Industry awards are a good barometer of the direction packaging innovation is taking, which in turn reflects broader industry and consumer trends informing design and material choices. The well-established Packaging Innovation Awards (PIA), sponsored by Dow, are no exception.
The PIA awards were presented at Tokyo Pack 2024, attended by PKN. Afterwards we asked Bambang Candra, APAC commercial vice president, Dow P&SP, to share his thoughts on the top trends evident through the winning designs, Asia's position at the forefront of packaging innovation, and his views on the value of these awards.
PKN: What were the top three trends observed from the PIA?
BC: A key trend that immediately jumped out from the entries received was the recognition of the value of renewable materials. With the use of materials like post-consumer recycled plastics and bio-circular materials, value chain stakeholders are delivering tangible benefits to consumers, business, and the environment. These materials contribute to reduced environmental impact, waste reduction, positive brand perception, regulatory compliance, and opportunities for innovative packaging solutions.
This is exemplified through innovations such as Korea’s CJ CheilJedang Hetbahn tray for cooked rice, created with 25 per cent ISCC Plus certified bio-circular materials, a process not commonly used in microwavable packaging. According to CJ Cheiljedang, this reduces carbon emissions by 17% – approximately 12.7 tons per year. The improved Hetbahn packaging blocks oxygen and bacteria, and coupled with an aseptic packaging process, can be safely distributed at room temperature with a shelf life of 9 months.
Next, there is an increasing shift towards mono-material packaging that is designed for recyclability. Mono-materials have gained significant traction in the face of growing consumer demand for sustainable packaging solutions and strict regulations governing plastic waste and recycling. Thanks to advancements in materials science and manufacturing processes, it is now feasible to produce high-quality packaging using a single material type.
For instance, Packaging Industries Limited in Kenya introduced the BarrierFlex NutVault plastic packaging bag for nuts, made from a fully recyclable high-barrier ethylene-vinyl alcohol copolymer (EVOH) bag.
Addressing critical challenges such as flex cracks and decreased effectiveness in oxygen and moisture barriers, the bag not only offers improved shelf life, enhanced safety, and significant environmental benefits, but it also represents a transformative step in the export packaging of cashew and macadamia nuts.
Lastly, we are observing lightweighting enabled by technology advancement and downgauging – the process of reducing the weight of packaging materials without compromising their performance. This has clear business and environmental benefits, but it has always been restricted by the limitations of technology. However, driven by innovative thinking, lightweighting has featured strongly across finalist nominations this edition, driving the industry's commitment to reducing packaging's environmental footprint while maintaining product integrity and meeting consumer needs.
One such entry that reflects this, hails from Gerdau, the largest Brazilian steel producer. It adopted a graphene-enhanced flexible plastic packaging that addresses issues with punctured packaging containing its nail products during the filling process in a quest to reduce its plastic consumption and packaging damage rates. Gerdau teamed up with Gerdau Graphene to enhance its packaging robustness with graphene, a nanocarbon material renowned for its exceptional mechanical properties, by using Poly-G, Gerdau Graphene’s first industrial-scale graphene masterbatch.
The solution helped Gerdau deliver significant improvements in processes and performance of its packaging, leading to a 25 per cent reduction in packaging thickness, saving over 72 tonnes of unprocessed polymer per year, which contributes to less plastic waste directed to landfills or recycling centres.
PKN: Since the event was staged at Tokyo Pack, what top 3 standout innovations have emerged from Japan in this edition of the PIA?
BC: Japan has had an exceptional showing at this year’s award. For starters, the Diamond Award, the most prestigious award at PIA, was awarded to Panasonic Energy and Toppan Infomedia for their innovative paper-based bag for dry batteries that was a transformative departure from the conventional blister pack.
This ingenious packaging immediately contributes to the reduction of its environmental impact while enhancing user experience.
The replacement of conventional blister packs reduces packaging material use by 38 per cent to 60 per cent depending on size, resulting in more than 50 per cent reduction in CO2 emissions. More importantly, the packaging can be easily produced globally without compromising size and durability, while offering enhanced convenience and ease of use.
Next, there is the incredibly fun “Pino Gacha” ice-cream packaging by Morinaga Milk Industry with Toppan. A gold award winner at the PIA, this irresistible packaging promotes greater engagement with the consumer whilst engineering greater product sales.
When consumers purchase two boxes of ice-cream, they can fuse both cardboard boxes together, transforming the packaging into a gachapon-styled vending machine, inviting consumers to spin the contraption, and be surprised by the ice-cream that is dispensed at random.
Finally, there is Toppan's “Tube Pouch” plastic tube container for food and cosmetics products combining tubular and flexible packaging technology to significantly reduce plastic while improving usability. Compared to conventional laminated tubes, this resealable tubular container boasts over 30 per cent plastic reduction and allows for easier access to product content. The special structure of the tubular container also makes it easy for users with limited strength, such as children and seniors, to completely squeeze out the contents.
PKN: Why is Asia a conducive environment for catalysing packaging innovation?
Considering Asia's well-established role as the world's manufacturing hub, there is no better time or place to spotlight and emphasise the significance of packaging innovation and its profound impact on our daily lives.
The region is on a world stage with many local and regional brands going global, and its rapid economic advancement has given rise to affluent consumerism of the middle class across key Asian cities, particularly in the key segments of food, consumer, healthcare and even automotive. Coupled with the rapid urbanisation in the region, this creates greater demand for packaging that meets needs such as convenience and sustainability, spurring the packaging industry to push the boundaries of innovation.
To promote collaboration and accelerate the development of innovative packaging solutions that support the circular economy in the region, Dow has three Pack Studios located in Shanghai, Singapore and Mumbai that provides brands with the opportunity to leverage Dow’s technical expertise, broad product portfolio and leading application testing capabilities.
For example, Pack Studios Shanghai is equipped with multiple fabrication lines, physical testing equipment and leading characterization technologies, enabling innovation and support at every step of the packaging process, from product validation and application development to packaging innovation and recyclability research.
PKN: Why are awards like the Packaging Innovation Awards (PIA) necessary to spur the industry to push the boundaries of packaging innovation?
BC: One of the brilliant things about awards like PIA is its ability to cast a spotlight on the future of innovation and its imminent influence across the industry. We approach every edition with excitement and anticipation at uncovering emerging technologies, practices, and innovations, and the 2024 round has not disappointed.
During a rigorous evaluation process held in Bangkok last June,18 industry experts* from across the packaging value chain convened to lend their expertise to identify the next generation of innovative packaging solutions that will help shape the future of the industry.
*Ed's note: Included on the judging panel from the Australian market was, Brian McKay, Fellow of the Australasian Institute of Packaging, and head of packaging at Woolworths.
