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, proces- sing, 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,