Unit 4 Food Science and Technology Packaging of Products Dr D' Hill

1
Unit 4 Food Science and TechnologyPackaging of
ProductsDr D. Hill
2
Format

• Introduction - including video
• Economics
• The sandwich market
• Practicality
• Legality
• Procurement
• Seasonality
• Manufacturing
• Packaging
• Types of packaging
• Safety/Allergy policies
• Food waste
• Travel/Transport
• Logistics

3
Introduction

• There are a number of issues relating to the
  production, preparation and presentation of
  foodstuffs
• These issues can be grouped into three headings,
  however, they are not mutually exclusive
• These areas are availability, cost and
  manufacturability
• This lecture will take the form of a
• Case study outlining the principles applied to
  sandwiches
• Type of packaging suitable for the products which
  you develop during the practical sessions

4
Economics

• The largest sector in the fast food industry is
  sandwiches
• It contributes 36 of all sales in the fast food
  sector
• There are a number of reasons for the increase in
  sandwich sales which include
• Shorter lunch breaks from the traditional one
  hour to ½ or ¾ hour
• People tend to eat on the move desk top dining
  or dash board dining

5
Economics

• The growth of the sandwich sector is outlined in
  table one
• The sector is continuing to grow, with expansion
  aided by the branded outlets such as Subway
• Concerns relating to obesity and the increase in
  range of types of sandwiches have also helped the
  increase in sales

6
Practicality

• The issues relating to the production/manufacture
  of sandwiches is outlined in the handout
  designing a sandwich
• The principles of developing a product are
  outlined within this lecture and applied to
  sandwiches

7
Legality

• Before producing any product it is necessary to
  ensure you have a recognisable brand name, logo
  and slogan
• You must ensure that any proposed name is not
  already registered
• There are a number of specialist agencies who can
  ascertain if the name is already registered
• You also must comply with the Trade Marks Act
  (1994) to ensure your product and packaging is
  different enough from a competing brand

8
Legality continued

• Your product may not need a new brand name as it
  may be a sub-brand or be launched under an
  existing brand name
• In terms of legality you must ensure that the
  ingredients list incorporated on the packaging is
  correct
• The ingredients should be listed from the one
  that is in greatest proportion to the least

9
Legality continued

• By law you need to ensure the big four are
  included on the label
• Some companies include the full eight
• If you are going to enter the low fat market you
  need to conform to the Food Standards Agency
  (FSA) regulations in terms of Low fat
• If you are going to enter the organic market you
  may wish to have your product endorsed by The
  Soil Association

10
Procurement

• You will need to locate a company that will be
  able to manufacture your product
• The company you select to make your product may
  make a portfolio of products
• These products may not be related to your product
• The ingredients also need to be sourced for the
  product you are going to produce

11
Procurement continued

• Within the sandwich sector it may appear that you
  only require bread, spread and a few fillings
• This is generally not the case, for example,
  Marks and Spencer currently offers a range of
  almost 70 different types
• The ingredients list for these is very extensive
• The companies that provide these ingredients also
  need to be supplied with product specifications

12
Procurement continued

• The company also needs to ensure traceability of
  ingredients due to consumer concerns
• The company needs to have an effective ordering
  system such as Electronic Transfer of Information
  (ETI) of Electronic Data Interchange (EDI)
• The company needs to consider the cost of
  installing such equipment
• They also need to have a belt and braces
  approach to ordering ingredients

13
Seasonality

• The company needs to take account of seasonality
  of ingredients
• For example, during the summertime you will be
  able to use English tomatoes for salad sandwiches
• In the wintertime, you may need to obtain these
  from a different source
• This leads to increased costs and the company has
  to decide if it wishes to fly ingredients half
  way around the world

14
Seasonality continued

• The manufacturer and the seller needs to discuss
  how they wish to price the salad sandwiches
• Do they have one price all year round or do they
  have different prices for the two seasons
• This is generally not favoured by retailers, as
  they do not want consumers switching products or
  brands

15
Manufacturing

• If new machinery to produce sandwiches is
  required capital is likely to be needed
• Most food factories today are large scale
  industrial technological organisations
• Most of the processes are automated with as
  little human input as possible
• This ensures that a consistent/standardised
  product is produced each time

16
Manufacturing continued

• The company needs to ensure the factory is laid
  out so that it conforms all hygiene requirements
  such as HACCP
• If the company needs to purchase additional
  equipment it is generally very specialised
• This equipment is generally made to order and
  possibly in another country

17
Manufacturing continued

• The company needs to decide if there is
  sufficient staff or does it require new staff
• This can be carried out via a Training Needs
  Analysis (TNA)
• Depending on the location of the factory will
  dictate the availability of labour

18
Manufacturing continued

• Producing a small number of sandwiches is a
  different scenario from producing tens of
  thousands
• Small scale/kitchen trials need to be carried out
  which are very detailed
• An ingredients list and product specification
  needs to be drawn up for each sandwich

19
Manufacturing continued

• Sandwiches are generally produced using the
  cook-chill method of production
• This means that they need to have a shelf life of
  5 days including production and sale /
  consumption
• Different types of sandwiches require different
  shelf lives for example, salad sandwiches
• Other require Modified Atmosphere Packaging (MAP)
  which extends their shelf life

20
Packaging

• Packaging will depend on the sandwich being
  produced
• For example, wraps could be packaged in cardboard
  and barrier film
• Whilst wedge sandwiches are placed in the classic
  clear plastic triangle packaging
• This enables the consumer to see the sandwich
  without the need to read the label as they can
  see the filling

21
Packaging continued

• The packaging needs to be made from a type of
  material which is opened by all types of consumer
  from the very young to the elderly
• Thus it needs to be made from a material that is
  easily opened
• There is currently the trend of peel and reseal
  which allows consumers to eat it at different
  times
• If the sandwich is redesigned or re-packaged it
  must be done gradually so as consumers still
  recognise it

22
Other types of packaging

• See table two for the main types of packaging and
  the popularity of their use
• Paper and paper based products
• Metals
• Plastics
• Glass

23
Paper and Board Materials

• These can be produced in many grades and
  converted into many forms
• It can be combined with other materials to form a
  coated or laminated product see examples
• An example of where paper is used in its thinnest
  form to make packaging is the new packaging for
  smarties sweets

24
Paper and Board Materials continued

• Where heavier board material are required it can
  be used as a sleeve to place around a plastic or
  aluminium tray
• The sleeve can have should incorporated or left
  without see examples
• In addition, cardboard can be used for a lid for
  example on the top of Sainsburys Shepherd's pie
• A window can also be place in the sleeve
• Another method of allowing the consumer to view
  the product is to use a partial sleeve

25
Metals

• Aluminium can be used as a packaging material
• It benefits include, that it is lightweight, that
  it does not allow light, moisture or odours to
  penetrate
• It tends to be used for fizzy drinks such as Coke
• It can be moulded into trays and food products
  placed inside such as lasagne
• The current trend is for the food to be cooked in
  the foil tray

26
Metals continued

• As breadcrumbed products may stick to the tray a
  rippled effect on the bottom is now used
• This minimises the contact with the food product
  and therefore reduces the opportunity for burning
• Metal can be laminated with a plastic coating to
  protect delicate items for example, strawberries
  and rice pudding
• Steel can also be coated with tin which makes it
  suitable for the packaging of high acid foods
• Steel can be thermally processed for high risk
  products

27
Metals continued

• When metal is used as packaging for a product
  such as biscuits the plastic coated information
  can be used and the tin reused
• This would usually happened with biscuits
  packaged for Christmas
• The metal may be shaped into a decorative feature
  so that it becomes part of the product for
  example Champagne Chocolate Truffles

28
Plastics

• No two plastics are identical in their properties
• Most are light weight and do not allow moisture
  or gas to pass through
• They are resistant to bacteria and provide food
  insulation
• They can be of several grades and thickness and
  van be shaped and moulded

29
Plastics continued

• Foods which could be placed in a metal tray can
  generally be placed in a a plastic tray
• They can be made in a variety of colours
  depending on the current trend
• The current trend is black trays whereas, before
  it would have been white or cream
• Where the consumer needs to see the product it
  can be placed in a clear plastic tray and a clear
  outer plastic used for example, crispy potato
  slices

30
Plastics continued

• Plastic trays can be moulded so that they can
  hold a plastic pouch
• For example, steaks with a plastic pouch of
  pepper sauce
• The advantage of the pouch is that it is
  transparent
• In addition, a thinner plastic can be used to
  cover the plastic tray in which the food is
  placed
• A moisture mat can be added to absorb liquids so
  as to prevent the deterioration in the product

31
Plastics continued

• Thin plastics are also used to cover product
  where it is the only protective covering for
  example, biscuits e.g. Digestives
• The advantage is that all the product information
  can be printed on to the plastic
• It offers little protection, however, and the
  biscuits can get broken and you cannot see the
  product

32
Plastics continued

• Pemium priced biscuits are placed in a heaver
  plastic container for each biscuit and then
  covered in a thinner plastic
• This is then placed in a cardboard box for
  example, Milk chocolate toffee covered biscuits
• The current trend is for foil wrap to seal in the
  freshness or to place them in a tub see example

33
Glass

• If the sandwich is produced in a factory where
  there are lots of other products, then the
  manufacturer needs to examine the type of
  products that are being produced
• If it is made in a factory where glass is used it
  must be produced in a separate section
• It is therefore preferable to exclude glass from
  the production process and substitute it with
  another suitable product e.g. aluminium

34
Glass continued

• Where it is part of the packaging an alternative
  could be sought for example, toughened glass
• For example, Northern Foods repackaged their
  Tiramisu in toughened plastic sundae shaped
  glasses rather than glass ramekin dishes
• Glass would have been previously used for salad
  cream, tomato ketchup and fizzy drinks, but has
  been replaced by plastic
• Glass now tends to be used for bottles e.g.
  alcohol and sauces and jams

35
Safety/Allergy policies continued

• The packaging needs to be tamper proof from
  production to final sale
• This is to ensure that foreign objects cannot
  be placed in the sandwich thereby creating a food
  scare
• This would result in the sandwich having to be
  recalled
• Retailers now provide products such as toys
  which appeal to children, also must be safe
• If it is produced in a factory where nuts are
  present the sandwiches need to be labelled may
  contain traces of nuts

36
Food waste

• Food waste analysis needs to be carried out at
  various stages of the process
• A sandwich producer needs to determine if it is
  more cost effective to purchase in products
  prepared
• During the manufacturing, food waste will be
  collected at various stages of production
• If this is excessive management need to determine
  how this can be minimised or automated

37
Food waste continued

• Customers can add to food wastage
• They can try to view a sandwich to see how well
  it is filled, thus damaging the packaging
• Therefore the product has to be discarded
• Many retailers operate a chill chain
• This ensures all high risk products such as
  sandwiches must not be out of chilled conditions
  for more than 30 minutes allowing the temperature
  to rise above 5oC

38
Travel/Transport

• Transporting the sandwich where it is produced to
  where it is sold can also generate food waste
• The sandwich needs to be handled at various
  stages of transportation
• It needs to be loaded onto lorries, transported
  on ferries, off loaded at distribution centres
  reloaded onto smaller van(s) to be distributed to
  various outlets

39
Travel/Transport

• The sandwich needs to be placed on the shelf for
  sale to the consumer
• If the sandwich is damaged in any way customers
  will not purchase it
• Travel/drop test also need to be carried out to
  test how much maltreatment a product can
  withstand during transport

40
Logistics

• The logistics of route to market need to be
  examined
• In the case of the video, the order was received
  on day one, produced on day two and dispatched on
  day three
• Figure one shows a Gantt chart for sandwich
  preparation and dispatch based on this principle

41
Logistics continued

• This is a simple forward-front approach of
  production to sale
• If it was for a special occasion or a particular
  time of the year it needs to take a
  back-the-front approach
• For example, Marks and Spencer adopt this for
  products such as party food for Christmas and the
  New Year
• They identify the date of launch and then work
  back through delivery time to how long it will
  take to produce, which determines when production
  has to commence

42
Group Exercise

• At the end of week one you need to compile a
  check list of requirement for your product based
  on the principles outlined today
• At the end of practical session two you need to
  conduct/carry out a product analysis
• You should have compiled a product specification
  for your product