Health and safety takes priority when it comes to food-grade packaging. Everything from the materials to the manufacturing process to the packaging design must protect the food inside and make sure that it's safe to eat when it reaches the consumer. This is why there are strict regulations, testing procedures and packaging codes in place to ensure that all food packaging is fit for purpose.
Modern food packaging has evolved and now includes a huge array of styles, from soft baby food pouches to HDPE plastic milk bottles. Whatever food or beverage needs to be shipped or stored there will be packaging to match. Keep reading to discover what sets food packaging apart from other packaging, and a glimpse at just some of the options available.
What makes packaging food grade?
Packaging must be made from the right materials and manufactured in the right way to the right design to be certified as food-grade. There are five key properties that all food packaging will have in common;
- Material stability - Firstly it must be made from an inert material, that won't react when it comes into contact with food. Some plastics are unsuitable because they degrade and leach chemicals into food. Polyethylene (PE) and polypropylene (PP) are chemically inert, so they are often used for buckets, jerry cans and bottles designed for food and beverage use.
- Fit-for-purpose - Packaging choice will depend on what it will be used for. Any food packaging designed for wholesale shipping or storage must be fit-for-purpose. Rigid packaging is the best choice for safely shipping in bulk because it offers the best puncture resistance and the highest level of protection.
- Non-Toxic - There must be no toxic internal coatings, dyes or additives that might be harmful. This is why a metal jerry can that’s designed for fuel can't be used to carry drinking water, the internal powder coating that protects the can from degradation is toxic and soluble in water, so it would contaminate the contents, making them dangerous to drink.
- Certified - Legislation exists to ensure that packaging meets the right criteria. Certified packaging must meet the regulatory standards set by the Food Standards Agency (FSA). The Food and beverage packaging logo of a glass and fork can be found on approved packaging and offers a quick way to check whether a container is designed for food and beverage use (or not!). The BRC Global Certified scheme ensures that manufacturers and suppliers meet the right safety standards when it comes to food, and is a requirement for food and beverage storage and distribution.
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Sealable - Packaging that's designed to store and transport food must be sealable. A range of measures such as tamper-evident tabs, heat seals and snap caps can all help to keep the contents safe in transit.
Hygiene standards are essential when making food-grade packaging.
Here Invopak's Scott Sandilands visits our BRCGS certified small tub manufacturer in Denmark.
What's the difference between food safe and food grade?
Food Grade is a categorisation given to a particular material. Food Grade means that the material doesn’t contain any toxins or dangerous contaminants and has been manufactured according to health and safety regulations. It means that a product can be used to store a wide range of raw materials and finished food and beverage goods.
Food Safe refers to a finished product. For an item to be certified food safe it must be made from food-grade material and also be fit for the specific purpose for which it’s designed. This means that other factors are also important such as; temperature, how long the item will be in contact with food and cleanability. A coffee cup is a good example of a food-safe product. Because it’s designed to hold a hot drink it needs to keep its shape and remain intact even under wet, boiling conditions!
In a nutshell, Food Grade means the packaging is suitable for general food and beverage use, whilst Food Safe means the finished product is safe to use for a specific purpose.
What kind of packaging is food grade?
There’s a huge variety of food-grade packaging available. It can broadly be split into two categories, flexible packaging and rigid packaging.
Flexible packaging
Flexible packaging can be made from a wide range of materials including soft plastic (pouches, films and shrink wrap), paper and foil. It's thin, lightweight and malleable and is often used to package the final product, it includes anything from a crisp bag to a shrink-wrapped lettuce. Its main function is to seal the contents from the outside world protecting them against oxidisation, moisture and contamination.
Flexible packaging is excellent at lengthening the shelf-life of goods and is a cost-effective way to preserve produce and keep it safe. However, the thin, soft nature of flexible packaging means that it offers minimal physical protection, making it vulnerable to puncturing or transit damage. It is often used for the final product and will be packed in bulk in stronger secondary containers to ensure safe shipping.
Rigid packaging
Rigid packaging is made from hard materials including metal, glass and hard plastic. It offers the highest level of protection and is suitable for shipping consumable items in bulk as well as for storing the end product that will be stacked directly on the supermarket shelf. Rigid packaging comes in a wide variety of sizes and styles and includes buckets, bottles, jerry cans, tubs and cans.
Plastic buckets are one of the most versatile types of rigid packaging. They come in a wide variety of sizes from 1 litre to 25 litres and in a range of colours including clear, white and black. Clear 1 litre buckets are popular for popcorn, candyfloss and sweets because they showcase the product as well as protecting it, whilst larger sizes are great for wholesale use, such as chip shop mushy peas or sauces.
Traditionally liquids have relied on the strength and puncture resistance of rigid packaging. Everything from milk to wine to oils to Coca-Cola relies on rigid packaging. Carbonated drinks are bottled under pressure so the packaging and closure must be strong enough to resist these forces, this is why they are packaged in cans or bottles engineered for the purpose. Plastic jerry cans are ideal for storing sauces, oils and liquids in bulk and they are available with spouts and nozzles that make for easier dispensing too.
Whatever your food packaging needs we can help. We are a rigid packaging specialist and can advise you on the best packaging choice for you. We also offer in-mould labelling on most of our products (MOQs apply), just get in touch with our team if you'd like to find out more.
The three types of food packaging
Primary Packaging
Primary packaging is any packaging that has direct contact with the product, and if the product is a food or beverage it must be made from certified food-grade materials. Primary packaging covers the widest range of packaging types and includes soft and rigid packaging.
Soft primary packaging includes mesh fruit bags, food and drink pouches and anything shrink-wrapped. If soft packaging is used the goods will usually need to be packed in secondary or tertiary packaging to keep them safe in transit.
Rigid primary packaging provides the highest level of protection, so there's less need for strong secondary and tertiary packaging. This type of packaging is made from hard PP or HDPE plastics, glass and metal (steel and aluminium), and common examples include food tins, ring-pull cans, plastic buckets, tubs and glass jars. It is used for a wide variety of products too including; jams, sauces, ready meals, pulses, soup, cakes, sweets... the list is endless!
Liquids are also commonly stored in rigid primary packaging because it helps to minimise the risk of spills and leaks. Thin aluminium cans and clear HDPE bottles have an excellent strength-to-weight ratio whilst keeping the contents safe and sealed until needed. Expensive food flavourings and essences may be stored in specialist aluminium bottles which protect the contents against spoilage from exposure to light or odours.
Secondary Packaging
Secondary packaging is the next layer of packaging. A cereal box is a good example of a product that uses primary and secondary packaging. The plastic bag (primary layer) seals against air and moisture to keep the contents fresh, whilst the cardboard box is the secondary layer which will include the branding and necessary nutrition information. Each material has a specific purpose - one protects (the primary plastic packaging) and one promotes. (the secondary cardboard layer).
Tertiary Packaging
Tertiary packaging is the third category, it's also called shipping or transit packaging because it’s designed to protect the primary and secondary packaging when goods are transported. Tertiary packaging is purely functional and is typically made from cardboard or shrink wrap. It won’t be seen by the end customer so there’s no need for printed decoration or advertising slogans - it serves one function, to make sure a product gets safely from A to B.
Tertiary packaging also allows goods to be moved efficiently, as well as safely. Pallets and pallet wrap keep the goods in standardised units for more efficient handling. Plastic wrap is a good option for this purpose because it is economical, flexible and can be used with a wrap machine, making it fast to use. It also offers a level of protection against dirt and moisture.
Food packaging labelling must include all sorts of information including nutrition facts
What are the major functions of food packaging?
The first function of food packaging is to keep the contents safe and fit for consumption, but the best packaging does that and more. Food packaging typically serves four purposes;
- Protection
- Preservation
- Promotion
- Regulatory Compliance
Protection
The level of protection needed will depend on the produce and the challenges it needs to meet. The best packaging will protect the goods cost-effectively and efficiently - it should provide the necessary level of protection but no more. If packaging is over-engineered it will incur larger manufacturing and material costs than is necessary. The cardboard egg box is the classic example of a packaging design that keeps the contents safe, whilst also being light, recyclable and efficient to pack in bulk.
Once upon a time, food packaging was minimal, people went to the local greengrocer or butcher and things were wrapped in brown paper bags or carried home in a basket. The move to supermarket chains and the explosion of global brands has meant that food travels further and needs to be preserved for longer, so the demands on packaging have changed as a result. Tamper-proof designs and rigid, protective packaging are essential for foods that will travel long distances from production source to consumer.
Preservation
Food packaging plays an important role in preservation. The right packaging keeps produce fresher for longer by protecting it from oxygen, moisture, pests, contamination and odours. Shrink wrap plastic packaging can nearly triple the shelf-life of fruit and vegetables, helping to limit food waste. A longer shelf life offers more time to ship and sell, increasing profitability for food manufacturers and retailers.
Promotion
Packaging is also about promotion. Well-branded packaging will attract buyers on the shop floor and is essential for building brand recognition and loyalty. The best designs become iconic and instantly recognisable, think the Heinz Beans can or Cadbury's chocolate bar - they are easily recognisable at a glance. Advances in digital printing have opened up even more opportunities by making it possible to do shorter print runs. Small craft brewers can now package their beers in digitally-printed aluminium cans, giving them a premium look that matches their premium-price product. Plastic buckets and tubs can also be printed with designs at the point of manufacturer, which offers a durable and high-quality finish for wholesalers and manufacturers.
Regulatory compliance
If marketing is the art of labelling then regulatory information is the science. In the UK there's a host of information that must be displayed on the packaging including; the name of the food, "best before" or "use by" date, necessary warnings, allergens, net quantity, ingredients, and place of origin (if required). This is a legal requirement and food companies must ensure all foods and drinks are correctly labelled.
Food Grade Packaging from Invopak
We stock a wide range of food packaging and are also BRC Global Standards Certified AA for storage and distribution, so you can order your food packaging from us with confidence. We also offer in-mould labelling and offset printing options, just get in touch with the team to find out more.