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Logistics of pkg key; represent core of integrated supply chain
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Wednesday, 07 May, 2025, 08 : 00 AM [IST]
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Ganesh Gaikwad, Dr R B Kshirsagar & Sugreev Shinde
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The beverage industry is one among the front-liners where massive investments are being made for expansion and technological upgradation. The packaging of beverages both carbonated and non-carbonated, is a complex technological branch in the food processing/packaging industry. The traditional returnable glass bottle has given way to newer plastic containers as well as cartons.
The current trend is to improve the conventional containers, extend their share in the large market, extend the shelf-life of the products, provide greater consumer convenience and ultimately to produce economic packages.The changing Indian scenario, with implementation of various technologies and market promotion activities, has changed the scope for this industry exponentially.
Beverages can be defined as “any fluid which is consumed by drinking”. It consists of diverse group of food products, usually liquids that include the most essential drink “water” to wide range of commercially available fluids like fruit beverage, synthetic drinks, alcoholic beverage, milk, dairy beverages, tea, coffee, chocolate drinks.
Despite differences in their properties one common feature that exists in all beverages is their ability to act as thirst quencher. In simple words beverages can be defined as “liquid which is essentially designed or developed for human consumption”. Beverages are rarely consumed for food value but are vital for life. Although their prime role is to fulfil the human need but these are part of our culture.
Packaging fulfils important functions such as protective function, storage and transport function or the information function for ingredients, sugar content, best before date, barcode or disposal notice. Today’s consumers expect more from beverage brands – not only in the product they purchase, but also in the way those products are packaged.
They want packaging that not only protects products and keeps them safe and hygienic, but also contributes to the circular economy – all while providing a delightful experience. In response, leading beverage brands are reimagining their approach to packaging to meet shifting consumer expectations and achieve operational goals of reducing total cost, increasing sustainability, reducing risks and growing sales.
When assessing beverage production facilities, today’s packaging lines are viewed, assessed, photographed and accepted or critiqued as a modern-day marvel of technology. Generally, observers see a production line filling containers with product and discharging cases or units to unseen storage areas. However, mention logistics in reference to a beverage packaging line and experience, and one might find that a remote or vague relationship exists between such a line and logistics. Why the focus on logistics?
The logistics of beverage packaging lines are important and vital because they represent the core of an integrated supply chain. So what is meant by logistics? Definitively speaking, package line logistics consist of an input-output movement cycle of procurement, maintenance and transportation. In real time, simple terms, the line logistics mean providing materials (processed raw and packaging), facilities (machinery and equipment) and staff (trained people) to result in a finished product. Without this logistical flow, there would be no saleable product.
To accomplish the mission of an efficient packaging line, the logistical elements must be comprehensively defined and evaluated to determine what actually is needed and whether it will be effective in production. In this perspective, several sensitive operating issues are involved: the facility and the type of lines, speed, capacity and space; the materials, including product characteristics, batched/inline, container type, closures, coding, labelling, container wrapping, self-manufacture and supply space; and lastly, the people such as the operators/attendants, multi-tasking, qualifications required, experience, manual/auto/semi-auto. These logistical packaging line elements must be updated and integrated when physical operating conditions change.
The packaging requirements for all types of beverages are:
- Absolutely leak-proof and prevent contamination
- Protect the contents against chemical deterioration
- No pick up of external flavours
- Be hygienic and safe
- Retain carbonation in the case of carbonated beverages
- Economical, easy to use and dispose
- Good aesthetic appearance
Key parameters to be considered when selecting a packaging system are:
- Process
- Distribution, shelf-life requirements, legislation
- Product composition and quality as produced and at full shelf-life
- Product protection required during storage, distribution and retail sale
- Pack size, printing options, display etc.
- Packing system concept, automation options, ability to integrate with existing and/or future systems
- Consumer appeal, image of product and packing
The different packaging materials used are:
Glass Containers:
The use of glass bottles for the packaging of fruit beverages was widespread although the hot-fill/hold/cool process had to be applied with care to avoid breakage of the containers. Glass is still the preferred packaging medium for high quality fruit beverages. However, over recent years, an increasing proportion is being packed aseptically, into cartons.
The improvements that have occurred in glass bottle packaging are: Light weight, Surface coating to increase abrasion resistance, Use of wide mouth containers fitted with easy-open-caps.
Metal Containers:
Tinplate cans made of low carbon mild steel of 99.75% purity, coated with tin with easy open ends are used. These tinplate containers are either 2 piece or 3 piece containers. They are lacquered internally to prevent corrosion.
Plastic Containers:
Fruit juices contain organic substances, which are sensitive to bacterial contamination. Packaging of such products is done through hot filling, to achieve extended shelf-life, PET bottles are usually used for hot filling applications. Special features are added to the containers through design and manufacturing process. The package is heat-set in order to improve the temperature resistance of the containers. PET resins with a higher Tg (glass transition) temperature and/or a faster rate of crystallisation are used.
Aseptic Packages:
Ready to serve fruit beverages and fruit pulps / concentrates, packed in aseptic packages provide excellent protection for fruit juices / pulps. These aseptic packages are made by combining thermoplastic with paperboard and aluminium foil. Their multi-layered construction enables the carton to protect the contents from various factors responsible for spoilage. The aluminium foil layer is a strong barrier for O2 and light. The inner plastic layer made of polyethylene makes it possible to seal through the liquid. The outer paper layer provides stiffness making it possible for the cartons in a brick shape, thus, enabling maximum utilisation of available storage and transportation space. Excellent graphics are possible leading to good display and shelf appeal and also providing information regarding the product. The aseptic process makes the product bacteria-free before being packaged.
Rigid Containers:
The purpose of this container, is to hold the bag during storage, transportation and use. As is evident, the bag being made from flexible films, is incapable of being stored and transported by itself. Hence, each bag is individually stored into rigid outer container post filling. For packs of capacity below 50 litre, corrugated fibreboard cartons are generally used as the rigid containers. Beyond that plastics and metal drums are used. For very large bags, 1000 litre, + polygonal (6-8 faces) corrugated fibreboard containers made from 7 to 9 ply are used, though there are other alternatives as well.
(Gaikwad is research scholar, College of Food Technology, VNMKV, Parbhani; Dr Kshirsagar is head, Department of Food Engineering, College of Food Technology, VNMKV, Parbhani; Shinde is research scholar, College of Food Technology, VNMKV, Parbhani. They can be reached at ganeshpg107@gmail.com)
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