Out of the (Ice) Box

Dairy Field, Oct 2004 by Petrak, Lynn

With a range of stringent processing requirements, aseptic packaging remains a slow mover in the cold-based U.S. market.

Shelf appeal has always gotten a lot of attention from dairy manufacturers and marketers, but these days, it's being interpreted in a novel way.

Shelf-stable dairy products, once the stuff of 21st century predictions or thought of as relegated to cold chain-challenged parts of the world, are slowly making their way out of refrigerators in this country.

To be sure, the emphasis is on slow - there is no rapid change in the way dairy products are produced and distributed in the United States and it's not likely the average mom will open the pantry door to serve her kids milk from an ambient bulk container.

That said, there have been breakthrough concepts and potentially effective and profitable areas for aseptic packages of various dairy and dairy-based foods and beverages. "The way to think about it is that it is a very specialized application. While applications are getting broader and more mainstream, aseptic packaging will never replace the gallon jug. Its role is to do things the gallon jug can't do," says Jeff Keller, vice president of strategic business development for Tetra Pak, Vernon Hills, Ill., a supplier of packaging materials for dairy, including aseptic capabilities. "Aseptic packaging adds value, improves flavor in certain products and improves supply chain economics of many systems."

The aseptic process is decidedly different from traditional production and packaging of perishable foods like dairy products. First, and probably foremost, aseptic processing sterilizes a food or beverage product by destroying potentially harmful microorganisms by a stringently controlled thermal process, also known as flash or ultra-high-temperature (UHT) pasteurization. All products must then be conveyed a sterile (think operating room) environment to be placed in a sterile package. The packaging material itself is a critical aspect of aseptic technology, since it is the barrier between production and end use.

As Keller points out, aseptic processing and accompanying packaging technology can impart several benefits to a product and, in turn, to a processor. In addition to long-term shelf stability and food safety attributes, aseptic technology also can produce items of improved sensory quality, enhance nutrient retention and allow for a more versatile use of containers that range in material type and design.

The Arlington, Va.-based Aseptic Packaging Council, for its part, promotes the fact that aseptic packages tend to be energy efficient and recyclable as well as convenient and appealing to consumers leery of added preservatives in their food and drinks.

Many industries have utilized the technology for years, in fact. Aseptic packages are used for a wide variety of food and beverage items in the United States, including soy-based drinks, infant formula, tomato sauce and liquid eggs.

For all of the advantages, though, there has been at best a gradual expansion of aseptic processing into the dairy category. "One thing holding back the aseptic market is cold-chain distribution in this country, which is rock solid. That makes it a challenge," says Christopher Hoemeke, who works in business development for filling equipment supplier Sidel Inc., Norcross, Ga., noting such systems also require a significant capital investment.

Such barriers don't mean there aren't windows of opportunity opening for the movement of aseptic products through new or even existing distribution channels. "One thing that could really change it is the rising cost of transportation," Hoemeke says.

In addition, the creative use of aseptic formats in Europe, Asia and even South America, where they are now flourishing, may also cause U.S. processors to take note of some trends and possible applications here. "If you travel in Europe, aseptic packaging is more common. Although that level of acceptance has yet to be realized in this country, I think there is potential based on the European experience," says Paul Burdick, director of marketing and sales for Schneider Packaging Equipment Co. Inc., Brewerton, N.Y., which supplies various packaging systems for traditional as well as aseptic purposes.

Brick by Brick

Currently, one of the most common formats for dairy-based aseptic products is the multi-layered, high-barrier carton, also known as a drink box or brick package. Tetra Pak is a leading supplier of this type of package, supplying Tetra Brik and Tetra Prisma® packages for single-serve consumption.

The Tetra Prisma was first used to a national extent in the dairy market by Longmont, Colo.-based Horizon Organic for shelf-stable, single-serve flavored milks. Launched nearly three years ago, the milks became popular grab-and-go items at nationwide Starbucks Coffee stores as well as in natural food stores, club stores and eventually in mainstream supermarkets, where they are now also available in multi-packs.

Although usually merchandised in the refrigerated section, the shelf-stable format helped operators add value to their business by easier storage and distribution. In another way, the visibility of such products introduced many Americans to the concept of fluid milk that did not require refrigeration.