One of the biggest challenges when designing innovative packaging that saves food is looking at the features of the pack that could potentially waste food through poor design, or save food from being wasted through good design.
Questions to consider at the design stage include:
- Is your packaging fit for purpose?
- Is it Functional?
- Is it Accessible, Openable & resealable?
- Can the pack minimise food loss and waste?
- Can the design and the material selected extend the shelf life of the product?
With so much focus right now on plastic and packaging waste, we must not lose sight of the key role packaging plays in the protection of a product. Inadequate packaging that results in wasted food defeats the whole purpose and is a much bigger waste of resources and environmental impacts. Packaging needs to be designed to ensure that a product is protected, preserved, container and transported all the way through the value chain from production until it is used in the household.
The challenge for packaging technologists & engineers is to be able to design optimum packaging with the lowest environmental impact at the start. It is about finding the balance between meeting food waste targets, at the same time as achieving packaging waste targets.
If the balance is tipped either way it will create unintended consequences which could see overpacking (wasting packaging materials) or underpacking (wasting food). Finding the perfect balance can be challenging and requires technical knowledge and understanding of packaging design.
Looking at some of the Save Food Packaging winners in the 2024 round of the Australasian Packaging Innovation & Design (PIDA) Awards two packs stand out for incorporating a high number of Save Food Packaging design principles; both have looked at finding the balance between food waste and packaging waste through better design at the start.
When designing packaging for potatoes the pack needs to protect the product from spoilage and damage through transportation. It also needs to be designed with air circulation to help preserve the potatoes for longer periods without deterioration. Effective communication for how to store the potatoes is also important as the ideal scenario is to store them in complete darkness and a cool environment once in the household. As a part of the nightshade family potatoes contain the toxin solanine and if exposed to light and not stored properly can spoil quickly.
Dutch Cream Potatoes Red Gem have designed an FSC certified recyclable pack that has a unique popcorn box closing mechanism. The pack design creates a flume-like entry when potatoes are dispensed and is easy openable and reclosable to extend the shelf life of the product.
The innovative design is pivotal in shifting from traditional non-recyclable plastic bags to a more environmentally friendly, fully recyclable cardboard option, that extends beyond simple containment.
Cardboard inherently blocks light, which is crucial for potatoes that are prone to greening when exposed to light. This characteristic significantly extends the shelf life and preserves the quality of the potatoes by preventing the natural greening process.
The sturdy construction of the box minimises damage and bruising during transportation and handling and ensures that the potatoes remain in pristine condition from the farm to the retailer. The interlocking design of the box not only facilitates easy stacking for eye-catching in-store displays, but also serves as an effective storage solution for consumers. This box design keeps kitchen pantries tidy and preserves the quality of the potatoes by protecting them from light exposure, which can lead to spoilage.
One of the unique features of the pack is the controlled dispensing whereby the potatoes can be easily removed one at a time or in controlled quantities, which helps in managing portion sizes more effectively. This controlled dispensing feature is crucial for households looking to cook precise amounts, reducing excess that might otherwise go unused.
The ‘popcorn box’ top opens widely, creating a flume-like entry when potatoes are dispensed from the weighing machine. This design facilitates the smooth filling of the box, reducing the likelihood of impact damage as the potatoes enter the box, thereby maintaining their integrity and appearance.
In addition, the communication of storage ideas is linked to the website via a QR code on the pack. The consumer information includes a range of recipes specifically designed for Dutch Cream potatoes, known for their creamy texture and rich flavour. This encourages consumers to try new dishes and use the potatoes more comprehensively, which can significantly reduce food waste by providing ideas for using every part of the potato, including skins and smaller cuts.
The website also includes proper storage details on how to store the potatoes to maintain their freshness for as long as possible, thereby preventing premature spoilage.
This comprehensive approach to packaging design not only contains and protects the product but also significantly contributes to reducing food waste and spoilage by addressing common issues faced during the distribution and retail display stages. By integrating these features, the packaging ensures that the Red Gem Dutch Cream potatoes reach consumers in optimal condition, enhancing overall satisfaction and reducing waste due to spoilage or damage.
Don Smallgoods have designed an Australian-First intuitive and innovative flow wrap (envelope pack) with reseal functionality for the smallgoods industry called Deli-Cuts. The packaging provides consumer convenience, communicates to consumers intuitively for the easy to open and close features, provides product visibility, minimises the mess of liquid in the pack and is a mono material lightweighted packaging solution that does not compromise food quality and freshness.
Traditionally packaging in the smallgoods category is conventionally thermoformed and is not resealable and the new flow-wrap solution is a first for this region.
Research says that Reseal functionality is a consumer’s number one tension when it comes to smallgoods packaging, followed closely by bulky packs; lack of sustainable options; visibility of the product itself and the presence of free liquid in the pack. (BrandTonic Nov 2022)
The intuitive reseal functionality preserves food freshness, sealing in moisture and flavour, thus reducing wastage due to dry, spoiled product. It enables consumers to retain the product in its original packaging for fridge storage, thus product information such as use by dates are visible to consumers. It also prevents wasteful double packaging through use of cling wrap and therefore reduces packaging disposal.
The secondary seal and reseal functionality is secured on the reverse and provides clear intuitive and visual instructions on how to open and close the pack.
Whilst consumers want to see the product, there is a tendency for Ham and Bacon to lose their pink colour when under bright lights. To resolve this, the design has enabled the product to be viewed on the reverse side of the pack.
On cooling pork products, it is normal for products to release some moisture. This can be seen as free liquid in the bottom of packs. To alleviate this, they have placed the products onto an aqueous board which will absorb any free liquid.
The future of the smallgoods category is all about less waste, less packaging waste, less food waste, and less energy waste. This innovation addresses these issues through food preservation, less plastic, and less energy utilisation.
The new flow-wrap pack uses 50% less plastic than the current DON 100g Fillers Range (10.2g vs 4.9g plastic) and 69% less plastic than current competitors 100g Fillers range in market (15.8g vs 4.9g), therefore reducing the amount of plastic in the market.
The more compact pack, improves pallet efficiency by 150%, moving from 144kg per pallet to 222kg/pallet. The cascading effect is the improved efficiency in transportation and reduction in emissions as materials move between supplier to manufacturer and manufacturer to retailer DC and DC to stores. The material being utilised in the new packaging design is CEFLEX compliant and recyclable through alternate pathways, such as the council trial program and return direct to recyclers. The internal board is kerbside recyclable and complies with Australian pulpability testing.
By using the five Save Food Packaging design principles in their New Product development process, both Dutch Cream Potatoes Red Gem and Don Smallgoods have developed unique, intuitive packaging that can play a significant role in minimising food loss and waste from farm to fork.
Nerida Kelton FAIP
Executive Director-AIP
Vice President Sustainability & Save Food – WPO