Effective dairy packaging plays a vital role in ensuring that dairy products are delivered to consumers in optimal condition. In a highly competitive global dairy product market, brands are striving to differentiate themselves through innovative packaging while also meeting strict safety, quality, regulatory, and environmental standards.
In today's competitive market, brands are facing increasing pressure to meet consumer demands for convenience, sustainability, and freshness. This shift in consumer preferences has pushed companies to innovate their dairy packaging to not only boost customer loyalty and brand recognition but also to offer eco-friendly options and a wider variety of shapes and sizes for dairy products. As brands strive to stand out in the market, creating packaging that aligns with these factors is essential for success in the ever-evolving dairy industry.
How can companies effectively align various factors in creating sustainable and recyclable rigid dairy packaging, while maintaining brand identity, functionality, and product protection? Let's explore some of the essential factors to consider when creating sustainable and recyclable rigid dairy packaging:
Sustainable Material Selection
The first step to developing a sustainable dairy packaging design is material selection. While various polymers may provide the mechanical properties required for the application, not all of them will be sufficient from a sustainability perspective. It is important for companies to take a holistic approach to evaluating material alternatives to ensure that packaging solutions offer true improvements to sustainability & recyclability that will meet organizational goals long-term.There are three key areas to consider when selecting rigid plastic materials for sustainable dairy packaging design:
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- Recyclability: Is the material recyclable at-scale today or is it expected to be in the future? Resources like the Association of Plastic Recyclers and How2Recycle serve as a great starting point to see if the proposed material will meet the baseline requirements for recyclability.
- Plastic Waste: Will the selected material result in more or less plastic waste? Considering a polymer's weight & density, and selecting a lighter-weight material when possible, can go a long way in helping reduce material consumption and plastic weight.
- Life-Cycle Assessments: Companies seeking a more data-driven approach may turn to LCAs to inform and support sustainable packaging decisions. A LCA considers all stages where potential impacts can occur at varying times over the course of a products “life,” analyzing the impact on emissions and consumption including transportation emissions, water consumption, fuel consumption, and CO2 equivalents.
- Recyclability: Is the material recyclable at-scale today or is it expected to be in the future? Resources like the Association of Plastic Recyclers and How2Recycle serve as a great starting point to see if the proposed material will meet the baseline requirements for recyclability.
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Balancing Sustainability with Process Compatibility
Once a company has narrowed down material selection to a few sustainable choices, it is essential to consider how the material will perform with their existing or planned processing method.
The selection of processing methods for dairy packaging is intertwined with the choice of materials and the desired performance of the final package. From cold-fill to aseptic processing, each method plays a pivotal role in determining the most suitable material for ensuring the safety and integrity of the product.
For example, if the packaging material will undergo high heat conditions, using a polymer with a high heat tolerance like polypropylene would be ideal. Or if the company has existing thermoforming or form fill seal equipment, they will want to evaluate alternatives against equipment capabilities and limitations to ensure that the material will offer compatibility with existing systems and processes to avoid unnecessary capital expenditure.
Consult Design for Recyclability Guidelines
Design for recyclability is an essential step in achieving industry-wide goals for waste reduction & improved sustainability in packaging.
When it comes to recyclable dairy packaging design, there are five organizations whose guidelines have emerged as the standard for design for recyclable food packaging to help companies determine if their packaging solution can be effectively recycled including the APR Design Guide, US Plastics Pact Problematic & Unnecessary Materials List, How2Recycle, Walmart’s Recycling Playbook, RecyClass and the Consumer Goods Forum Golden Design Rules.
In addition to evaluating if the base material is recyclable at-scale in the US and abroad, these guides take it a step further by encouraging companies to evaluate how incorporation of different elements such as color, barrier materials, or inks & dyes used to impart design features may affect recyclability. In addition, the design guides provide guidance for additional packaging components outside of the rigid container including lidding films, caps & closures, labels, and banderols, so that companies can make sure that these necessary elements are not detrimental to recycling.
Sustainability Meets Consumer Experience
Outside of consumer's desire for improved sustainability in packaging, consumer preference for convenience and on-the-go products have resulted in an increase in the variety of dairy products packaging formats and sizes.
One of the ways in which brands are doing this is through adding versatility among packaging sizes. For example, consumers can choose from a selection of bulk tubs or single-serve cups for yogurt, individual cups vs bottles for creamers, etc. While these variations in size for the same product consider different consumer experiences, brands must also consider how these products will perform from a sustainability perspective. One consideration is if smaller-sized formats will pass the 2” minimum threshold to be effectively sorted through the ballistic sorting process at the MRF.
Further examples of how brands have innovated dairy packaging designs to elevate consumer experiences involve incorporating toppings like granola or candy, mixable fruits in yogurt products, or introducing features that allow products to be bundled and easily separated. For instance, there are designs with two compartments that flip open or yogurt multi-packs that effortlessly snap apart for individual consumption.
In every scenario, it is essential for companies to verify that the chosen material possesses the required mechanical attributes to fulfill these functional aspects, all while refraining from introducing materials, fillers, or additives that could potentially compromise recyclability. For instance, the inclusion of additives or mineral fillers aimed at enhancing rigidity could negatively impact the material's recyclability.
Resealable packaging, such as a resealable cheese & cracker snack-pack, or deli container, can also enhance consumer experience and by allowing them to store uneaten food in the same container and cut down on food waste and the resulting environmental implications.
Preserving Product Protection
At its core, the main function of the packaging is to preserve the product. This is particularly essential for dairy items such as yogurt, creamers, and milk, as any spills during transportation can lead to a messy situation. Factors such as the material's impact strength to withstand drops and its top-load strength to prevent crushing in transit are key in safeguarding both the packaging's integrity and the product's quality throughout the supply chain. Opting for a material that meets the required impact and top-load strength specifications, all while maintaining recyclability, is paramount for a successful dairy packaging design solution.
Packaging not only plays a crucial role in safeguarding the product during distribution but also serves as a key factor in maintaining the safety, quality, and freshness of dairy products. It is essential to identify and address the shelf-life and sensory requirements of the product in the dairy packaging design process. This involves considering various elements such as food processing, protection against UV degradation, the supply chain, consumer appeal, and intended usage to ensure the longevity and appeal of the dairy product.
Given the vast array of dairy products on the market, the decision between barrier and non-barrier materials depends on factors such as the specific food item, storage conditions, and desired shelf-life. Companies must assess whether the intrinsic barrier properties, such as Oxygen Transmission Rate (OTR) and Moisture Vapor Transmission Rate (MVTR), of the chosen material are sufficient. If not, the incorporation of specialized barrier materials should be evaluated, taking into consideration the potential impact on the recyclability of the packaging.
Incorporating Design Elements without Sacrifice to Sustainability
In such a saturated market, the design and shelf-appeal of dairy products packaging plays a highly important role in attracting consumers’ attention and affecting their product perception and buying behavior. According to the paper “Studying the Influence of Packaging Design on Consumer Perceptions (of Dairy Products)” some marketers believe that packaging is a more powerful tool in influencing consumers than advertising or other marketing tools, and presents an opportunity to persuade the consumer to buy the product before brand selection occurs.The role of branding and aesthetics in dairy packaging design is crucial for attracting consumer attention and building brand loyalty, yet it must be balanced with considerations for recyclability. While opaque pigments can contaminate recycling streams and hinder recyclability, the strategic use (or absence) of color can greatly influence consumer perceptions and product recognition. When transitioning to transparent materials, companies must carefully assess the impact of incorporating light degradation additives on recyclability. If maintaining design integrity on the plastic container risks recyclability, alternatives like direct printing or banderols may be considered. In any case, it is essential to ensure that inks, dyes, and adhesives used are easily removable during the recycling process.
Interested in learning more about ICPG’s sustainable, functional and versatile solutions for dairy packaging? Download our Ultimate Guide to Rigid Dairy Product Packaging today:
