Advances in aseptic dairy packaging

THE surge in demand for packed food products is driving growth in the packaging industry, with India and China possessing especially huge potential to thrive due to factors such as investments from multinational corporations, the development of rural areas and the growing affluence of their citizens. To identify how to best meet the demand, we need to first examinethe reasons driving it.

First and foremost, the living environment in Asia is changing. Work is increasingly hectic, families are growing smaller, more women are joining the workforce, and as such, time is becoming a premium. The value of convenience has never been higher, with packed food products surging in demand as they are able to offer time-poor individuals a convenient solution.

With living standards getting higher as a result of rising affluence, consumers now want their food to be fresh and healthy as well. These factors are influencing packaging solutions and brand owners are capitalizing on the opportunity to offer more than just protection and convenience in packaging; they are also working on incorporating brand awareness and product identity as they look at offering product differentiation in healthy and fresh options for consumers.

An example of how convenience and the growing trend for healthy eating have influenced packaging solutions is the growth of aseptic packaging. An aseptic package is a laminated structure comprising an outer layer of polyethylene, paperboard, tie layer, aluminum barrier, tie layer and a final inner layer of polyethylene. The growth of aseptic packaging has been driven by the success of the Tetra Brik system for liquid cartons –most notably with dairy products.

Since 2008, Asia has accounted for almost 80% of the global growth in the use of aseptic packaging. China alone accounted for slightly under 50% of the market for UHT white milk. In 2011, dairy products accounted for more than half of aseptic packaging demand worldwide, and this is expected to continue growing, especially in the packaging of liquids and semi-solid foods: dairy products, e.g. flavored milk, creams, desserts, yogurts and coffee creamer; fruit juices, sports and energy drinks; and sauces and soups.

Packaging integrity

In recent years, developments around aseptic packaging such as pack shapes, sizes and type of closures, have been a result of marketing. However, the fundamentals behind the packaging of liquids and semi-solid foods remain unchanged. Good packagingrequires proper selection of materials to ensure zero leakage of the contents from the package. Package toughness and seal integrity are among the key requirements for this segment.

To rise to the challenges of this growth opportunity, Dow Packaging and Specialty Plastics (www.dow.com/ /packaging) has created tailor-made solutions for aseptic packaging offering low density polyethylene resins. In addition, the company has also developed metallocene-linear low density polyethylene polymer (m-LLDPE) resin produced via proprietary INSITE? technology: ELITE? 5815 that is a perfect fit running at high speed extrusion coating line. The product is designed to offer excellent low temperature seal initiation, ultimate seal strength, hot tack strength and good taste and odor performance. The recently launched developmental m-LLDPE resin, XUS59900.99 by Dow is also designed for running at medium speed extrusion coating line with reduced neck-in.

As a key part of Dow’s broad line of high performance resins, PRIMACOR? copolymers offer excellent adhesion to polar substrates and metal foils, tear and puncture resistance, as well as added benefits of low moisture, liquid and grease transmission. This is needed in the construction of aseptic packaging which comprises polar and non-polar substrates.

For increased versatility and exceptional sealing, AFFINITY? polyolefin plastomers are well suited for extrusion processes. The exceptional toughness of these products makes them an excellent choice for the down gauging of coextruded films as well as outstanding sealing in terms of lower seal initiation temperature resulting in faster packaging speeds thereby increasing productivity and profitability.

Plastics from Dow provide a desirable balance of properties for high performance films such as multi-layer co-extrusions or laminate structures. Many of Dow’s products are used as the critical sealant layer, providing a broad packaging window and high seal strength while the polymers may also be used as a toughness layer buried in the structure. Dow’s products offer opportunities for cost-effective processing, whether it is blown and cast film co-extrusion, extrusion coating, or lamination of monolayer and co-extruded films to barrier substrates.

As the market for food packaging in general, not just aseptic packaging, grows and evolves, innovation will be the differentiator for any organization. From snack food packaging to individually-wrapped sliced cheeses to regular and pre-marinated meats to stand-up pouches for a wide variety of foods, beverages or personal care, Dow is at the forefront of new developments in the food and specialty packaging films. One of the world’s largest producers of plastics used in food packaging, Dow’s market-specific expertise and innovation gives you the advantage as the market grows and evolves.

* Jayne Wong is marketing director, Food & Specialty Packaging, APAC at Dow Packaging and Specialty Plastics