Efficient and Sustainable Packaging for Frozen Food Welcome to Syntegon Technology

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Reduce Reuse Recycle. Efficient and sustainable packaging for frozen food Welcome to Syntegon Technology.

Syntegon Technology is a leading global process and packaging technology provider. Formerly the packaging division of the Bosch Group, the company, headquartered in Waiblingen (Germany), has been offering complete solutions for the pharmaceutical and food industries for over 50 years. More than 6,100 employees at 30 locations in more than 15 countries generated a total revenue of 1.3 billion euros in 2019. The portfolio of intelligent and sustainable technologies includes stand- alone machines, as well as complete systems and services. Fields of application in the pharmaceutical industry are the production, processing, filling, inspection and packaging of liquid and solid pharmaceu- ticals (e.g. syringes and capsules). In the food industry, the portfolio includes process technology for confectionery as well as packaging solutions for dry foods (e.g. bars, bakery products and coffee), frozen foods and dairy products.

About the Business Unit Food Syntegon Technology is a leading global process and Syntegon Technology supports food manufacturers packaging technology provider with 6,100 employees in project planning, development and implementation and annual sales of 1.3 billion euros. With a wide range as well as with digital solutions. In addition, customers of intelligent and sustainable technologies, Syntegon worldwide have access to a comprehensive network of Technology ensures the safe processing and packaging service specialists who support them throughout the of high-quality food products. entire machine life cycle.

The portfolio includes stand-alone machines and The following product brands are included in the port- complete system solutions for the primary and secon- folio for the food industry: Ampack, Doboy, Elematic, dary packaging of dry food products such as bars, Hansella, Kliklok, Makat, Osgood, Sigpack, Tevopharm, biscuits, bakery products and coffee, frozen food or Togum and Woodman. dairy products, as well as process technology for the production of confectionery. Content.

1. Executive Summary 4

2. Introduction 5

3. Sustainable packaging in the frozen food segment 9

4. The OEE Challenge 10

5. Creating value through reliable partnerships 12

6. Checklist: Criteria for your sustainable frozen food 13 packaging line

7. Conclusion and outlook 14

8. Contact details and links to more information 15 1. Executive Summary.

The frozen food segment covers a wide range of products – While fresh products require multi-layer packaging that offers a ranging from fruit, vegetables and potato products to fish, wide range of functionalities, a limited oxygen and water barrier suf- seafood and meat – and is growing in most regions of the fices in frozen food packaging. This is why polyolefin monomaterial world. Just like in other food segments, debates surrounding packaging films are already widely used to bag frozen products. plastic packaging and sustainability are driving innovation in Most commonly, frozen food products are packaged in pillow bags the frozen food industry. Packaging material suppliers, brand made from LDPE. owners and equipment providers are working together to reduce, reuse, recycle and even replace plastic packaging. KEY FACTORS FOR SUSTAINABLE FROZEN FOOD PACKAGING This whitepaper shares industry insights into the ongoing Brand owners can increase the sustainability of their frozen food efforts to make frozen food packaging and vertical bagging products by reducing the amount of packaging and increasing equipment more sustainable. It gives an overview of the food the recyclability of their packaging. This whitepaper sets out a markets, of different kinds of monomaterial films and show- number of options, including choosing a thinner packaging material cases how brand owners can boost the sustainability of their (downgauging), such as BOPE, selecting a future-proof pack style packaging solutions even further – without having to compro- based on recyclability and point-of-sale requirements, or adjusting mise on OEE and bag quality. A handy checklist summarizes packaging machinery and sealing technologies to thinner films. the key sustainability considerations for frozen food. CREATING VALUE THROUGH RELIABLE PARTNERSHIP Brand owners can increase the sustainability of their products MARKET PERSPECTIVES without having to sacrifice speed and bag quality by choosing the During the ongoing COVID-19 pandemic, consumers are opting for right packaging material and equipment. Having a reliable partner frozen products, which is fueling the frozen retail market1. Combi- makes a huge difference: In most cases, equipment suppliers ned with continuous growth in the food service industry, the frozen not only provide the required technology, but work closely with food market is expected to flourish. Annual growth rates of just over packaging material suppliers to promote sustainable solutions. This five percent are forecast by 2025. Products packed in bags and significantly shortens the time it takes to get a new, sustainable pa- pouches are predicted to account for more than a third of sales. ckaging concept to market. What is more, the equipment provider of your choice should also provide valuable additional services, FROZEN PRODUCTS REQUIRE LESS from retrofitting, maintenance and packaging material testing to PACKAGING FUNCTIONALITIES specialized training. The freezing process effectively and efficiently preserves the products. For this reason, the barrier demands on frozen food packaging are less complex.

1. https://progressivegrocer.com/higher-frozen-food-sales-could-last-beyond-covid-19 2. Introduction.

GROWTH MARKET : FROZEN FOOD FROZEN FOOD PACKAGING MARKET - GROWTH RATE BY REGION In recent years, food retail has been characterized by continuous (2019-2024) significant growth. The further development of retail channels, such as supermarkets, hypermarkets and convenience stores, has helped the industry to grow steadily around the world. In the frozen food segment in particular, this development lays the foundation for further market opportunities.

THE FIGURES SPEAK FOR THEMSELVES In 2019, the frozen food market volume totaled approximately 291 billion US dollars2, and market analysts expect it to grow at an annual rate of 3.4 percent (CAGR)3 by 2027, reaching around 381 billion US dollars in worth. The main driver for the steady growth is a busy lifestyle and a subsequent preference for ready-to-eat, frozen products that do not require much preparation time. REGIONAL GROWTH RATES The food service industry dominates the frozen food market, garnering a 53.9 percent share in 2019. This segment includes hotels, fast food restaurants, retail outlet caterers, hospitals and High Mid Low care facilities, among others4. The retail segment, which accounted for 46.1 percent in 2019, is recording significant growth during the ongoing COVID-19 pandemic as consumers around the world shop Source: https://www.mordorintelligence.com/industry-reports/frozen-food-packaging-market less frequently and instead opt for frozen products with a longer shelf-life5.

GLOBAL FROZEN FOOD MARKET SHARE, BY PRODUCT, 2018 (%) MORE THAN 2/3 OF THE GLOBAL VOLUME OF FROZEN FOOD (EXCL.

SOUP AND ICE CREAM) RELIES ON BAG/POUCH

PACKAGING FOR PRODUCT PROTECTION3

Frozen Ready Meals Bag/Sachet/Stand up pouches Frozen Meat Tray Frozen Fish/Seafood Other Frozen Fruits & Vegetables Source: https://www.industrialpackaging.com/blog/different-types-frozen-food-packaging Frozen Potatoes Frozen Soup Others

Source:https://www.grandviewresearch.com/industry-analysis/frozen-food-market 2. https://www.grandviewresearch.com/industry-analysis/frozen-food-market 3. https://www.grandviewresearch.com/press-release/global-frozen-food-market 4. https://www.alliedmarketresearch.com/frozen-food-market 5. https://progressivegrocer.com/higher-frozen-food-sales-could-last-beyond-covid-19 With a market share of more than 35 percent, Europe was the lar- NEW DIETS gest market for frozen food in 20196. Consumers in Germany, U.K., Potential for the frozen food industry is also evident when it comes and France show strong acceptance of long-shelf products, an at- to product range and variety. With many consumers choosing to titude which works in favor of the industry. Asia Pacific is expected forego meat, new products will appear on the menu. Good growth to show the fastest growth with a CAGR of 3.9% from 2020 to 2027, figures are expected for the plant-based food market in particular. considering that working-class people and college grads in India Market researchers estimate that the plant-based market will reach and China tend to consume more ready-to-eat food7. around 480 billion US dollars by 2024, with CAGR for 2019 to 2024 The most common packaging for frozen food8: estimated at 13 percent. It is obvious that part of this demand will ʩ Polyolefin shrink film: sealing of boxed frozen foods such be met with the help of frozen vegetables and meat alternatives.11 as pies, pizzas, cakes, baked goods, vegetables, fruit ʩ Flexible bags: pouches made from food-grade plastics, 2.3. FOCUS ON SUSTAINABILITY foils, or other food-safe materials for frozen vegetables, Plastic packaging is omnipresent – much to the detriment of nature fruit, pre-made meals, pasta and society. Fossil fuels used to manufacture traditional plastics ʩ Chipboard/cardboard: Boxing of pies, pizzas, cakes have a considerable carbon footprint and negatively impact the environment. Microplastics and leaching12, i.e. the transfer of chemicals to food or beverages, threaten the health of humans and animals. At the same time, plastic packaging essentially contributes to product protection, longer shelf-lives and less food waste, making the search for more sustainable alternatives all the more pressing. The use of plastics in packaging13 has led the industry to reassess its attitude towards this widely used packaging material, with brands around the globe vowing to make use of more sustainable solutions14. In this regard, different strategies can be observed across industries, aiming to reduce, reuse, recycle and even re- 2.2. TRENDS DRIVING THE FROZEN FOOD SECTOR place plastics. The global frozen food industry is driven by changes in consumer demand and behavior, combined with demographics and income Tesco: In 2018, the UK’s largest retailer Tesco pledged to growth. remove all hard to recycle plastics from packaging. This has already been achieved for their own brand products. By the POPULATION GROWTH end of 2020, the retailer will have removed a billion pieces of The continuous growth of the middle class, especially in Asia, will packaging from their business1. change consumer habits. According to a recent study9, the middle Walmart: The US retailer aims to achieve 100 percent recy- class in China, India, Indonesia, Thailand and Malaysia in particular clable, reusable or industrially compostable packaging for its will grow by an average of 160 million people per year. This leads to private brand packaging by 2025 and pledges to use at least a higher disposable income and improved living conditions for this 20 percent post-consumer recycled material in private brand population group, thus changing consumers’ buying habits. packaging by 20251. Aldi: The German discount retailer has pledged to use 30 LIFESTYLES BOOST FROZEN FOOD CONSUMPTION percent less material for their own-brand packaging by 2025 In future, food will not only be purchased for immediate consump- and to use fully recyclable packaging for their own brands tion. Convenience and more storage opportunities at home will by 20221. determine consumer behavior. In this regard, freezing technology Lidl: The German discounter pledges to use 20 percent less opens up new avenues. Processed foods and products that were plastic and maximize recyclability for their own brands previously unaffordable or not suitable because of storage restric- by 20251. tions can now be added to the menu. Mondelez: By 2025, Mondelez International aims to make Due to urbanization and increasingly busy lifestyles all over the their packaging fully recyclable and labelled with consumer world, the demand for frozen products plays a major role in recycling information1. consumer’s purchasing decisions. Moreover, comprehensive P&G: Procter and Gamble announced its 2030 sustainability information is available to all consumers - especially to so-called goals in 2018, including a number of packaging-related objec- millennials - via online channels and international networking. tives, such as the use of 100 percent recyclable or reusable Young people are travelling more or even living abroad, which in- packaging by 20301. creases their demand for products from other regions. Processed Nestlé: Nestlé is striving to make 100 percent of its packaging food, e.g. frozen food, can reach consumers in every corner of the recyclable or reusable by 20251. globe.10

6. https://www.grandviewresearch.com/industry-analysis/frozen-food-market 11. https://www.foodbev.com/news/five-major-trends-driving-the-plant-based-food-market/ 7. https://www.grandviewresearch.com/press-release/global-frozen-food-market 12. http://www.biomasspackaging.com/the-harmful-effects-of-bpa-and-plastic/ 8. https://www.industrialpackaging.com/blog/different-types-frozen-food-packaging 13. https://plasticoceans.org/the-facts/ 9. https://www.refrigeratedfrozenfood.com/articles/95638-how-macro-trends-drive-packaging-trends-in-frozen-food-sector 14. https://www.packagingdigest.com/sustainable-packaging/5-sustainable-packaging-trends-to-look-out-for- 10. Ibid. in-2020-2020-02-21 REDUCE, REUSE, RECYCLE RECYCLING in turn, aims to repurpose post-consumer plastic Current efforts primarily focus on reducing or recycling plastics packaging. Across the food industry, multi-layer composite mate- that would otherwise be disposed of15. In an effort to produce less rials are widely used. They assign different tasks, such as barrier waste, packaging material producers and brand owners are either protection, sealing or printing, to individual layers made from differ- pledging to use less material in the first place or to use recyclable ent materials, including PET (polyethylene terephthalate), aluminum packaging materials16. foil, PVC and PA (polyamide). These heterogenous solutions are difficult to recycle, and often require thermal recovery. REDUCING plastics involves the use of downgauged, e.g. thinner In contrast, polyolefin monomaterial packaging – such as low-den- films as well as packs that can be sealed more tightly around the sity polyethylene (LDPE), polyethylene (PE) and polypropylene product. At the same time, less material means more material-effi- (PP) bags and pouches – are fully recyclable via well-established cient packaging equipment, such as systems with a wider tolerance recycling streams. PE and PP account for more than 50 percent of range and less film reel usage. These solutions process slightly the demand for recycled resin, offering a viable option to food com- imperfect packaging material that would previously have been dis- panies eager to make a sustainable difference. carded. In some cases, plastic packaging can also be reused, as is The industry is following suit: When it comes to recycling, major the case with some deposit schemes for beverages. consumer brands like Mondelez, P&G and Nestlé have committed to making all of their packaging 100 percent recyclable by 2025, while leading retailers like Walmart, Aldi or Lidl are either pursuing “zero waste” or fully recyclable packaging approaches17.

15. https://www.packagingdigest.com/sustainable-packaging/5-sustainable-packaging-trends-to-look-out-for-in-2020-2020-02-21 16. https://www.packaginginsights.com/news/top-packaging-trends-2020-communicating-the-language-of-environmental-sustainability.html 17. https://www.packagingdigest.com/sustainable-packaging/5-sustainable-packaging-trends-to-look-out-for-in-2020-2020-02-21 SUSTAINABILITY IN FROZEN FOOD PACKAGING Replacing plastic with petroleum-free alternatives The frozen food industry already contributes to global sustainability In an effort to minimize the impact of plastic on the environ- efforts in a number of ways: Frozen products have a much longer ment altogether, entirely new, petroleum-free alternatives are shelf-life than their fresh counterparts18. The flavors, nutrients and also on the agenda. Alternative solutions include paper-based, freshness are preserved by the freezing process. Consumers can bio-based and even edible materials: easily store frozen products for a long time and can portion them according to their needs19. This helps to reduce food waste and Paper-based packaging: Paper is one of the most common contributes to global food security efforts20. packaging materials, with corrugated board accounting for almost 30 percent of all packaging used1. Paper-based pack- What is more, frozen food packaging is more sustainable than aging is the most frequently recycled packaging material in packaging in other market segments. Where multi-layer laminates Europe1 and is an ideal solution for vertically packaged dry use as many as three to seven different polymers – one for each goods, such as pasta, rice, flour, beans and cereals. Com- packaging requirement, monomaterial packaging has to do all the pared to plastic films, however, paper is less tear- and punc- work on its own. For sensitive products that have high barrier re- ture resistant. quirements, finding packaging materials made of only one polymer is a big challenge21. With frozen food products, polyolefin mono- Bio-based packaging: Concerns over the use of fossil fu- material packaging offers sufficient product protection: The barrier el-based plastic spurred the development of biopolymers requirements are much lower. As a result, the demands on the from natural materials, such as maize or sugarcane. These packaging material are also less complex. bio-based materials can be composted at industrial facilities, using the degradation process for energy recovery. While the In vertical bagging, a multi-head weigher drops the frozen prod- production of biopolymers is less energy- and greenhouse ucts into a tube consisting of the packaging material, which is then gas-intense1 than fossil fuel-based materials, it requires the sealed and cut. Sharp products, such as French fries or chicken use of crops that could otherwise be used to feed human and wings can easily damage the material. Consequently, puncture animal populations. resistant materials are essential. For this reason, petroleum-free materials, such as biopolymers or paper, are currently not a suit- Edible packaging: Albeit still a niche product, edible pack- able alternative: They neither offer the required barrier protection aging made of seaweed, potato starch or milk proteins is a and puncture-resistance nor not meet manufacturers’ efficiency viable alternative to plastic packaging. Unlike their polymer goals. counterparts, edible packaging solutions present a waste-free alternative that can either be integrated into consumers’ diets or composted at home1.

18 https://frozenadvantage.org/sustainabillity/ 19 Ibid. 20 https://www.newfoodmagazine.com/article/92610/could-frozen-foods-help-reduce-food-waste/ 21. http://polymerdatabase.com/Films/Multilayer%20Films.html 3. Sustainable packaging in the frozen food segment.

Throughout the packaging industry, the three Rs reduce, reuse LLDPE is a copolymer of ethylene and an additional, longer olefin28. and recycle are leading the way. Two Rs in particular characterize These materials are used to form, fill and seal bags of fruit, vegeta- the sustainability efforts in the frozen food segment: reducing the bles and potato products. amount of packaging and increasing its recyclability. 3.2.2. Polyethylene (PE) and polypropylene (PP) REDUCING THE AMOUNT OF PACKAGING Polyethylene (PE) and polypropylene (PP) are two very closely Minimizing the amount of plastic used to produce packaging can related polymers that are most commonly used in consumer pack- help significantly reduce a product’s carbon footprint22. The impact aging. These polymers are used to make films for stand-up bags of material efficiency is manifold: Packaging that uses less mate- like doy, doy zip and corner-seal bags for premium brands and rial is lighter, which saves carbon emissions during transport23. By protein products, such as prawns or chicken wings29. The films can optimizing material usage and transport logistics, brand owners comprise multiple layers, such as PE-PE or PP-PE structures, de- can not only reduce their carbon footprint, but can also lower costs pending on the required barrier properties and material stiffness. significantly. 3.2.3. Bi-axially oriented polyethylene (BOPE) Material efficiency can be obtained by using thinner materials, Biaxially oriented polypropylene (BOPE) film is stretched in both which is also called downgauging24. Additionally, brand owners can machine and transverse directions, producing molecular chains that reduce the amount of plastic used during the packaging process: are oriented in two ways. This results in increased toughness and Retrofits and upgrade kits are available for vertical forming, filling stiffness, as well as enhanced barrier properties to water and oxy- and sealing machines that minimize or, in the case of new sealing gen. This material is posed to replace LLDE and LDPE packaging technologies, even eliminate the free skirt. materials for frozen food products.

ENSURING MAXIMUM RECYCLABILITY 3.2.4. Recyclability The current trend is in packaging is to use monomaterial films Mechanical recycling is technically possible with all three wherever possible instead of multi-layer laminates25. Monomaterial above-mentioned monomaterials. However, packaging made from packaging – even when it comprises several layers of the same mechanically recycled materials cannot be used for food applica- material – is fully recyclable, as long as the suitable streams and tions. Furthermore, not all countries and regions have a recycling facilities are in place. market in place for each material. Globally speaking, the plastic recycling market is expected to generate a revenue of more than In the frozen food segment, polyolefin monomaterial films are al- 64 billion USD by 2024 – up from 41 billion USD in 201830. Europe ready the packaging material of choice since they offer sufficient has the most rapidly growing plastic recycling market at an annual product and barrier protection as well as being fully recyclable via growth rate of 9.1 percent in terms of volume by 202431. established PE recycling streams26. The polyolefin family includes polyethylene and polypropylene thermoplastics. They are predom- PE is the most recycled material, with a predicted annual growth inantly produced from petroleum and natural gas by the process rate of 8.7 percent by 2024. This can be attributed to three factors: of ethylene and propylene polymerization, respectively. They are the high production volume of virgin PE, high disposal rates and highly versatile, which makes them one of the most popular plastics the high recycling rate for this type of plastic32. The market for PP in use today27. recycling is also well established. With a total recycling capacity of The following polyolefin monomaterials are currently used in 1.7 million tons, polyolefins are the most commonly recycled plastic vertical frozen food packaging: in Europe33. ʩ Low density polyethylene (LDPE) or linear low-density polyethylene (LLDPE) Chemical recycling by pyrolysis is possible with PE. Since BOPE ʩ Polyethylene (PE) or polypropylene (PP) can be recycled via conventional PE recycling streams, chemical ʩ Bi-axially oriented polyethylene (BOPE) recycling is also an option. Packaging films made from chemically recycled materials can be used for food applications, which means 3.2.1.Low density polyethylene and linear low-density polyeth- these materials offer a huge potential for the establishment of a ylene circular economy. In vertical frozen food packaging, the most commonly used material is low density polyethylene (LDPE) and linear low-density polyethylene (LLDPE). LDPE is a homopolymer made of ethylene monomers.

22. https://www.packagingdigest.com/sustainable-packaging/5-sustainable-packaging-trends-to-look-out- 28. Ibid. for-in-2020-2020-02-21 29. Ibid. 23. https://packagingeurope.com/downgauging-when-less-is-more/ 30. https://www.globenewswire.com/news-release/2019/10/09/1927072/0/en/Plastic-Recycling-Market-Share- 24. https://www.packagingdigest.com/bottles/do-frozen-foods-heat-planet to-Hit-64-139-7-Million-by-2024-P-S-Intelligence.html 25. https://packagingeurope.com/the-monomaterials-challenge/ 31. Ibid. 26. https://www.plasticseurope.org/en/about-plastics/what-are-plastics/large-family/polyolefins 32. Ibid. 27. https://www.plasticseurope.org/en/about-plastics/what-are-plastics/large-family/polyolefins 33. https://www.k-zeitung.de/europa-kapazitaet-fuer-polyolefin-recycling-erreicht-17-mio-t/ 4. The OEE challenge.

While monomaterials pave the way to a more sustainable pack- 4.2.1.Film thickness considerations aging usage, they also pose specific challenges to brand owners’ When it comes to packaged frozen food products, brand owners overall equipment effectiveness (OEE). This key indicator for a can minimize their plastic consumption and thus act sustainably by single line or an entire plant’s effectiveness is based on three major reducing film thickness. This not only lowers the costs of material pillars, i.e. availability, quality and performance34. As such, OEE can per pack, but also lowers the amount of packaging tax that is due be affected on many levels: unnecessary or lengthy downtimes, in countries where such regulations apply. The use of thinner films for instance, might reduce the equipment’s availability over a given also increases the pack yield per film reel, leading to less film us- time period, while frequent scrap challenges a company’s quality age in total. From an OEE perspective, this significantly boosts pro- commitment. Speed losses caused by defective equipment, in turn, ductivity by maximizing run times and requiring fewer film changes. hamper performance. In order to boost OEE and get the most out of its equipment, any brand owner is advised to prevent or remedy Films made from the most commonly used monomaterial, LDPE, causes for low OEE, including process defects as well as unsuita- are between 30 and 80 microns thick, thereby nearing the aver- ble machinery setups. age diameter of a human hair (75 micron)37. Appropriate thickness In essence, high OEE hinges on maximum speed35 and thus flex- is necessary in order to prevent the bags from being punctured ibility. In the food packaging industry, it builds on equipment that during the packaging process as well as transport. Alternative ma- ensures high-speed packaging while remaining cost efficient. This terials, such as BOPE, offer the same level of puncture resistance implies fast format changeovers which are required for the rapid and product protection at a thickness of 20 micron – a 50 percent processing of different products and packaging materials. Besides reduction compared to LDPE with a thickness of 30 to 40 micron. adding to a packaging line’s flexibility and output, fast and easy Depending on the LDPE used, switching to BOPE can enable man- changeovers further minimize downtime, another major threat to ufacturers to halve their film thickness without compromising on convincing OEE. Easy cleaning and concepts like vertical startup product protection. Tenter frame BOPE films offer as much as twice ensure that processes continue seamlessly after any downtime – the tensile modulus and impact strength, three times the tensile and that products boast reliable quality from the very first pack. strength and puncture resistance, and 80 percent less haze compared to traditional blown film38. Thicker films of 25 micron or more OEE AND MONOMATERIALS are available for heavier packaging formats. With regards to OEE, When processing monomaterials, additional factors have to be BOPE helps brand owners increase their packaging speed signifi- taken into consideration. Mono-material are particularly demanding cantly, thus overcoming the limitations of conventional LDPE. when it comes to choosing the right sealing technology, especially in the high output range. Due to their temperature-sensitive outer 4.2.2.Sealing technology considerations layer36, the sealing window is much smaller. If the sealing times are The integrity of the sealed seams is key for product freshness. too long, materials will be damaged. At the same time, insufficient Tightly formed seals protect the products from outside contami- energy input leads to inadequate sealing. nants and extend their shelf-life. Packaging material that is made The film thickness in particular impacts the choice of sealing tech- of only one type of plastic molecule is especially prone to melting. nologies and sealing speeds. Thin films like BOPE call for pack- For safe and reliable seals, the different sealing parameters and aging machines that are adjusted to the film properties in order to machinery components need to be adjusted to the specific charac- process the material at constant speeds. This means that operators teristics of the molecule type. need to coordinate sealing parameters like pressure, temperature and time optimally, and according to each film’s properties. De- When heated, LDPE melts and begins to flow uncontrollably. Ver- pending on the monomaterial, brand owners might need to pur- tical forming, filling and sealing (VFFS) machines have to clamp chase new or upgrade existing machinery that allows film process- the material tightly during the sealing process and cool it to the ing without comprising on their OEE. required temperature. The sealing process is complex and requires careful adjustments based on the packaging dimensions and KEY CONSIDERATIONS FOR BRAND OWNERS weight of the packs. Using monomaterial films means applying innovative packaging technologies that meet the material and product requirements. Increased sealing speeds through reduced cycle times Recent innovations in the field of sealing technology enable higher Similar considerations and technological challenges apply to the speeds and reduce packaging material. This proves that sustain- use of BOPE. The material’s specific sealing requirements – lower ability does not mean having to compromise on quality, speed or heat, gentle sealing – can either be fulfilled by acquiring new ma- maximum OEE. chines or upgrading the existing VFFS equipment. Innovative seal-

34. https://packiot.com/7-biggest-mistakes-packaging-factories-make-with-oee/ 35. https://www.oee.com/calculating-oee.html 36. https://www.packaginginsights.com/news/reverse-technology-bring-mono-material-benefits-dow-and-menshen-launch-sustainable-spouted-pouches.html 37. https://en.wikipedia.org/wiki/Hair%27s_breadth 38 https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6964308/

` ing technology developed specifically for BOPE is able to achieve products displayed in freezer chests. significant OEE benefits, securing a 25 percent speed increase compared to solutions for LDPE. This is achieved via reduced cycle Pillow packs and bags are the most commonly used pack style for times, i.e. the overall process involving sealing, cooling and cutting frozen food displayed in freezer chests, including fruit, vegetables the sealed films. The sealing jaws of current state-of-the-art ma- and potato products. The food service industry also most common- chinery cut the sealing time in half by using double-sided heating. ly uses pillow bags for frozen food supplies40. LLDPE and LDPE are Cooling times are also reduced – by 30 percent – by optimizing the typically the material of choice. air-cooling system. What is more, changeovers take 20 percent less time to complete. With BOPE films and the right sealing technology, However, BOPE films are becoming increasingly popular and out- they can pack up to 130 bags per minute compared to 60 to 100 perform LDPE films in many ways. Manufacturers can benefit from bags with LDPE – a substantial performance gain from an OEE major efficiency and quality gains: BOPE maximizes the material angle. yield per film reel and achieves more consistent, higher quality seals. What is more, consumers can easily open BOPE bags with- REDUCING MATERIAL CONSUMPTIONG out the use of scissors since the cross-seams are peelable. From New sealing technologies also contribute substantially to material an OEE perspective, this material is promising given its easy pro- reduction, a key sustainability goal. New sealing technologies cre- cessing, even on entry-level equipment. Manufacturers can reduce ate reliable seams using 25 percent less material in film length. On the amount of plastic used in packaging without compromising on top of that, at two millimeters the free skirt is minimal. This reduces their premium brand image: The material offers good printability costs and material consumption even more – on top of the benefits and is highly glossy, giving it a high-end appearance. of downgauging. Increasing the effectiveness of packaging machines helps prevent product waste as well; the greater the process Protein products, such as prawns or chicken wings are often dis- stability, the fewer products are rejected due to faulty seams or played standing up in freezer cabinets. They are packed in visually extended downtime. appealing, stand-up doy, doy zip and corner seal bags made of polyethylene or polypropylene – often in combination41. Doy zip pouch- 4.2.3. Pack style considerations es are resealable, making them more consumer-friendly. However, Brand owners choose a certain pack style based on a number of these pack styles are more intricate and have higher material costs factors, including customer preferences, material characteristics, than simple pillow bags. Producing these pack styles takes longer equipment types and retail requirements39. Products that are dis- and requires more complex packaging and sealing processes, played upright in freezer cabinets and packaged differently than which reduces output rates and affects OEE.

39 https://www.packagingstrategies.com/articles/95010-frozen-foods-heating-up 40 https://www.newfoodmagazine.com/article/85261/exotic-non-seasonal-fruit-veg-frozen-food/ 41 https://www.packagingstrategies.com/articles/95010-frozen-foods-heating-up

` 5. Creating value through reliable partnerships.

No matter what monomaterial brand owners use, changing the upgrades for current technologies are done cost-efficiently, making setup of their machines while maintaining high OEE is best done sure that machine downtime is kept to a minimum. with a reliable partner. In most cases, equipment suppliers not only provide the required technology, but also valuable additional servic- SYSTEMS LIFECYCLE APPROACH es, from retrofitting, maintenance and packaging material testing to Besides the purely technical aspect of modernization, equipment specialized trainings. Because OEE requires much more than just suppliers also focus on OEE strategies, offering proper OEE con- running state-of-the-art machines: The effectiveness of a given pro- sulting along the process chain: They support brand owners more cess and packaging system also depends on the smooth interplay widely in the implementation of specific solution concepts, identify between machine and operator. Given the constant technological system weaknesses and formulate individual suggestions for im- progress and an increase in digital assets, such as digital interfac- provement. As systems rather than single machine providers, they es for quick and transparent troubleshooting (HMI), operators and coordinate equipment integration projects throughout the entire plant managers need to constantly acquire the necessary skills to lifecycle of systems. run high-end equipment. MATERIAL TESTING: TRAILING SUSTAINABLE RETROFITS AND MODERNIZATION PROJECTS INSTEAD OF ALTERNATIVES NEW MACHINERY In this respect, material testing provides room for further efficiency An OEE-conscious and sustainable equipment approach lies in adjustments: Knowing the chemical and physical properties is key upgrading existing machinery rather than purchasing entirely new to establish a material as food packaging42. The earlier a brand one. Retrofitting a packaging line with new sealing technology, for owner knows how a given material performs on the line, the better instance, caters to the industry-wide strategy to reduce or even they can adjust processes or opt for another material altogether. recycle resources – be it packaging material or expenses. Besides Across industries, equipment providers work with material suppli- turning used packaging material into new one, recycling also means ers and offer material testing, including tests on various options, preventing machinery already in circulation from becoming obsolete such as mono-polyolefin flexibles and paper. These are tested prematurely. In this regard, a comprehensive retrofitting program with regards to material processing, consumption, sealing, speed and appropriate service support are decisive factors. The benefits and quality. Packaging samples convey a realistic image of the of upgrading packaging equipment are long-lasting: modernization solution’s look and feel – for quick guidance through the wealth of helps to sustain equipment performance even after decades of possible options. Working with an equipment provider who takes a use, reducing costs that would come with ordering, installing and proactive approach to sustainability helps brand owners to shorten running new machinery. With a knowledgeable partner, technical the time it takes to bring new, sustainable packaging concepts to market.

SEAL TESTING

Sealed area Unsealed area

42 https://link.springer.com/chapter/10.1007/978-981-13-1909-9_3 6. Checklist: Criteria for your sustainable frozen food packaging line.

required? When designing sustainable packaging for frozen food products, ʩ What requirements does your transport packaging have to the four main functionalities of packaging have to be taken into fulfil? Have you optimized it in terms of pallet utilization? account: product preservation, consumer requirements, distribution ʩ What requirements does the packaging material have to fulfil and recycling. Exploring these functionalities with regard to vol- in terms of puncture resistance? ume, variance, variety and visibility helps you get the most out of ʩ What are the cooling chains and cooling infrastructure like? your packaging processes and equipment. The following checklist What does this mean in terms of shelf-life requirements? guides you through the most important considerations. Recycling Product preservation ʩ What kind of recycling streams exist in your target country? ʩ What products and segments will you use your line for? (e.g. ʩ What is the legal framework that regulates packaging in your poultry, meat, fish, seafood, vegetables, fruit, potato products) target country? ʩ How many products/how much weight do you intend to pack ʩ Are there specific packaging-related taxes? into each bag? What is the maximum weight you want to pro- ʩ Is your packaging material validated for recyclability? cess per pack? ʩ Are your customers (food service / retail) willing to pay more ʩ How sharp are your products? What level of puncture resist- for sustainable packaging concepts? Are end-consumers ance does your packaging have to offer? willing to pay more, too? Do they have any packaging-related ʩ What shelf-life is required for your product? Are you willing pledges, i.e. full recyclability or a certain percentage of recy- to reduce the shelf-life? Are you able to perform accelerated cled material? shelf-life testing? ʩ Processing and equipment requirements ʩ What requirements does the packaging material have to fulfil? ʩ The parameters volume, variance, variety and visibility are In terms of barrier protection? important when it comes to choosing the right processing and ʩ Which pack style (pillow bag vs doy bag/corner seal bag) is packaging equipment. The following questions can help guide required? you. ʩ Which material do you intend to use? Would an alternative packaging material offer the same benefits? Volume: ʩ What does retail / food service expect in terms of packaging ʩ What output do you want to achieve? Is your demand seasonal functionality? or is your annual volume stable?

Consumer requirements Variance: ʩ How will your product be displayed at the point of sale? Lying ʩ Do you want to run films at the same speed? Would you be down in freezer chests or standing upright in freezer cabinets? willing to reduce film speed if it meant using a more sustaina- What are the associated pack style (pillow bag vs doy bag/ ble solution corner seal bag) requirements? ʩ How do you convey information? What do you want to com- Variety: municate? Nutritional information? Instructions on how to use, ʩ What are your requirements in terms of flexibility? Do you store, recycle or dispose of the pack or product? intend to process different products, formats and pack styles ʩ Does a glossy or a matt finish convey your messages and on the same line? image better? ʩ What is the total cost of ownership of your equipment? What ʩ What does retail/food service expect in terms of packaging are the total costs of ownership for the different packaging functionality? How important is easy-to-open packaging for materials? end-consumers? What about portion packs? Is recloseability a requirement? Visibility: ʩ Would your customer choose an alternative pack style if it ʩ How do you want to position your product in the market? meant increased sustainability? ʩ How you do want to position your organization/operation in the market? Distribution ʩ What packaging dimensions and weight does your customer (retail and food service) require? ʩ Which pack style (pillow bag vs doy bag/corner seal bag) is 7. Conclusion and Outlook

In the context of frozen food packaging, sustainability reveals its Explore more info on our sustainable complexity: At a closer look, sustainability appears as an inter- solutions for the frozen food industry on our section of multiple factors, such as packaging materials, machine dedicated microsite. setup, product characteristics and consumer. Brand owners can Explore now therefore leverage sustainability in different ways, for example by choosing packaging material that caters to the the Rs – replace, reduce, reuse and recycle – or adjusting their machinery in accord- ance with the latest film specifics and OEE considerations. Request your free box with sample The pursuit of OEE is closely linked to sustainability benefits: bags and info on packaging equipment for Efficient processes and equipment reduce energy consumption, the frozen food industry. minimize product and material waste, and ensure a high level of Request now flexibility – making production future-proof. This may require brand owners to retrofit, if not restructure their equipment and production processes. Expert advice and support are key when it comes to sustainability without having to compromise in terms of speed, flexibility and quality. Brand owners therefore can – and should – Learn more on the latest trends in consider sustainable packaging as a multi-layered project: not only snack packaging material and equipment on the production side, but also from a planning and logistics per- during our frozen food webinar. spective. In this respect, food and equipment manufacturers who Register now partner with industry leaders early on in their journey have the most to gain. Sustainability requires joining forces with specialists who share their expertise throughout the supply chain and lead the way to a sustainable future.

In the ever-growing frozen food market, sustainability’s potential is far from exhausted: Research into alternative packaging material has gained traction, with companies pushing beyond the bounda- ries of traditional polyolefins towards easily recyclable solutions. With edible and paper packaging on the horizon, the next round of equipment and OEE challenges is already looming – and calling for close cooperation between food and technology providers alike. Sustainable packaging is far from a linear, closed-off phenomenon. It is an evolution, with the most exciting part yet to come. Contact us.

Contact details and links to more information To find out more about vertical packaging, please visit our website or contact us directly.

PIERRE HAMELINK: Key Account Management, Sustainability Strategy VFFS. Mail: [email protected]

FRANK VAN DER BEEK Industry Manager Frozen Food Mail: [email protected]

Link Website Topic: https://www.solutions4value.com/en/insights

Syntegon Packaging Solutions Business Unit Food Vertical Industriekade 43