat No. 8,187,653 )

Smart Packaging:Multi-tasking

Component FunctionGFF Service Module Sum of these parts/temperature

controlPallet Basic transport unit/Cube shipping

container Product Stored in rigid totes

SAF-D Sealed Enclosure Flexible controlled atmosphere packaging

GFF Blue Box Convert residual O2 to H2OSmart Packaging:Team Player

Impressive Results

• 30+ days shipping/storage– 14 Day ocean transport– 14 day retail shelf life

• Green Supply Chain– CO2 emissions/lb: 99%

– Recycled content corrugated– Reusable packaging components– Natural gases/no preservatives

In Summary

• Packaging is a critical part of food technology

• Food technology involves other disciplines

• Packaging must work with these other parts

• There are always new jobs for packaging to do!

• Preservation & processing drive packaging.

• Begin with Food Science

• End with food safety

Thank you!…questions?

www. flexpacknology.com tdunn@flexpacknology.com