NCA

2008
Packaging Innovations

Fres-co System USA, Inc. Confidential – Reproductions Prohibited

 Agenda

Coffee Packaging Quiz

Packaging Trends

Market Developments
 Coffee Packaging Trivia
• How does O2 the barrier of foil compare to
metalized film?

A. 2 x better barrier
B. 10 x better barrier
C. 100 x better barrier
 Coffee Packaging Trivia
• What O2 % is desired level off the a coffee
vertical, form, fill and seal machine?

A. Less then 10%

B. Less then 2%
C. Less then .2%
 Oxygen Content of Bags Packed With
Freshly Roasted Whole Bean Coffee
25.00%

20.00%

15.00% Gas Flush

10.00% Atmospherically
Packed
5.00%

0.00%
0 15 35 50
 Coffee Packaging Trivia
• How many time does a Fres-co degassing
valve open and close during the degassing
period of freshly packaged coffee?

A. 5-10
B. 50-100
C. 100’s
 Fresco System USA Valve Results
Fre sco

0.10

0.05

0.00
2/9/05 0:00 2/9/05 2:24 2/9/05 4:48 2/9/05 7:12 2/9/05 9:36 2/9/05 12:00

Reliable, reproducible opening characteristics throughout the

lifetime of the coffee's degassing period. Reproducible opening
characteristics under radically different environmental conditions.
 Flexible Packaging Trends
Sustainable Packaging
Convenience
Senior Friendly
Portioning
Quality and Safety
Active Packaging
Customization
Sensory
Packaging Regulation and Specifications
Increasing Shelf Life
 Sustainable Packaging:
• Is beneficial, safe & healthy for individuals and communities throughout its
life cycle.
• Meets market criteria for performance and cost.

• Is sourced, manufactured, transported, and recycled using renewable energy.

• Maximizes the use of renewable or recycled source materials.
• Is manufactured using clean production technologies and best practices

• Is made from materials healthy in all probable end-of-life scenarios.

• Is physically designed to optimize materials and energy .

• Is effectively recovered and used in biological and/or industrial cradle-to-
cradle cycles.
 Wal-Mart’s Packaging Scorecard
• Wal-Mart’s packaging scorecard is a measurement tool
that allows suppliers to evaluate themselves relative to
other suppliers, based on specific metrics.
• The metrics in the scorecard evolved from a list of
favorable attributes, known as the “7 R’s of Packaging”:
• Remove Packaging
• Reduce Packaging
• Reuse Packaging
• Recycle (able) Packaging
• Renew (able) Packaging
• Revenue (Economic Benefits)
• Read (Education)
 Wal-Mart’s Packaging Scorecard
• 15% will be based on GHG / CO2 per ton of Production
• 15% will be based on Material Value
• 15% will be based on Product / Package Ratio
• 15% will be based on Cube Utilization
• 10% will be based on Transportation
• 10% will be based on Recycled Content
• 10% will be based on Recovery Value
• 5% will be based on Renewable Energy
• 5% will be based on Innovation
 Sustainable Materials
•Evlon PLA® Film

•BI-AX INTERNATIONAL INC.

DEVELOPMENTAL DATA
SHEET
•EVLON® EV (Co-Extruded Plain
Polylactide Film)

•Description: EVLON® is a crystal clear film

manufactured form NatureWorks PLA® (Polylactide).
PLA is derived from corn, a widely accessible,
renewable, natural resource. EVLON® film can be
used in many packaging applications either plain or
printed and laminated. After use, EVLON® products
can be composted, and the material will breakdown
and revert to carbon dioxide and water.

Fres-co System USA, Inc. Confidential – Reproductions Prohibited

 NatureWorks PLA® Resin
• NatureWorks LLC, a division of Cargill

• Derived from plant based materials

• Plant material is fermented creating dextrose, a sugar

• The sugar is transformed into lactide monomer

• The lactide monomer is transformed into Polylactide

polymer
 Stackability and Stability:
• The package needs to
be easy to stack and be
attractive and stable on
the retail shelf
 Stackability and Stability:

• Minimize air space in

the package to prevent
deformation from
handling
 Stackability and Stability:

• Package needs to be
stable after opening to
minimize spilling
during use
 Convenience:
• Opening convenience
such as peel seal – no
scissors required

• Dispensing Features
 Convenience:
Reclosure

Fres Close®
Slider Reclosure

Tin Tie

Fitment Reclosure Lift & Lock

Fres-co System USA, Inc.
 Senior friendly:
• Easy to read and
understand BIG BOLD PRINT

• Light and easy to handle Smaller portions

with easy grip
space or handle
• Easy to open (including
child resistant packaging) The package must be easy to
open but retain a hermetic
seal throughout shipping and
distribution.
 Portioning:
• Single serve
• Diet control
• 100-calorie portion
• Dispensing measured
portion
 Quality and Safety:
• Non-glass structure

• Quality indicator such as

oxygen sensor or
temperature recorder
• No sharp edges

• Tamper-evident
 Active Packaging:
• Scavengers for
• Moisture
• Oxygen
• Carbon Dioxide
• Moisture
• Odor
• Anti-static
• Antimicrobial
 Customization:
• Regional sizes and graphics

• Seasonal or other promotional items

 Sensory:
• Beyond visual
appearances:
• audio
• touch
• taste
• scent
• Shaped packages
 Packaging Regulation &
Specification:
10/01/2007- The European Food Safety
Authority (EFSA) has issued
positive scientific opinions on
another batch of 10 packaging
• Carbon dioxide substances, part of an EU-wide
effort to prevent the chemicals
emissions from contaminating foods.

• Residuals in material
• Source of raw materials
• GMO free
• BSE free
 Increasing Shelf Life:
• Higher barrier

• Oxygen removal

• CAP

• Gas scavengers
Market Developments
 Sustainability
Organic coffee adds PLA layer to 12-ounce bag
In a first for coffee, Jim’s Organic Coffee, Wareham, MA, replaces inner layer of
polyester in its 12-ounce foldover top stand-up bag with modified film made from
polylactide (PLA) resin from Natureworks LLC, Minnetonka, MN. Lamination from
Fres-co System USA, Inc., Telford, PA, results in structure with 19% renewable content,
reflects “green” positioning of firm’s more than 35 varieties of hand roasted, certified
organically grown coffees.
According to Chris Burger, coffee product manager for Fres-co, four layer adhesive
lamination consists of 48-gauge rotogravure printed polyester/28-gauge aluminum
foil/80-gauge PLA/2.5 mil coextruded polyethylene (PE). PLA layer replaces 48-gauge
polyester, which had been adhesive-laminated to 3-mil coextruded PE. Foil provides
oxygen barrier, coextruded PE serves as sealant layer. Copy on bag bottom provides
subtle indication of PLA content: “This bag is the first generation of sealed, stay fresh
coffee bags to include renewable resources in its design.” Jim’s Organic Coffee’s Emily
Sheehan, marketing, explains, “We don’t really like to be over the top and preachy
about the good things that we do, they are just the way we conduct business.” However,
she notes, all elements work together to entice senses. “These bags now feature a great
one-way valve for de-gassing the fresh roasted coffee…strategically placed inside the
artwork on the coffee cup’s steam to add the stimulant of aroma to the packaging.” Bags
also feature sticker with new detailed descriptions about coffee, information about
country of origin. Color-coding identifies coffee roast. “Tin ties that allow for resealing
now feature botanical and company information on them,” Sheehan reports. “For
example, ‘In Guatemala, we have built and supplied a children’s library’ or ‘In Costa
Rica, our supplier is part of a 40,000 acre eco-preserve.’” Follow-up: At Fres-co Chris
Burger, +1 215-721-4600, ext. 2129, cburger@fresco.com; at Natureworks, +1 877-
423-7659; Link: www.natureworksllc.com. Packexpo.com, Sept 10, 2007
 Sustainability
Social Responsibility Leads the Way at Green Mountain Coffee Roasters

“GMCR packages its ground and whole bean

coffee in multilayer flexible packaging.
The company is working with its
supplier—Fres-co® System USA, Inc —
to research the feasibility of replacing as
many as 2 of the 4 nonrenewable polymer
layers in the flexible packaging with
PLA. The key will be to maintain vapor
and moisture barrier specifications.
GMCR recently introduced new
packaging for its Newman's Own®
Organics line of coffees that incorporates
a single layer of PLA into the overall
packaging.”
Sustainable Packaging newsletter, Sept 07
 Sustainability

Current standard12 Retail Items

4-ply easy open = 48PET/Ink/adh/28Alu/adh/48PET/adh/3.0PE

0.48 mil Polyester Film (provides heat & abrasion resistance)

Adhesive

0.28 mil Aluminum Foil (provides oxygen, moisture & light barrier, stiffness & dead fold)
Adhesive

0.48 mil Polyester Film (provides oil barrier, improves seal performance, protects foil from cracking)
Adhesive

2.5 mil Polyethylene (provides structure bulk & feel, abuse resistance, sealant layer)

0.5 mil Easy Open 11Ax3 (provides hot tack and easy peel )
 Sustainability

Revised 12 Retail Items

4-ply easy open = 48PET/Ink/adh/28Alu/adh/80PLA/adh/2.5PE
0.48 mil Polyester Film (provides heat & abrasion resistance)
Adhesive

0.28 mil Aluminum Foil (provides oxygen, moisture & light barrier, stiffness & dead fold)
Adhesive

0.80 mil PLA (provides oil barrier, improves seal performance, protects foil from cracking)
Adhesive

2.0 mil Polyethylene (provides structure bulk & feel, abuse resistance, sealant layer)

0.5 mil Easy Open 11Ax3 (provides hot tack and easy peel )
 Sustainability

NatureFlex
Packaging referenced as
‘biodegradable and
compostable’.

www.SuperfoodSnacks.com
 Sustainability

NatureFlex

Significant Cost Upcharge Coff

ee
Frac
Pack e
Coffe
c Pa ck
Fra

100% renewable and compostable Frac-pack?

 Reduce

Current standard12 Retail Items

4-ply easy open = 48PET/Ink/adh/28Alu/adh/48PET/adh/3.0PE

0.48 mil Polyester Film (provides heat & abrasion resistance)

Adhesive

0.28 mil Aluminum Foil (provides oxygen, moisture & light barrier, stiffness & dead fold)
Adhesive

0.48 mil Polyester Film (provides oil barrier, improves seal performance, protects foil from cracking)
Adhesive

2.5 mil Polyethylene (provides structure bulk & feel, abuse resistance, sealant layer)

0.5 mil Easy Open 11Ax3 (provides hot tack and easy peel )
 Reduce

Revised standard 12 oz. Retail Items

4-ply easy open = 40PET/Ink/adh/26Alu/adh/40PET/adh/2.0STF

0.40 mil Polyester Film (provides heat & abrasion resistance)

Adhesive

0.26 mil Aluminum Foil (provides oxygen, moisture & light barrier, stiffness & dead fold)
Adhesive

0.40 mil Polyester Film (provides oil barrier, improves seal performance, protects foil from cracking)
Adhesive

1.5 mil STF

0.5 mil Easy Open 11Ax3 (provides hot tack and easy peel )
 Reduce
Standard 2 oz. “Frac Pack”
2-ply easy open = OL/Ink/48METPET/adh/2.0PE

48 Gage Met PET

Adhesive

2.0 mil Polyethylene

 Reduce
Revised 2 oz. “Frac Pack”
2-ply easy open = OL/Ink/40METPET/adh/1.0 STF

40 Gage Met PET

Adhesive

1.0 mil STF

 Graphics
Holographic

Fres-co System USA, Inc. Confidential – Reproductions Prohibited

 High Pressure Packaging

Zip Lock
Reclosure

Shaped
Pouch

High Pressure
Valve

•A study has been conducted at a university in

Italy which shows that coffee under pressure of
CO2 maintains its organoleptic properties longer.

Fres-co System USA, Inc. Confidential – Reproductions Prohibited

 Valves

Frac Pack
Direct pack from Grinder

No “Degas” time

No need for storage Coff

ee
degassing bins Frac
P ack
e
Coffe
Extreme FRESH coffee Pack
Frac
Reduce Secondary Packaging
(Box Size)
Fres-co System USA, Inc. Confidential – Reproductions Prohibited
 Valves
Lid Stock

Fres-co System USA, Inc. Confidential – Reproductions Prohibited

 Questions

Fres-co System USA, Inc. Confidential – Reproductions Prohibited