Trends of Food Packaging &

Packaging Technologies
in Japan and the World
October 2013
Mitsuhiro Sumimoto
Registered Engineer (No.15790, IPEJ)
President & Chief Consultant
E-mail: sumi1901@jcom.home.ne.jp
SUMIMOTO PACKAGING CONSULTANT OFFICE


1
Agenda
1. Trends of food and beverage manufactures in the world
2. Major trends in Food Preservation Technology
2-1. Retort Food
2-2. Aseptic Packages
2-3. High-pressure treatment sterilization
2-4. Food filling packaging in a clean environment
2-5. Use of active oxygen
2-6. Chilled distribution
2-7. Freshness keeping packaging
2
3.Application of renewable energy for production of packaging
material
4. Trend of new packaging for the future
5. Latest topics of packaging
Innovative packaging is always necessary in the
packaging industry.
1) Society and our lifestyles are constantly changing.
2) It is important to respond to these changes.
3) Packaging contributes to enriching our lives.
Innovation:
1) Packaging technology
2) Shapes
3) Concepts
4) Software
5) Management
technology
6) Others
Save Foods
Sustainability
Storefront effect
Security and
safety
Cost performance
Traceability
3
4
1. First priority is to meet the needs of your clients and consumers.
a. Business model of simple production and supply has
already ended. As more and more people in the world
are becoming richer and their life style is changing , their
needs for products are becoming more diverse and
demanding.
b. What is Important is that the product stands out at the
store and the product information is clearly described on
the face of the package so that the consumers can
understand the product well.
c. Thus, what is necessary is to arrange the package
design and size in accordance with the situation that
consumers eat or drink the product .
Production capacity also needs to match the demand.
5
2-1 Retort Food
Curry
Seasoned sauces for cooking

Pasta sauce

Retort
In Japan, 45% of retort food produced are curry products.
6
Tons
Thousand
boxes Tons
Thousand
boxes
1

Curry

144,941

22,211

9

Mabo Tofu
sauce

6,482

1,096

2

Seasoned sauces for
cooking

42,104

6,764

10

Seafood
products

5,339

594

3

Pasta sauces

41,171

5,087

11

Cooked meat
products

3,932

514

4

Seasonings and sauces

35,774

4,335

12

Agricultural
products

2,904

455

5

Ingredients for
Kamameshi (Japanese-
style pilaf)

14,161

2,259

13

Hashed beef

2,518

452

6

Soups

14,033

2,085

14

Meat sauce

2,467

438

7

Rice

13,648

1,924

15

Stews

2,207

297

8

Stewed mixture of meat
and vegetables

12,036

1,876

16

Others

10,980

1,709

Total

317,868

46,541

Retort Food Production Volume in Japan (2012)
Retort
7
Retort Packages:
1. Pouch
2. Stand-up Pouch
3. Tray
4. Paper Carton
When eating:
1. Heat in Boiled Water ---- Heat without opening
package
2. Heat in Microwave -----
1) Cut part of package and heat in microwave
2) Self-venting type (Heat in microwave without
opening the package)
Retort
8
Package specifications for soft packaging material
1. Specifications that include aluminum foil
PET/print /ad/Aluminum/ad/CPP
PET/print/ad/Aluminum/ad/PA/ad/CPP
Retort
9
2. Specifications not including aluminum foil
1) PET/print /ad/PA/ad/CPP
2) PET/print /ad/PA/ad/CPP (PP/white PP/PP)
3) PA/print/ad/PA/ad/CPP
4) PET/print/ad/SiOx (or Al2O3) PA (PET)/ad/CPP
5) PET/print/ad/white PET/ad/CPP
Retort
10
Total Volume of Retort Food
Source: www.allied-dev.com
Retort
Unit: ton
Year
11
1. Cooked foods
Curry (beef, chicken, pork), stew (cream, corn, tomato), hashed beef,
soup (corn, potage, chicken, vegetable), pasta sauce (meat sauce,
cream sauce, pepperoncino), cooking sauce (demi glace, white sauce,
Chinese blended seasoning), kamameshi (Japanese pilaf) ingredients,
Chinese stir-fried meat and vegetables, mabo tofu, donburi (rice bowl)
ingredients, oden stewed vegetables
2. Processed meat products
Hamburger, meatballs, yakitori (grilled chicken), chicken in oil, corned
beef, sausage, subuta (sweet and sour pork)
3. Processed seafood
Tuna marinated in oil, shrimp stewed in cream sauce, unagi (eel)
grilled in sweet soy sauce, sanma (Pacific Saury) grilled in sweet soy
sauce, saba (mackerel) stewed in miso sauce
4. Rice food products
Sekihan (sticky rice steamed with azuki beans), flavored meat and
vegetable rice, flavored beef rice, ketchup-flavored chicken rice,
flavored chicken rice, white rice, okayu (congee), zosui (rice porridge)
5. Other food products
Zenzai (sweet red bean soup), baby food, liquid food
Reference material
Retort
12
Allied Development Corp.
CLP Industries, Ltd
Retort Food
Retort
13
http://www.hisaka.co.jp/vital/food/?c=zoom&pk=4
Retort cooker: Hot water spray type
Uniform sterilization
temperature dispersion
Retort
Homogeneous heating
Nozzle location in processing tank
Spray nozzle image
14
1. Retort soup is already being exported from South
Africa to Europe.
2. Food in retort pouches can be more widely
exported.
(Stand-up Pouch & Microwavable Pouch with self-
venting)
3. Investigate market of export destination (types of
food favored, quantity per pouch)
4. Easy-open pouches will be increasingly important.
(Accessible design)
5. In cases of long term preservation such as 5 years,
packaging material with aluminum foil is used, and
normally, either material with aluminum foil or clear
high-barrier is selected depending on the product.
Retort
15
About 300 billion packs were filled using aseptic filling
worldwide in 2012.
Milk and other dairy products, fruit juice, nectar,
juices, tea, and other beverages are the major market,
and there is also market for soups, sauces, tomato
products, and baby food. More than 30 companies in
35 countries around the world provide aseptic filling
systems.
Further growth is also expected in the pharmaceutical
and cosmetics industries.
Source: Report issued by Zenith International Global Aseptic Packaging Report
2-2-1. Global market for aseptic filling packaging products
2-2. Aseptic Packages
ASP
Market scale---Global Aseptic Packaging Market
86 billion liters, 187 billion items (2008)
113 billion liters, 265 billion items (2013)
----- Zenith International and packaging experts Warrick Research
The quantity has grown at an annual rate of 6%, and 13% in Asia.
- The market is largest in West Europe and Asia. Particularly in West
Europe, there was a marked growth for PET bottles for beverages.
There is a demand for containers with added value.
The total cost and profit of operations and the flexibility of the
system are essential.
Milk and milk beverages: 45%, Liquid paper containers: 75% share
Pouches and PET bottles are growing, and this trend is expected to
continue for a while.
Aseptic filling system:
More than 11,000 in operation with systems supplied
by more than 30 companies.
16
ASP
17
2-2-2 Global expansion of asepsis packaging technology and
expansion of target products
(1)Spreading of beverages
(2)Spreading of processed food and chilled distribution
(3)Spreading of dairy products
Aseptic and Asepsis packaging market is expanding steadily in the global
market for beverages, food, pharmaceuticals and medical supplies.
The global aseptic filling packaging is forecast to grow to a $35.8 billion industry
with an annual growth rate of 9.1% by 2015. (35.8 billion dollars = Approx. 3
trillion yen)
Expansion of uses
(1/2 of total is for beverages and in addition to beverages and food, it can also
be used for bio pharmaceutical products.)
Superior cost effectiveness (store at room temperature, room temperature
distribution)
Convenience
Growth in Asia, Brazil, and developing countries
(Delays in building chilled network, store at room temperature, room
temperature distribution)
1) World population: 9 billion people
2) Secure and save food
ASP
18
Yogurt
Cream
Milk
Smoothie
Nectar, fruit juice
Water, soy milk beverage
Global expansion of asepsis packaging technology
and expansion of target products
Sterilization technology and packaging
technology (shape, filling machines, software,
etc.) have contributed greatly to the
expansion of asepsis packaging technology
Aseptic & Asepsis
ESL/Ultraclean
ASP
Hydrogen peroxide, peracetic acid
ray (gamma ray), electron beam (EB)
High-pressure sterilization
Active oxygen
19
Heat
sterilization
Steam/ Hot water
Chemical
sterilization
Ethylene oxide gas
Physical
sterilization
Ultraviolet ray (UV)
Sanitization
Filtration (ceramic filter)
Cleaning
Various sterilization methods
Reference
material
ASP
20
http://mtrainier.jp/about/
Aseptic Packages in Japan
ASP
21
Moriyama Milk Industry: 400 yen (not incl. tax)
Flavors of Cafes Series 3 types
Expiration date: 180 days (Cocoa 1000)
Dai Nippon Printing:
L aluminum (Aseptic)
490 yen (1000ml)
540 yen (1000ml)
Doutor Coffee
TopValu
Corn Cream Potage 900g
198 yen
(900g)
ASP
22
A beverage that contains vegetables and living lactic acid bacteria
http://www.otsuka-chilled.co.jp/product/yasainosenshi/index.html
Beverage that has 0% milk component and includes living lactic acid
bacteria
http://www.otsuka-
chilled.co.jp/yasaino/index.html
One bottle contains 50 billion living lactic acid bacteria
The sterilization process of raw
material vegetables is set in CCP.
Lactic acid bacteria are added to
sterilized vegetable juice and
fermented, then the bottled are
filled with the juice cooled.
Glass bottle
Chilled distribution
Expiration date (30 days)
ASP
23
First product in Japan to obtain the Food for Special Dietary
Uses (General Nutritional Food) label approval. A liquid food
with a mixture of 5 types of trace elements (Zinc, copper,
selenium, manganese, chromium) and dietary fiber.
http://www.askul.co.jp/review/1163412/
Aseptic filling packaging
Nursing Care Food
http://www.niceday-
kenko.net/shop/g/g9026718/
ASP
24
http://ichiban-
foods.jp/products/list.php?category_id=184&utm_source=google&utm_medium=cpc
&utm_campaign=A%EF%BD%84Words
7g 30 sachets/month 6,300 yen
N-acetyl-glucosamine, proteoglycan mixture
Contains 500mg of N-acetyl-glucosamine
Drinkable hyaluronic acid
Moisturizing drops
New Aseptic Market
<Health Conscious Beverages>
ASP
25
Miyajima Shoyu: Straight Udon Soup and Chanpon Soup
To make Udon soup, dashi broth is extracted from
bonito flakes and Konbu seaweed. To make Chanpon
Soup, broth is made from pork bone, chicken bone,
and fragrant vegetables.
Sterilized for 5 seconds at 135C under pressure.
Fill in aseptic packaging material in a clean room.
Aseptic packaging material is sterilized by
irradiating it with gamma rays.
Asepsis for Liquid Seasoning
ASP
26
ASP
Aseptic filling machine for pouches
27
Examples of Aseptic Filling Product Pouches
ASP
Consumer pouches
Big content pouches and BIB
28
Example of an Aseptic filling
packaging machine for pouches
Pre-Pouch method: Put in external bag and sterilize
pouch with gamma rays. The external bag is sterilized
with hydrogen peroxide in the stockyard.
Capability: 60 to 80 pouches/min. (160g)
High viscosity food with solids (Size of solids: 10 to
15mm per piece)
Filling nozzle: Piston measuring type plunger nozzle
ASP
29
Individual portion LL Cup Soup Corn Chowder 180g
Clam Chowder 180g with solid ingredients that can
be heated in the microwave.
Hearty Hot Soup for Women
Cups
http://news.nissyoku.co.jp/Contents/urn/newsml/nissyoku.co.jp/20121109/KINBAR
A20121102020301304/1
Preservation method:
Refrigeration required
(10 or lower)
Expiration date: 60 days
Meiraku Group
178 yen (incl. tax)
ASP
30
40g 100 yen
Expiration date: 18 months
Secret flavoring of Curry Shops
Saffron rice powder
http://www.sbfoods.co.jp/products/catalog/pr
oducts_detail.php?GDSCODE=11624
S&B Foods
135.1g, 250yen
Expiration date
12 months
(Unopened)
Popular Restaurant Series
Cream Sauce with Four Types of
Cheese
Aseptic filling
packaging
pouch
ASP
31
Volume: 300ml Volume: 300ml
Kanto-style soba soup Kansai-style udon soup
http://www.marutomo.co.jp/mobile/shouhin/tuyu/index.html
Content: 100g2 bags
http://www.marutomo.co.jp/shouhin/guro/guro5.html
Sanuki-style
Bukkake Udon Soup
Stand-up Pouch
126 yen
Marutomo Co., Ltd.
Aseptic
pouch
http://www.marutomo.co.jp/
ASP
32
Trends in aseptic filling food in Japan
Dairy and
fat
Fruit juice,
fruit
Drinks Western-style
sauce, soup
Dashi,
sauce
Prepared
food,
ingredients
1970 Cream
portions
Bag-in-Box

1980 - Fruit juice
- Fruit for
yogurt
Coffee,
juice

1990 PET
bottle,
cup
drinks
Western-style
soup
Natural
dashi
soup
(BIB)
Rice
2000 - Pasta sauce
with solids
- Cold soup
- Base sauce
for cooking
Solid
Aseptic
beans
2010
2020
ASP
33
Elvir, belonging to the Bongrain Company, a global
leader in dairy products processing
Cream is UHT treated
Spouted flexible packaging (Alcan Packaging (Amcor))
Spout (IPN)
pH neutral
120 days room
temperature
ProAseptic Technologies
Spain
Sealed Air Corporation
In-line Electron Beam
Advanced Electron Beams
http://www.aeb.com/

Advanced Electron Beams: Have results with British Fresh Milk
(Aseptic stick pack). Gualapack provides Cheer Pack Asepsis
using AEB System.
Guala Pack S.p.A.
EB (Electron Beam)
sterilization device:
34
5-(2)
1
2
3
35
28 to 40 kGy
In-line
Sterilization
Electron Beam Sterilization
Europe
Will this be start of the age
of EB sterilization?
5-(2)
36
http://www.hitachi-
ies.co.jp/pdf/voltage/2011/201107_1.pdf
EB Bottle Sterilization Machine
SHIBUYA KOGYO CO.,LTD.
Shibuya Kogyo delivered an EB sterilization method aseptic
filling system to Hokuriku Coca Cola Bottling (Tonami Plant).
500 ml PET bottles at 600 bpm
This is the first time in the world for a Coca Cola Plant.
Scheduled to be able to handle 280 to 2 liters. Space saving
compared to existing lines.
http://jp.hamamatsu.com/resources/products/etd/jpn/html/ebengine_001.html
Hamamatsu Photonics
5-(2)
37
Insonification to atmosphere
Insonification
of electron
Transportation velocity:
Aseptic filling packaging system overview
1. Filling speed: 120 pcs/min
2. Spout and cap size: 8.6 mm
3. Pouch size : 50 ml to 150 ml
4. Both side gusset and bottom gusset pouch
5. Compound lamination film: Regardless of whether or
on aluminum foil is used.
6. The time it takes to switch sizes is shorter.
1. Product bag supply method
2. No chemicals used
3. Operates at room temperature
4. Possible to save and control energy
5. Operating conditions can always be reproduced
6. Very efficient
38
Pro-Aseptic Technologies: Delivered FFS (form, fill and seal)
Aseptic filling packaging machine for pouch type products to dairy
manufacturer in Spain and France, Elle & Vire. With two Pro-
Aseptic Pro-A2 Spout Stand-up pouch each, can product 6,000
pouches/hour. Shelf-life: Room temperature 180 days
Pouches:
- Convenience
- Light
- Easy to carry-on, to drink and
reclose.
http://www.proaseptic.com/ing/asepticas_ing.shtml
http://www.proaseptic.com/ing/nuestra_empresa_ing.shtml



Various products: Spout Pouch
39
Dairy Stix: Semi-skimmed milk (UHT)
Long-life & UHT Milk and long-life milk has been sterilized by being heated at
temperatures above 135C for 1-2 seconds. UHT milk has a storing shelf life of
between 6-9 months
- Convenience
- Light weight
----- 50% reduction from existing plastic mold cups
Transport efficiency ---- 40% space saving
- Easy open - Room temperature distribution, 6 month
storage
Single Source Limited
Received Environment Award
Member of PortionPack Europe (PPE)
http://www.singlesourceportions.com/index.php/about/
Foodservice
Packaging
Association
Milk in a stick
Worlds first aseptic stick milk
Various products: Stick packaging
40
Compliance with ISO and the EHEDG standards
Our equipment has been validated by the CTCPA Laboratories in
France -Technical Centre for the Preservation of Agricultural Products-
of the European Community.
A-300/1 A-300/2 A-300/3
1 row 2 rows 3 rows
1500 ml 1000 ml 250 ml
Cycle 35 cpm 40 cpm 50 cpm
Pouch/min. 35 ppm 80 ppm 150 ppm
Bossar pouch aseptic filling system
Reference
material
41
42
Bottle mold
Sterilization of
exterior and
interior of bottle
Aseptic
Water
Rinse
Content
filling
Content
(Drinkable
water)
Heat
sterilization
Seal
Steriliza
tion
Cap
Positive
pressure
air
HEPA
Filter
Products
PET Bottle Aseptic Filling Packaging System
Aseptic chamber
ASP
43
Comparison of environmental burden in Aseptic, Retort, Frozen packaging
Reference material
Comparison of consumption energy and emissions of CO2 through
production of packing material, filling process, transportation and
storage process of 1000 bags of 200g pouch of each method.
<Transportation> 4t truck, 100km
<Frozen storage> -30, 1W
*Freezing process by electricity is
included in filling operation.
Consumption energy Emissions of CO2
Aseptic Retort Frozen Aseptic Retort Frozen
Storage
Transportation
Filling process
Material production
Calculating condition:
<Packaging material>
Aseptic: PET12/AL9/PE60
Retort: PET12/AL9/CPP60
Frozen:PET12/VM-PE40
Storage
Transportation
Filling process
Material
production
Aseptic Blow Fill (Airstar): GEA Procomac (Italy)
Switched from conventional peracetic acid to hydrogen
peroxide.
Worlds First Rotary Aseptic Blow Molding Machine.
Obtained a letter of non-objection (LNO) from the FDA for
low acid shelf-stable products.
Operate for beverages and juice in Poland: Production base and
convenience of room temperature transport
Sterilize Pre-Form, 48,000/hour, reduce energy used, reduce
operators
PET bottle
44
ASP
45
Tetra Top
ASP
46
Promoting the use of supercomputers
For complex design treatment, the design software
has become more expensive but there has also been
an increase in memberships for the shared use of
design software.
http://digitalcontext.se/website-relaunch/
Design in important for storefront effect
http://www.packworld.com/package-type/cartons-and-boxes/small-size-aseptic-carton-little-
sensation??utm_source=Packaging_Insights&utm_medium=newsletter&spMailingID=5224981
&spUserID=NzgwMDkzMjY4OQS2&spJobID=60165780&spReportId=NjAxNjU3ODAS1
CFA 1224-36 system from SIG Combibloc
Worlds First Small Volume Cartons: 80 to 90 ml
Friesland Campina of Thailand:
Omega brand
For children, released in Aug. 2012
Dairy product, vitamin, mineral enriched
90 ml, 4732.5 mm
Combibloc XSlim carton
There is a demand for volumes of 100 ml or less.---- Asia and
South East Asia
24,000 cartons/hour
Royal Friesland Campina group: Sell products
at over 100 countries worldwide. Europe,
Asia, and Africa are major sales regions.
19,000 people in 25 countries.
http://www.sig.biz/site/en/index.html
47
2-(1)
Aseptic, Room
Temperature
Distribution OK
ASP
http://www.morinagamilk.co.jp/research/story/st09.html
Can provide the foods original flavor, color,
and freshness of the ingredients with the
convenience of bag type containers.
Food must be visually appealing so that
patients can take their nutritional
treatment smoothly.
Adopted new plastic bag containers that are easy to use in
medical settings: Morinaga Milk Industry, Aseptic filling
liquid food
Market for nursing food including
liquid food:
132 billion yen/2013 (Fuji Keizai)
Aseptic filling + flavor + preservability=New product for patients
48
Pouches
with spouts:
Use tubes
http://www.clinico.co.jp/ec/products/compare.php
180 days, cost of one bag
Approx. 400 to 500 yen
ASP
Aseptic
environment
Aseptic
liquid
food
Aseptic
container
Bacteria
Bacteria
Bacteria
First aseptic liquid
food in the world
49
Small liquid paper containers :
Cartcan
http://www.chato-plus.com/SHOP/0017.html
Low temperature sterilization
+ Aseptic filling packaging
Tea
Use 30% domestic wood material
Use forest thinning material
First adopted in Japan in 1996
http://www.kagom
e.co.jp/gift/recycle/
index.html
http://www.shi
seido.co.jp/kire
susu/product/in
dex.html
ASP
50
SIG: combibloc
Obeikan Investment Group
ASP
http://www.ecolean.com/en/producer/aseptic-packaging
The Ecolean EL3 is a
modern filling machine
with a small footprint and
high efficiency, designed
for the aseptic filling of
low-acid food products
into Ecolean Air Aseptic
packages
Printing/PP/PE/EVOH/PP (Ca compound/carbon black layer/PE (inside)
140m (14g) EB sterilization was adopted for the packaging material (2 seconds for the
sterilization and filling process) Adopted by Helsingborg in Sweden for milk beverages
Co-Ex: Multi-layer film---- Printability, flexibility, oxygen barrier, light-blocking effect, HS
51
Inventor: Ecolean
Approx. 50 to 60% reduction in volume
(compared to bottles of the same size)
Easy open and spout
Easy to empty
Stand-up Pouch
<Use air>
ASP
52
Adopted for milk in China and
juice for children in France.
Three dimensional container
made of soft packaging
material combined with
asepsis will be one future
direction for packages.
ASP
Spread of three dimensional containers made of soft packaging material
combined with aseptic filling packaging
(1) THIMONNIER
DOYPACK (Stand-up
Pouch): 1963
For general packaging for snacks
and refill containers
For Retort Spout: Drinks, etc.
3D Containers such
as QUATRO, etc.
(2) VOLPAK BRICKPOUCH
(3) Bosch SurePOUCH
(1) http://www.thimonnier.com/en/Historique.php
(2) http://www.brickpouch.com/areas/packaging.php
Aseptic filling packaging:
beverages
Refill containers for
detergents, etc.
(3) http://www.boschpackaging.com/Pouchsystems/eng/index.asp
53
ASP
Bosch SurePouch
54
Filling volume: 100 ml - 10,000 ml
Viscosity: up to 25,000 centipoises
Quick change-over to many formats
Handles particulates up to 25 mm diameter
http://www.boschpackaging.com/Pouchsystems/eng/index.asp
Example of shelf life
(aseptic):
3 months (e.g. milk)
12 months (e.g. enteral
feeding)
Cases of adoption
ASP
Stand-up pouch
55
VOLPAK
Brick pouch
BOSCH: SurePouch
http://www.volpak.com/public/product_cat.jsp?id_language=1&catId=11&dt=1350740615703
Three dimensional containers made
with soft packaging material
Combine with Aseptic
packaging
New shapes
Lighter containers
1. Innovative Packages
Interpack 2011 Sumimoto Report
ASP
56
AMCOR Flexibles Europe
COCKER CONSULTING, Holland
Packaging material
Aseptic
TELSTAR INDUSTRIAL, Spain Machine
Structure for development with Partners
A single company cannot conduct all of the
development work for new products. It is important
to cooperate with Partners in the development.
http://aseptic.volpak.com/partners.htm
VOLPAK, S.A
ACMA- Volpak --- Coesia Group
http://www.packworld.com/machinery/bagging-amp-formfillseal/unique-spouted-
fitment-aseptic-
pouch??utm_source=Packaging_Insights&utm_medium=newsletter&spMailingID=5
224981&spUserID=NzgwMDkzMjY4OQS2&spJobID=60165780&spReportId=NjAxNj
U3ODAS1
Unique Aseptic Stand-up Pouch with Spout from IPN
(Innovative Packaging Network)
Volpak: form/fill seal system
Winding: Constantia.
Non-spill aseptic spout
57
Functional spouts are becoming increasingly important.
Functional spout + Package shape + Aseptic packaging technology
Taste, Convenience, Food Saving
ASP
58
Using combined sterilization technology to provide
an even higher level of safety for aseptic filling
packaging in combination with a new package shape
Example:
1) First it is sterilized with steam H
2
O
2
, then sterilized
additionally with UVC, after which the inside of the container is
flushed with heated Aseptic air and dried before filling.
Combination of hydrogen peroxide vapor
(HPV) and ultraviolet (UV) light
Residual H
2
O
2
: 0.5 ppm or less
Combination of H
2
O
2
and UVC
ASP
Asepsis Technology
1. Packages differ depending on the content, filling volume and
purpose of use, so various packages will continue to be used,
however, Asp will have an important position as a sustainable
package as part of the aim to complete the ideal Performance
Package.
2. From the perspective of saving food, the packaging food and
products are commercialized, for the products to complete
their mission, ASP is vital to maintain quality for a long period
of time during distribution and storage (including storefront)
until it reaches the consumer and users.
3. For food and pharmaceuticals, depending on the content,
either aseptic filling packaging or Asepsis filling packaging is
necessary.
4. Aseptic filling packaging or Asepsis filling packaging will shift
towards methods with even higher levels of safety.
59
ASP
60
5. With asepsis packaging technology, a variety of optimal methods are
applied depending on the content and package shape.
6. With asepsis packaging technology, not just the individual method but also
the use of combined asepsis packaging technology which mutually
complements the technology will also develop.
7. With the expansion of the optimal production base, with regards to
transport and storage, for food and pharmaceuticals, depending on the
content, aseptic filling packaging or Asepsis filling packaging will be
necessary.
8. In regions where a proper distribution network is not set up, aseptic filling
packaging products that can be stored at room temperature are optimal.
9. When delivering food during emergencies such as disasters, aseptic filling
packaging products are ideal.
10. Regarding bad weather, there is a need for packaging types that can be
preserved, used immediately and are convenient. A representative
example of something appropriate in such situations is aseptic or asepsis
filling packaging.
ASP
61
Application of Asepsis Technology and its Limits
Issues with content that contains solids and
sterilization
Issues with asepsis of food itself and maintenance
of Aseptic state
Issues with packaging material and sterilization
methods
Issues with device cost and investment value
Merits of Aseptic qualities and issues of production
and product cost
Issues with maintenance of Aseptic and Asepsis
state
ASP
Astepo
Bosch - Cups & Coffee Cream
Filler
Bosch Pouches
Dole Canning Systems
DuPont/Liqui-Box Bag-in-Box
DuPont/Liqui-Box Pouches
FBR-Elpo
Fenco
Fres-Co
HRS Process Technology
JBT Food Tech
KHS
Krones
Oystar Hassia
Procomac
Purity
Rapak
Rossi Catelli
Scholle
Serac
Shibuya
Sidel
SIG Combibloc
Stork
Tetra Pak
DNP(Japan)
Aseptic filling packaging machines:
Many companies worldwide are entering this market
Source: Packaging Strategies Survey Material
62
ASP
Reference
material
Retort packaging requires sterilization at 120C for 10 minutes and a total of
more than 1 hour of heat sterilization. With aseptic packaging, the container and
food are sterilized separatelythe food is sterilized at 143C (highest) for two
seconds. The total heating time is extremely short and the effect on quality is
minimal.
http://packaging.jp/modules/serial/item-59-1-8.html

Merits of Aseptic filling packaging
Reference
material
63
heating temperature
Aseptic filling packaging Retort packaging
Heating duration (second)
143 2s 120 25 minutes
64
2-3 High Pressure Sterilization
65
2-3-1 High-pressure sterilization:
High pressure pasteurization
700 MPa (100,000 psi) to destroy many food-borne
pathogens such as Listeria, E. Coli and Salmonella,
To provide safer food: Very little damage to food itself
TO provide fresher food: Food can be stored in an
even more natural condition
Better taste, texture, color and nutritional
components
HP
The patent was submitted in 1985 for this technology that uses
several dozen to several hundred kgf/cm
2
of pressure to
conduct sterilization. The basic patent is considered to be the
one submitted by Kobe Steel in Sept. 1985 called Kokoku
(examined patent publication) 6-57236 High pressure
sterilization device for sterilization of treated liquids under
high pressure.
High-pressure sterilization
66
With Asepsis packaging technology, the most
appropriate of the various methods is applied
depending on the content and package type.
HP
67
Ready-to-eat whole muscle and sliced meats
Processed fruits and vegetables
Fresh juices and smoothies
Deli salads and dips
Shellfish shucking and meat retrieval
The global market is 2 billion $/year
Peeled lobsters,
Shucked oysters and clams
HP
68
With sterilization at 100 MPA or less, you can expect a
certain level of effect on various bacteria, such as E.
coli bacteria of gram-negative bacteria, Salmonella,
pseudomonad, Legionella bacteria, etc. However,
sterilization at 300 MPa is necessary for viruses and
yeast, and sterilization of 400 MPa or higher is
necessary for mold, lactic acid bacteria, Bacillus
subtilis and it is very difficult to achieve complete
sterilization through high pressure.
HP
Extension of shelf life by applying this method for pre-
cooked foods is under discussion but not yet in
practical use.
http://www.echigoseika.co.jp/freecontents-15/detail_freecontents-15_contseq_4.html
With the development of large and cheap fully automated
continuous batch type machines for high pressure treatment,
products have been released such as aseptic packaging rice that
touts flavors better than freshly cooked rice and non-cured
ham and sausages.
69
HP
70
High-pressure jam
Began sales in 1990 as the
worlds first high-pressure
processed food.
HP
High-pressure sterilization jams are
a long-selling item in Japan
http://www.avure.com/food/applications/?pi_ad_id=8613723738&_kk=high-
pressure%20food&_kt=53f4e855-6140-427f-b45f-
357eef9410a1&gclid=CKXZh9_X8bMCFckhpQodR2wATg
Pre-cooked and RTE sliced or whole
meats
Fresh cut fruits, vegetables and juices
Dips, spreads, guacamole, hummus, salsa
Dressings, soups, condiments
Deli salads
Seafood and shellfish
High pressure processing or HPP
Reference
material
71
HP
Multivac : 50 years
HPP: High Pressure Preservation
6000 bar (87000 psi)
Extend food shelf life
Consumers want a reduction in bacteria in meat and products that
do not contain preservatives.
Joint development with Uhde High
Pressure Technologies
Chamber size: 55, 169, 350 liters
4,000 bar (58,000psi) Low or room
temperature
58 000 pounds per square inch = 399 895 923 pascals
Sterilization after packaging
Little damage from heat
Little effect on flavor and vitamins
Allows for uniform treatment
No preservatives added
72
HP
- High-pressure treatment test device
Device name Special device for food processing
Model -
Max. Pressure 1,500 Mpa
Range of use
temperature
-20C to 80C
Inner volume
(Internal
dimensions)
1.5 GPa / 0.3 L (60120 mm)
700 MPa / 3.6 L (110380 mm)
400 MPa / 10 L (150400 mm)
Exterior
dimensions
L 3,000W 725H 2,995 mm
Pressurization
method
Hydraulic press booster method
Installation
location
General Research Center, Echigo
Seika
Uses
Pressurization test for various food
For HP researchers
Source: Echigo Seika
73
HP
Continuous High Pressure
Treatment Device for Food
Pressure
receiving frame
Treatment
bucket
Pressure
container (130L)
Maximum pressure: 400MPa
Use temperature: RT to 80C
(Differential pressure collection method)
Booster pump
Source: Echigo Seika
74
HP
75
2-4. Food filling packaging in a clean environment
There is an increase in methods where dairy
products, ham and sausage, sandwich, prepared
food, etc., are filled and sealed in a low-
temperature clean room.
UC
76
Ultra Clean Filling: Proaseptic Technologies
Stand up Pouch: smoothies strawberry juice,
yogurt, Apple juice
The packaging material is sterilized with
ultraviolet rays and hydrogen peroxide to
maintain clean state, then packaged and
supplied.
The expiration date is approx. 60
days in a chilled environment.
Ultra-clean (ESL): Extended Shelf Life
UC
iLLig: FFS machine, FS 48, FSL48
Optimal for uses that require clean environment such as dairy products
30 cups/minute, 250 to 500g cups
Flexibility, quality,
efficiency
In-mold labels
Cups: PS, PS multi-layer barrier, PP multi-layer barrier APET, PLA, etc.
Reduction 480 mm width, max. depth: 100
mm
77
UC
Thermoforming clean-fill machine (TFC)
Examples: Bosch Packaging Technology --- Plastic cups,
Anuga FoodTec 2012
1) Various products, 2) adjust height of cup, 3) flexibility of machines, 4)
reduction in down time, 5) operability and maintenance, 6) reduction and
conservation of packaging material
Yogurt, dessert: Cold chain
A flat contact heater that operates on a servomotor, heat transfer, energy
cost cutting, cylinder type mold, and labels facing outside the cup to ensure
visibility to consumers. Machine height is 1m to reduce energy consumption
during manufacturing and transport.
Struggle between Aseptic and Semi-Aseptic:
Difference in concept, high cost, expensive products
and consumers 78
UC
79
A system developed in Sweden and used in dairy
products in combination with chilled distribution
in Europe
Oxy
2-5. Use of Active Oxygen
Pastair works by adding active oxygen to the product during a certain
controlled time and then removing it again.
The achieved level of bacteriological reduction corresponds to ordinary heat
pasteurization; i.e. 99,9%
In
Active oxygen is introduced
Active oxygen is removed
Product flow
Inventor: Pastair
80
Pastair a new preservation method Use active oxygen
Supply active oxygen for a set period of time
Can sterilize 99.9% of bacteria
Cold Pasteurization
ozone application
http://www.pastair.se/cmarter.asp?doc=3205
Oxy
81
Set period of time, heating at 60C
Within the range that does not
cause changes in protein
Sterilizes bacteria, spores but preserves enzymes.
Used for milk for a more natural taste with the same shelf life
as heat treatment
Oxy
Ozone generator
Pastair capacity:
1 500 - 5 000 l/h
Size:
2.5m x 1.8m x 2.5m (L x W x H)
- Very little change in flavor
- Very little change to protein.
- Use ozone to make bacterial non-active
- Dairy products, fruit juice, protein drinks, cheese
82
Contributed to improvement in yield and
quality improvement for cheese
Pastair - Benefits for milk
As a result of advance research during 1997 to 2005, in 2005 a cold
pasteurization project was started.
Almost completely done in 2007, received support from investors to proceed to
mass production. Experimental production was conducted in 2008 and 2009. Issues
of bacteria were resolved and first plant was installed in Europe.
Shelf-life is said to be about 26 days
at temperatures at or below 8C
Oxy
83
2-6 Chilled Distribution
Chilled
Long-life prepared food in pouches
Many long-life prepared food in pouches are now being sold at various
convenience store chains and supermarkets. (Expiration date is about 30 days.)
They are sold at convenience stores in brands such as Seven Premium, Lawson Select, Family Mart
Selection, and Style One (Circle K), and are manufactured by companies such as Fujicco, Yamazaki,
Ichibiki, Salad Mate, Nippon Ham, Prima Ham, Ito Ham, Marudai Food, Kanehatsu Food, and Ichimasa
Kamaboko.
- Potato salad - Macaroni salad - Gobo (burdock) salad - Pumpkin salad - Various salads
- Chikuzenni (Stewed vegetables and meat) - Nikujyaga (Stewed beef, potato and onions)
- Hijiki-ni (Stewed hijiki seaweed) - Takenoko-ni (Stewed bamboo shoot) - Satoimo-ni (Stewed
satoimo yam) - Stewed sweet potato - Various stewed beans - Oden (Stewed vegetables)
- Tonjiru (Pork soup) - Pot-au-feu (Soup) - Kinpira Gobo (Sweet simmered burdock)
- Hamburger - Cabbage rolls - Karaage Fried Chicken - Chicken teriyaki - Stewed pork
- Subuta (Sweet sour pork) - Motsu-ni (stewed giblets) - Saba (mackerel) with miso sauce
- Iwashi (sardines) stewed with ginger - Grilled salted salmon, etc.
In the future, products that are not suitable for pouch, they may be sold in tray containers.
Source: Masuda
3-(2)
84
A variety of long-life prepared food in trays are being released
Long-life prepared food in trays are common in the UK and Europe but companies have also
began selling them in Japan recently. (Expiration date: One to three months)
Seven Premium Meat Shumai Dumplings (Nippon Ham) Circle K Sunkus Style One (Ichibiki)
Three month expiration date due to low
temperature sterilization technology!
New MicVac production method (Steam
valve method)(Fujicco: Oissina!)
Prepared food with
deep ejection type
low-temperature
sterilization (Fujicco)
Source: Masuda
85
Photos of other samples
Seven Eleven Premium Lawson Select Irodori Famima Deli
=> Changed to Family Mart Selection
Seven Premium
Chilled baby food from Korea made
using aseptic method
Evaluated as retaining nutritional value
Released this month: New Ichibiki products
Source:
Masuda
86
87
Chilled Long-Life Technology
Container cooking sterilization
method
Pre-treatment of
ingredients
Cooking,
branching
Container
filling
Cook in
container
Aseptic
seal
Cooling
Chilled
product
Tight seal
Cook in
container
Cooking method: Steam, microwave, far-infrared rays
10C or lower
Heating to 100C
Heating to 80C
30 to 60 days
7 to 14 days
10C or lower
MicVac: Microwave cooking, chilled preservation, Swedish technology
Fujicco
Dai Nippon Printing
88
89
Microwave In-Pack Processing
Production line
1
2
3
4
Packaging and Valve Application
Food ingredients (e.g. dry pasta, fresh
vegetables and pre-cooked sauce) are
inserted into a tray (1). The MicVac
valve is applied on the film and the
package is thereafter sealed (2).
Processing in Microwave Tunnel
The package is transported into a microwave
tunnel where the product is cooked and
pasteurised (3). The valve opens and a
controlled amount of steam is let out through the
valve together with air previously in the package.
Cooling
After cooking, the cooling process
begins immediately (4). The valve
is closed and the remaining steam
condenses, causing an under
pressure in the package. The final
result is a cooked, pasteurised
and vacuum packed product.
1 2
4 3
Reference material
90
Reference material
91
Reference material
92
Microwave sterilization: Prepared foods 90 days OK
MICROPAST
http://www.micropast.com/microwave-process.html
The Swiss
Creative New
Food Company
Flash pulse sterilization of cups:
Pulsed light sterilization
Can also be used
to sterilize bottle
caps.
Established in
2004. (France)
http://claranor.com/

93
UV sterilization
http://www.ushio.co.jp/documents/technology/lightedge/lightedge_21/ushio_le21-02.pdf
Flash pulse sterilization
Can emit strong ultraviolet rays which are effective for sterilization
This technology was invented by Ushio Electronics in 1980.
PurePulse (USA) began development of a device and began
selling products. Additionally, they obtained FDA approval.
New important non-heating sterilization
There are three types of light sources used in sterilization, 1) low pressure
mercury lamp, 2) high pressure mercury lamp, and 3) xenon flash lamp.
Energy supply Condenser
(Accumulate
energy)
Switch
(Energy release)
Pulse light: Irradiation target
94
Light pulse sterilization
Room temperature distribution Chilled distribution Room
temperature
distribution
Ultra
Clean
Use
preservative
Hot filling 35- to 45-day
shelf-life
45- to 90-
day shelf-life
Aseptic filling
Flavored
water
Flavored
water, tea,
juice
Flavored
water, tea,
juice
Sterilized milk, ESL milk, yogurt
drinks, juice (Clean-fill)

High Acid:
Juice, flavored
water, tea
Low Acid :
UHT milk
95
Strong sterilization effect (Short burst sterilization)(Can
sterilize black mold, spore bacteria, etc.)
Tailing does not occur
Easy to control (Can be light up instantaneously)
Does not generate residual substances
Very little effect on work
Space saving
Major characteristics are the strong sterilization effect and easy
control.
http://www.ushio.co.jp/documents/technology/lightedge/lightedge_21/ushio_le21-02.pdf
96
97
High acidity
products
- Juice
- Nectar
- Yogurt
based
beverages
Low acidity
products
- Dairy
products
- Beverages
Refrigerated:
Short shelf-life
(e.g. Approx. 10
days)
Retort:
Long shelf-life
(Issues with
flavor)
Add
preservatives:
Consumers
demand more
natural
products
Hot filling:
Issues:
Fresh flavor
Reduction
of nutrients
Limits to
packaging
material
Aseptic filling
packaging
Comparison of filling and
preservation methods for beverages
98
2-7 Freshness Maintaining Packaging
1. Agricultural Products
2. Marine Products
3. Meat Products
99
1. Agricultural products
1-1 Plant Factories
1-2 Maintaining freshness of vegetables and fruit
1-3 Cut Vegetables
1-4 Cut Fruit
1-5 Fruit Desserts
1-6 Mixed Juice
1-7 Dried Fruit and Nuts
100
Sharp Corp: Announced that they began
experiments in Dubai for a plant factory to
grow strawberries by controlling the light
and air environment. Utilizing their own LED
light and air purification technologies.
Considering commercial use in other
countries and regions in the Middle East.
Panasonic Corp. also planning to cultivate
vegetables in open space in the Fukushima
Factory (Fukushima City) starting in FY2013.
http://www.nikkei.com/article/DGXNZO60003590R20C13A9TJ1000/
304 plant factories
The share for plant factories is less than 1%.
http://www.nikkeibp.co.jp/article/tk/20130912/365020/
Freshness of vegetables can be
maintained longer than open culture
1-1. Plant
factories
Examples in Japan
101
1-2. Maintaining freshness of vegetables and fruit
1. Permeability control, antifogging treatment,
ethylene gas absorption
http://www.amcor.com/products_services/p-plus_fresh_produce_packaging.html
P-Plus is the most extensive range of tailored
permeability films, designed to maintain freshness
and extend shelf life of fresh produce.
Amcor P-Plus
Toyobo (Japan)
PYLEN film FG is an OPP film. It is a freshness
maintenance film for food that is transparent and
antifogging.
http://www.toyobo.co.jp/seihin/film/package/pdf/pylenot/P5763.pdf
102
http://www.foodfreshnesstechnology.com/
It's Fresh! e+ Ethylene Remover
Current applications include; Top Fruit, Stone Fruit,
Soft Fruit, Tropical Fruit and Floral.
The patented It's Fresh! Ethylene Remover technology
has been jointly developed with Johnson Matthey Plc,
a UK FTSE 100 company and a world leader in
advanced materials technology.
A simple to use plug and play, highly efficient, multi-
adaptable non-invasive, non-toxic, food safe
application (sheet or pad).
Case study
103
Aura Pack in Japan
1. Antidesiccant effect and prevention of excessive
breathing through molecular activity
2. Better antifogging functions than general
antifogging film
3. Economic prices that reduce food loss
4. Secure and safe as created using only
substances that have Food Sanitation approval
Developed by Mr. Isaka
http://bellegreenwise.co.jp/aura_pack/
Effective for vegetables
that are 90 to 96%
water
Case study
104
http://www.fenugreen.com/
FreshPaper keeps fruits & veggies fresh for 2-4 times
longer, organically
FreshPaperby Fenugreen
Often described as a "dryer sheet for produce," one
small (5" x 5") FreshPaper sheet can simply be
dropped into a fridge drawer, fruit bowl, or any other
container filled with produce.
FreshPaper is infused with organic spices and has a
distinctive maple-like scent that signals that the paper is
active.
Case study
105
2. Fruit: Prevent damage, ethylene absorbent, and
sensors to measure sugar content and ripeness
Pears, ethylene absorbent
Color photosensors:
Sweetness, ripeness
tests
Damage prevention:
PE cushioning material
106
106
Chile
Thailand
South Africa
3. Faces of producers:
Communication with consumers, security and safety
107
1-3. Cut vegetables
1. Washed and unwashed products: Convenience
Seasoned frozen salad
108
1-4. Cut fruit
1. Cut apples: Prevent browning using Vitamin C
--- Often packaged in pouches
109
2. Single type and mixed: in cups, trays
----Short shelf-life
110
1-5. Fruit desserts
1. Suspend cut fruit in jelly or agar: Taste,
convenience
2. Boil sterilization, oxygen barrier containers
(thermoforming)
111
1-6. Mixed juices
1. Aseptic packages: Long-Life, taste, convenience
2. Hot Filling
3. Liquid paper container, PET bottles, glass, cans
112
1-7. Dried fruit and nuts
1. Antioxydizing: Vacuum packaging, nitrogen
gas filling packaging, use of deoxydant
2. Easy-open/re-seal: Zippers
3. Sub-divided packaging:
4. Residual pesticides
113
1. In South Africa, there is a business opportunity for
processing and exporting agricultural products.
2. With vegetables, in addition to maintaining
freshness, a variety of processing methods include
refrigeration, chilled, retort packages of boiled
ingredients, and dried products.
3. In Japan, dried vegetables are used in instant
soups, instant ramen noodles, etc.
114
3. Application of Renewable energy for
production of packaging material
115
Used in the
printing process
We need to use more
Green Energy in the
packaging process.
Renewable Energy:
Green Energy
7
116
4. Trend of new packaging for the future
117
Non-coated board
High OTR
Coated board
Oxygen barrier
Anti microbial films
Examples of raw materials
Fermented food
CO
2

Package exterior
O
2

Active & permselective materials
Vitamins
Fats/grease
Aroma
Aroma
Extrusion
Plan for renewable barrier packages
Source: INNVENTIA
It is important to review
the pulp
118
Check freshness on mobile device (VTT)
Check freshness at the register (Scan barcode)
(TEMPIX Temperature indicator)
Freshness indicator
There will be a higher demand for food packaging to maintain
freshness and packages printed with freshness indicators shall
become widespread.
Sterile and aseptic packaging shall gain importance.
Method whereby freshness can be confirmed in one glance
Established in 2002.
The label shows consumers that the temperature of products
that require refrigeration and freezing are being properly
managed.
The purpose of this label is to verify and guarantee that
temperature was managed continuously and properly
throughout the entire refrigerated and frozen distribution
process.
If frozen products were handled for a set period of time at a
designated temperature at any point in the distribution
process, the black line in the box on the label disappears, the
barcode cannot be scanned and the line cannot be restored.
It is also possible to verify at which point the product was
exposed to temperatures higher than the designated level.
www.tempix.se

Packages with sensor technology
TEMPIX - Temperature indicators
119
Major supermarket
chains are moving
towards adoption of
this technology
Scanpack 2012 Sumimoto Report
120
System is available for purchase
Company supplies label material
121
5. Latest topics of packaging
122
Microwave -safe
Shift from metal can to multi-layered
barrier container
Conventional
canned product
123
Re-seal lid is introduced to Japan
124
Packages of soy sauce
to keep freshness after
opening the package.
125
Stay-on cap: The cap stays with the bottle after opening.
Cook-in bags debut in South Africa
http://www.packworld.com/package-
type/bagspouches/cook-bags-debut-
south-
africa?utm_source=Packaging_Insights&
utm_medium=newsletter&spMailingID=
6993845&spUserID=NzgwMDkzMjY4OQ
S2&spJobID=89102891&spReportId=OD
kxMDI4OTES1
the Woolworths chain of stores
launched two refrigerated
seafood ready meals in an
innovative ovenable bag.
In the other is a sauce. During
cookingin either microwave or
conventional oventhe seal between
the two compartments breaks so that
fish and sauce are united.
The interesting twist to this launch is that the bag has two
compartments. In one is the seafood item, either a salmon filet
or calamari rings.