Innovation in Food and Beverage Packaging:

Unwrapping the Testing Environment

Executive summary

Key takeaways 

Report Contents

Section 2: How are packaging professionals navigating these developments?

Section 1: Where do the opportunities lie? 

Looking ahead

About Industrial Physics

Methodology and demographics 

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To answer this, we surveyed 380 packaging professionals in the food and beverage industry across the UK, US, Germany, India and Malaysia. We also sought the opinions of a range of technical experts – both within Industrial Physics and more broadly across the industry - to gain insight from their invaluable experiences.

 
The findings overall present a promising picture, with half of packaging professionals in agreement that their company’s testing process has changed positively.  

Our report lifts the lid on the statistics - examining the testing processes that are proving most popular in 2024, and the causes behind the positive shift. Theories from our experts unpack these findings – exploring topics such as the greater focus on waste reduction in the testing process; the opportunity for cost advantages; and the improvement in quality control throughout and beyond the testing process.

 EXECUTIVE SUMMARY

In the first edition of our Innovation in Food and Beverage Packaging report series this year, we explored how internal factors including lay-offs, skills gaps and new technologies were impacting the level of innovation in packaging companies today. In our second report, we will be examining the testing environment; exploring where professionals see the most opportunity, and how they are capitalizing on this.

We know from investigating thoroughly over the past few years via research and our own experiences with customers that there are many complexities in food and beverage packaging. Navigating this environment with involvement from multiple teams can help to drive a company forward with quicker decisions, however, it can also halt innovation altogether.    

In 2024, packaging innovation does not have to be a concern for stakeholders. Over the years, test and measurement technology has evolved to support developments with new materials and processes. However, companies must understand the importance of selecting the right equipment and analyzing the data to protect the integrity of their packages and brand reputation as they innovate. As technology continues to expand and a wider spectrum of package testing solutions become available, do professionals understand how to utilize these tools to help meet objectives?

50%  of respondents feel their company has made positive changes to the packaging testing environment in the last five years: 

KEY TAKEAWAYS​

Responses varied between those based in different countries, and those working with different materials. Positive perceptions were highest in the US at 62%, perhaps driven by the strong corporate culture and appetite for process improvement. Meanwhile, there’s more inertia across parts of EMEA, with just 37% of German packaging professionals agreeing that they’d seen positive changes to packaging testing within their company.

100% inspection

100% inspection was the second highest ranking testing opportunity. This method presents several commercial benefits to companies, including significant reductions in waste and product recalls. Although experts agree with its desirability, they did identify barriers. Steve Davis explains, “100% inspection has always been the goal, but the constraint today is the ability for companies across food and beverage industries to access the technology. When it is further developed and a cost-effective choice for a higher proportion of businesses, we can expect to see significant investment in this method.”

As Michael Joseph outlines, the opportunity at this stage is in managed improvements: “I think it’s more likely that food and beverage manufacturers are increasing incrementally, perhaps from 10% inspection to 20% inspection, for example, which is still a significant achievement. The only realistic application of 100% inspection at this point is where the nature of the product requires it and the margins warrant the cost.”

However, across the board, businesses must consider the impact of downtime. If testers go down and calibration is required, production is halted – resulting in significant financial and reputational cost. Therefore, many manufacturers are now investing in back-up testers to overcome this.

Non-destructive testing methods

Yet, for many, the overarching motivator is financial. Pursuing processes that reduce waste in packaging manufacture and testing can save time on the line and reduce the quantities of materials required per batch – increasing cost effectiveness. 

Rodger believes there could be more of an opportunity for predictive modelling so paper professionals can either minimize testing or carry out spot checks, but for now it’s unlikely that they can move away from the destructive tests completely – especially without deviating from customer specifications and compromising on quality.

Ones to watch: in-line testing and handheld testing devices

While automatic process control, 100% inspection and non-destructive testing came out on top in our research, in-line testing came close in fourth place at 36%. The integration of testing equipment directly on the production line is becoming more desirable. It allows companies to detect issues immediately, reduce downtime and defects, and provide greater insights for process improvement.

However, hand-held testing devices offer less opportunity as a standalone test - it’s more like adding another tool to the toolbox, as Michael Joseph explains, “The reason packaging professionals want hand-held devices is not to replace, but to complement. They’ll still have benchtop units in the lab, but handheld devices will be used to spot check.”

Across both the food and beverage industries, a greater focus on waste reduction in packaging is undeniable. One continued driver of this change is sustainability, which was revealed to be the second highest goal for packaging innovation in Industrial Physics’ Unpacking Innovation in 2023 report last year.

Of overall packaging professionals believe 100% testing offers significant opportunity within their company

Non-destructive testing was identified by packing professionals as an opportunity for those working with the following materials: 

Rodger Segelstrom believes that bench top instrumentation built to the standard still has an advantage over many in-line testing systems. In-line systems still require bench top tests to be made in order to validate the readings of the in-line or on-line systems. 

The data and expert contributions highlight that testing methods do not hold equal value across materials and geographies, with many factors to weigh up. Therefore, it’s critical that companies leverage internal knowledge or source external expertise to determine the testing method that will best benefit the business as a whole. 

Packaging professionals working with organic materials (62%) were most likely to agree with the statement, presumably due to the nature of the material being newer, while aluminium (47%) and cardboard (39%) ranked the lowest in terms of positive change to the testing process. However, with well over a third in each material agreeing, these figures still indicate a level of continued innovation on even the most established paths.

In comparison, automatic process control was selected by just 29% in the UK and 36% in the USA.

However, according to Steve Davis, there’s gradually becoming more convergence between the countries and the gap is likely to keep closing: “There’s increasingly little difference in the types of testing processes between countries because of the big brand owners pushing down their processes globally. They need to meet certain standards and that eventually permeates local markets. If they’re a premium product, for example, smaller players that want to compete need to be replicating the quality standard, so it’s increasingly driven by the big brand owners globally.”

Michael Joseph, product manager at Industrial Physics, explained that this could be due to the conglomerate nature of many of the companies based there; “These companies typically operate with a lower number of facilities – possibly four or five across the country – but each warehouse is huge and primarily operates with an automatic process control set-up to achieve the required scale and volume.”

Automatic process control was ranked most highly by respondents in

In-line testing was identified as offering the most opportunity by US packaging professionals (43%), and according to Michael Joseph, is receiving a great deal of interest in this territory, with its scalability and integration into the production process being the key drivers. 

The material ranking highest in 100% inspection:

Of overall respondents identified hand-held testing devices as a strong opportunity. As a cost-effective option for small scale operations and spot checks, and its easy operation requiring minimal training.

It’s a method that’s clearly gaining traction, especially among UK respondents (57%). 

SECTION 1:

Where do the opportunities lie?

How are packaging professionals navigating testing developments?

Rodger Segelstrom believes that there has been a decrease in the collective knowledge held by testing professionals: “There’s a significant loss of knowledge across the paper and paper packaging industry as more knowledgeable personnel are retiring. Therefore, there’s not the same level of expertise or peer-to-peer learning.”

Increasingly, packaging professionals are seeking expertise outside of the business, and many are leaning on third parties, such as Industrial Physics.

Toby Lane, Product and Applications Manager at Industrial Physics, believes that support is predominantly required at the initial stage when a customer is deciding which testing instrument is most appropriate for their needs – once up and running, the level of support required reduces. 

Steve explains: “Because of paper’s recyclable properties, packaging professionals are reaching for as many applications as they can outside of its normal scope. It’s such an ecologically friendly material that we’re now seeing the boundaries being pushed with its application, and that typically requires an external expert with deeper specialist understanding.”

However, some companies are evidently struggling to find the expertise they require, with 47% saying they’ve had to delay innovation while they search for an external packaging and material testing expert. This was particularly high among paper professionals (57%).

In addition to the more novel applications of paper in packaging, external expertise may be sought because of testing standard opportunities. Toby explains: “Now we have materials, applications and test types that cross boundaries between different standards. Sometimes customers have a better way of doing something, a more rigorous test that will give them better data. But because it’s not required by the standard, it’s hard to justify the cost of the equipment. This in turn reduces the incentive to invest in development and expertise."

The majority of respondents say they know where to look for this knowledge, but almost half (49%) say they require external support with testing expertise.

This reinforces the diminished level of in-house knowledge and expertise Rodger references, as well as findings in our previous report from 2023.

Last year, 37% of packaging professionals across food and beverage, consumer goods, and medical devices and pharmaceuticals referenced lack of in-house expertise as one of their biggest challenges with testing standards.

Michael comments that the lack of processes that ensure knowledge transfer within teams is a big difficulty. Where expertise isn’t being consistently shared within internal teams, the risk that knowledge is lost entirely when a team member exits the business is significant. This approach has additional challenges too, as Michael explains, “The knowledge that testing personnel are being given is only surface level – many don’t know what the testing means or what the data is trying to tell them. This means that in addition to the risk of knowledge loss, there is also a missed opportunity for more valuable insights to be gathered in the first place.”

SECTION 2:

Many packaging professionals are aspiring to, or already reaping the benefits of, increased automatic process control and recognize the opportunity it affords them. This, paired with in-line testing and the added security of spot checking with handheld testing, appears to be where much of the industry is headed. There is evidently an appetite for 100% inspection and non-destructive testing methods, with greater accuracy and waste reduction being key drivers, yet widespread, affordable technology is currently hindering greater adoption.

Despite complex factors for consideration, half of packaging professionals agree that their company’s testing process has changed positively in the past five years. This is promising to see; however, professionals require support to take advantage of opportunities that will support their business objectives.

Elsewhere, it’s clear that a lack of expertise is influencing the level of innovation in the industries. Highlighted in both 2024 reports, the packaging industry must tackle the knowledge gaps created by experienced team members exiting the industry and new entrants joining with limited experience. Currently, surface level testing knowledge is being navigated with support from suppliers and third parties, however, this raises questions around the future of the industry. 

Deeper understanding of the testing methods, instruments and data can be easily facilitated by suppliers as part of a more thorough training arrangement. This would allow companies to optimize their operations and implement the tests that best ensure the quality and safety of their packaging.

Now we turn to our final 2024 report to complete the picture. The data will examine external factors including supply chain delays, financial pressures and consumer expectations. With insights from all three reports, packaging professionals can be supported to navigate industry complexities and reap the greatest benefits for their businesses by leveraging the right opportunities for them.

LOOKING AHEAD

Industrial Physics is a
packaging and material test
and measurement partner.

About Industrial  Physics 

Across a family of specialist testing brands, our organization fulfils a critical purpose – to protect the integrity of brands and products for quality, R&D, and operations professionals across the globe.

We’ve been doing this for more than 100 years. By providing high quality equipment, solutions, and services, we’re able to support organizations across a wide range of industries. And our specialist expertise within the world of food and beverage packaging in particular, allows us to deliver a diverse scope of solutions for some of the world’s biggest brands. 

From seam inspection, to leak detection, to burst testing, to headspace analysis, and to label testing, we offer test and measurement solutions across a whole host of packaging and material types. Whether you’re dealing with glass bottles, cardboard boxes, plastic pouches, metal packages, or an alternative type of packaging, we’re here to help.

You can learn more about the unrivalled expertise offered by the team at Industrial Physics here.

METHODOLOGY &

DEMOGRAPHICS

Industrial Physics surveyed 380 packaging professionals in 2024.

industrialphysics.com