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Complete Guide to Secondary Food Packaging

When it comes to food packaging, there’s more than meets the eye. Secondary food packaging, the first thing your customers see when picking up your products from retail shelves, plays a pivotal role in not only protecting your food and drink items during transit but also in conveying vital information about your brand.

Elevate Your Brand and Protect Your Products

Secondary food packaging is the unsung hero of the packaging world, and understanding its significance can make all the difference in the way your products are perceived and chosen by consumers.

Defining Secondary Packaging

Secondary packaging is the outer material that envelops and safeguards food, beverages, and consumer goods as they make their journey from production facilities to store shelves. It’s the layer that surrounds primary packaging, such as the packaging directly in contact with the product, and ensures that your products remain in pristine condition until they reach the end consumer.

In essence, secondary packaging is the gateway between your brand and your audience. How you choose to package, market, and display your products can influence a customer’s decision to purchase your merchandise over that of your competitors.

Secondary vs. Primary and Tertiary Packaging

To fully grasp the benefits of secondary food packaging, it’s essential to understand the three distinct types of packaging in the food industry: primary, secondary, and tertiary.

• Primary Packaging: This is the packaging that directly contains the product meant for consumption. For instance, it could be the plastic or paper wrapping around individual cookies, preserving their freshness and quality.
• Secondary Packaging: Secondary packaging contains one or more primary packages. Think of it as the metallic container holding individually wrapped cookies. It provides an additional layer of protection and organization.
• Tertiary Packaging: Tertiary packaging involves the cardboard box in which a certain number of secondary packages (cookie tins, for example) are placed for convenient and secure transportation to retail locations. It acts as a buffer against damage during transit and can even serve as an in-store display.

The Primary Functions of Secondary Packaging

While primary packaging is designed for direct contact with the product, and tertiary packaging focuses on transport and display, secondary packaging serves a unique set of functions that are vital for your brand and product presentation. The primary functions of secondary packaging include:

1. Making Your Products Display Ready
Secondary packaging is all about making your products visually appealing and display-ready. It provides a platform for product grouping and attractive display solutions, ensuring that your items catch the eye of potential customers.

2. Enhancing Branding
Packaging materials can play a crucial role in your company’s marketing strategy. They offer an opportunity to reinforce your brand identity and promote new products effectively. Your logo and branding elements on secondary packaging materials are the first things customers see when opening a package, leaving a lasting impression.

3. Adding Layers of Protection
In addition to primary packaging, secondary packaging materials act as an additional barrier during shipping and handling. They protect your goods from damage, preventing costly returns and keeping your customers satisfied. No one wants to receive products that are loose, broken, or scratched in any way.

4. Ensuring Customer Satisfaction
Secondary packaging is a critical element in ensuring the satisfaction of your customers. It not only safeguards your products but also conveys a sense of quality and care. At Peoria Production Solutions (PPS), we understand the importance of secondary packaging and go to great lengths to treat your products with the utmost care and attention through our secondary packaging services.

Common Secondary Food Packaging Materials

Secondary packaging comes in various forms, depending on the specific needs of a company’s packaging requirements. The type of packaging method chosen depends on the product and the stages it goes through during shipping, receiving, and unloading. Some of the most common types of secondary packaging materials include:

• Shipping Cartons: Sturdy cartons designed to protect and transport products safely.
• Shrink Wraps: Transparent wraps that provide protection and hold products securely.
• Outer Films: Protective films that wrap around multiple products or bundles.
• Cardboard Boxes: Versatile boxes used for various packaging needs.
• Trays: Custom trays that hold products securely in place.
• Paperboard Enclosures: Paper-based packaging for added protection.
• Plastic Packaging – Plastic is lightweight and comes in two primary forms: rigid and flexible, both serving as effective protectors for various food products.
• Glass Packaging – Glass offers the added benefit of being easily recyclable and chemically safe. However, its substantial weight and susceptibility to breakage present challenges when it comes to transporting bulk quantities.
• Metal Packaging – Metal is highly recyclable, rendering it an environmentally friendly storage solution.

Ideally, these secondary packaging materials are the only components making contact with primary packaging, ensuring the safety and integrity of the products inside.

Why is Secondary Packaging Important?

The significance of secondary packaging cannot be overstated, and it directly ties into the overall customer experience. When consumers purchase your products, they must interact with outer secondary packaging materials before reaching the primary packaging and the actual merchandise. Here’s why secondary packaging is so important:

Expressing Brand Identity

Secondary packaging provides a canvas for expressing your brand identity. Through branding phrases, signature color schemes, custom text, and eye-catching designs, you can make your products stand out and convey what your merchandise offers to the buyer.

Protecting Products in Transit

Getting products safely to their final destination requires meticulous planning. Everyone involved in handling your inventory interacts with your secondary packaging materials, making it crucial to safeguard your products during transit.

The Main Benefits of Secondary Food Packaging

Secondary packaging provides many benefits to food manufacturers and distributors. At PPS, we specialize in secondary packaging, and with more than 80 years of experience, we deliver a host of benefits to our food packaging customers.

1) Greater Protection for the Product
Secondary packaging shields contents from shocks and scratches, preventing items like cookies or chocolates from breaking or getting crushed. Additionally, it safeguards against the detrimental effects of light, which can compromise the taste and quality of certain products, such as tobacco or tea.

2) Enhanced Preservation Once Opened
Secondary food packaging not only prevents the deterioration of products before they are opened but also excels at preserving them once they are exposed.

3) Enhanced Presentation at the Point of Sale
Secondary food packaging immediately conveys a premium image. It is common to find food products meant for gifting, such as chocolates, cookies, or spirits, packaged in appealing materials that convey the uniqueness of the products inside. The presentation should be attractive and enhance the perception of the gift, conveying the value and quality of the food products inside.

PPS: Your Partner for Secondary Food Packaging

Peoria Production Solutions understands the unique advantages of secondary packaging. Our commitment to delivering quality secondary food packaging is unwavering. We recognize the importance of treating your products with care and attention, ensuring they reach their destination in perfect condition.

We offer a large, modernized facility with automated equipment and a trained, dedicated staff. PPS has vast experience in product kitting, assembly, packing, packaging, wrapping, bag-filling and auto-bagging, shrink-wrapping, labeling, palletizing and many other production solutions. We can help our customers to meet their production demands and provide input on the latest trends in secondary packaging services.

Stay Ahead with the Latest Food Packaging Trends

No comprehensive guide would be complete without a glimpse into the cutting-edge trends shaping the world of food packaging. Here are some of our favorite food packaging trends that can set your product apart from the competition:

Embrace Minimalist Designs
Minimalism isn’t confined to a specific industry; it’s a global trend. Step away from cluttered designs and opt for simplicity. Remember, less can often be more, especially in today’s design landscape.

Engage Through Interaction
Interactive packaging has taken the food industry by storm. In fact, it’s a trend we’ve highlighted in our top packaging trends for 2022. The key here is to let your creativity shine and introduce an interactive element into your packaging. This could involve technology or a unique physical characteristic that engages consumers and enhances their experience.

Embrace Bold Colors
While this may seem contradictory to the concept of minimalist design, bold colors are making a big statement in food packaging. When used thoughtfully, bold hues can complement a minimalist approach and draw the customer’s eye. They have the power to capture attention and leave a lasting impression.

These trends represent the forefront of food packaging innovation, offering exciting opportunities to elevate your product’s presence and appeal. By staying ahead of these trends, you can position your brand as a leader in the ever-evolving world of packaging design.

Secondary Food Co-Packing & Assembly Services

PPS offers a range of secondary food co-packing and assembly services, including secondary food carton kitting. Our highly trained and skilled packaging operators excel in providing quick and accurate carton kitting services, including subscription box fulfillment. We precisely pack your primary packaged food products into specified cartons with extraordinary efficiency focused on high-quality processes.

Quality Standards and Accountability

At PPS, we maintain strict quality standards with top-down involvement in every process. Our commitment to quality control includes rigorous testing of secondary packaging materials to ensure they meet your specifications. We implement lot code tracing and utilize our Enterprise Resource Planning (ERP) system for full accountability. Materials are inspected for the right thickness and dimensions, and quality control tools are employed to meet your requirements for critical dimensions.

Partner with PPS for Quality Secondary Food Packaging

With over 80 years of experience in providing contract packaging solutions, PPS stands as a leader among secondary packaging suppliers. What sets us apart is our commitment to our staff and our not-for-profit status, which prioritizes jobs over profits. This unique approach allows us to meet your requirements at a different level, offering customized packaging solutions tailored to your needs and budgetary goals.

Peoria Production Solutions is your trusted partner in secondary food packaging. Our skilled staff, controlled processes, and unwavering dedication to quality make us a leading packaging supplier, assisting OEMs of all sizes in meeting their shipping and distribution goals. Contact us today to discover how our secondary packaging solutions for food and beverage items can enhance your brand and protect your products.

Subcontract Repackaging: Enhancing Business Operations with Contract Packaging

There often comes a time when businesses need repackaging services for a variety of reasons in the constantly evolving landscape of product packaging. Whether it’s a change in labeling, alterations in packaged components, or dealing with non-conforming products, the need to rework packaging can be a critical aspect of ensuring that your products reach the market safely and efficiently. This is where the expertise of a subcontract repackaging company can prove to be invaluable.

The Role of Contract Packaging

Your products are not just commodities; they are a direct representation of your company’s dedication and hard work. As you strive to release your products into the marketplace with the utmost quality and precision, a contract packaging company can become your perfect last-step partner. These companies can serve as quasi-extensions of your business, offering specialized services, capabilities, and expertise to safely and efficiently deliver your products into the hands of consumers.

One of the key aspects of contract packaging involves pack-out and kitting, which includes packing products into retail packaging or displays. This process can encompass bundling different products together or packaging them in a specific manner tailored to your requirements.

When to Collaborate with a Contract Packager

There are several scenarios where partnering with a contract packaging company becomes a strategic move:

• Lack of In-House Packaging Capabilities: If your company is not equipped for packaging operations and doesn’t plan to start in-house packaging in the near future, a contract packager can bridge the gap.
• New Packaging Requirements: When your product adopts a new packaging scheme that your current manufacturing line cannot accommodate, a contract packaging partner can step in.
• Cost Efficiency: Sometimes, it’s more cost-effective to send components to a location near a remote point of sale and distribution for packaging. Contract packagers offer cost-efficient solutions.
• Capacity Constraints: If your in-house packaging lines are already at capacity or prioritized for another product, outsourcing can be the solution.
• Regulatory Compliance: Certain products have specific regulatory requirements, and contract packaging companies are well-versed in meeting these standards.
• Short-Run Packaging: For products designed for a short run, investing in new in-house staff and equipment might not be the most practical option.
• Resource Constraints: During downsizing or when personnel are not available to handle packaging projects in-house, a contract packager can step in to fill the gap.

The Diverse Landscape of Repackaging Services

Repackaging services encompass a wide range of activities tailored to specific needs. Some packages may require simple relabeling, while others might need to be completely unpacked and sorted. In the case of assembled kits, perhaps only one product needs replacement, repackaging, and resealing. Repackaging can also involve transitioning products from wholesale packaging to retail packaging or assembling them into gift sets or kits.

These services include, but are not limited to:

• Relabeling
• Sorting
• Inspection
• Counting
• Adding or removing components from kits
• Transitioning from wholesale to retail packaging
• Creating gift sets or kits

The Advantages of Contract Packaging Outsourcing

Opting for a contract packager can bring a host of benefits that significantly improve your business operations and overall efficiency. Here are some of the key advantages:

1. Expertise and Experience

Contract packaging companies possess specialized knowledge and experience in packaging. They stay updated on the latest trends, use effective materials and practices, and excel in complying with various industry regulations, especially in sectors like food, pharmaceuticals, and healthcare components with stringent packaging requirements.

2. Customized Solutions

These companies offer a range of services tailored to your specific product needs. From high-speed vision inspection to shrink wrapping, laminating, cartoning, and bottle labeling, these customizations ensure that your products are packaged optimally for safety, efficiency, and market appeal.

3. Cost Efficiency

Outsourcing packaging operations means savings on expenses related to setting up and maintaining an in-house operation. This includes costs for equipment, training, and staff. Contract packagers have the infrastructure to provide high-quality packaging at a lower cost.

4. Increased Internal Capacity

Outsourcing frees up your company’s resources, allowing you to focus more on core manufacturing processes. This can lead to increased productivity in your primary business operations.

5. Improved Flexibility and Speed to Market

Contract packaging companies can quickly adapt to changes in packaging standards and consumer trends. They also have established supply chains for faster material sourcing and reduced turnaround times, enhancing your product’s speed to market.

6. Reduced Capital Investment

Working with a contract packager means you don’t have to make heavy investments in packaging equipment and supplies, offering significant financial advantages, especially for businesses aiming to allocate resources more efficiently.

7. Seasonal Packaging Solutions

For companies with seasonal production, contract packaging is an ideal solution. It allows you to manage increased production during peak times without investing in additional packaging resources.

8. Comprehensive Services

Many contract packagers offer a wide array of services, including product packaging, shipping, labeling, and package design. This comprehensive approach streamlines operations and ensures consistency in the packaging process.

Partnering with Peoria Production Solutions

Peoria Production Solutions is a reputable provider of secondary packaging services, including repackaging, with over 80 years of experience. As a fully sustainable, not-for-profit organization, we invest in individuals with alternate abilities, providing them with training and a promising future. Our dedicated workforce boasts nearly perfect attendance and extremely low turnover. Our organizational structure allows us to offer cost-competitive packaging services and to meet your budgetary goals.

We offer customized repackaging services to meet your specific production requirements, including labeling and shipping as per your instructions. Our Enterprise Resource Planning (ERP) system provides complete lot number traceability, ensuring a controlled flow of goods and full accountability of customer-supplied materials. We strictly adhere to a quality policy as part of our ISO9001:2015 certification, enforced throughout the company with top-down management involvement.

Our primary focus is on total customer satisfaction through high-quality secondary production services, competitive pricing, and on-time delivery. We have the resources, staff, and capacity to provide high-quality rework, sorting, or repackaging services promptly and efficiently.

Subcontracting repackaging to a contract packaging company can offer significant operational and financial benefits, leading to improved efficiency, cost savings, and enhanced product presentation.

Peoria Production Solutions is your skilled contract packager, allowing you to concentrate on core business activities while leveraging our packaging expertise. Trust Peoria Production Solutions for all your repackaging needs and experience the difference in efficiency and quality. Contact us for more information on our repackaging services and a glimpse into our comprehensive production and packaging solutions.

Heat Seal vs. Cold Seal Packaging: Which Is Right for Your Products?

Two distinct methods for sealing products have gained prominence in flexible packaging applications – heat seal and cold seal packaging. These methods come with their own unique characteristics and applications, making it crucial for businesses to make an informed choice when creating packaging solutions for their products.

The Significance of the Right Seal

While it may seem like a minor detail, the type of seal chosen for product packaging can significantly impact the shelf-life and overall protection of your products. Particularly in the realm of food packaging, the seal plays a critical role in regulating the entry of gas and moisture, ensuring that your products remain fresh and safe for consumption.

Sealing a package is not merely about closing it; it’s about achieving both protection and user-friendliness through seal quality and integrity. In this context, two sealing methods, namely cold seal adhesives (also known as self-seal adhesives) and heat seal adhesives, come into play. Both are employed in various flexible packaging applications, including food packaging and medical devices. However, each seal type has its own set of advantages and disadvantages, making the choice dependent on specific product requirements.

Understanding the Seal Mechanism

It is essential to grasp how these sealing mechanisms work. This understanding is crucial for preventing product spoilage and ensuring consistent food quality during storage.

Heat Seal Packaging

Heat sealing, the more commonly used of the two methods, is the go-to choice when high-integrity seals are required. Contrary to its name, the actual bond is not formed until the package structure solidifies during the cooling phase. Pressure must be continuously applied during this cooling process to maintain control over the package and ensure a visually appealing and secure seal.

Heat seal packaging does not necessitate special processes or materials like pressure-sensitive adhesives, making it a cost-effective option. Moreover, it offers a wide range of laminations and performance characteristics that can be customized to suit specific product needs.

• Process: Heat is applied to create a seal, typically involving a multi-layered film with an outer layer to prevent melting, a core layer (e.g., polypropylene), and an interior sealant layer.
• Applications: Commonly used in packaging foodstuffs, beverages, cosmetics, pharmaceuticals, and more, especially when high-integrity seals are essential.
• Advantages:Economical, versatile in terms of performance characteristics, and allows for the creation of tamper-evident seals.
• Considerations: Requires precise management of heat, dwell time, and pressure during the sealing process for effectiveness.
• Common Usage: Seen in the packaging of bags, films, and containers made from thermoplastics, particularly in food packaging.

Achieving an effective heat seal necessitates careful control of three factors: heat temperature, dwell time, and pressure applied by the sealing machinery. Any change in one of these factors requires adjustments in the other two, which underscores the importance of manufacturers understanding the procedures, methods, and materials involved in achieving quality seals.

Cold Seal Packaging

Cold seal adhesives have a long history and are employed in a different manner. This method involves using a combination of rubber, resins, plasticizers, extenders, and other additives to create an adhesive bond between the substrates used in flexible packaging. Commercial cold seal packaging can comprise anywhere from two to a dozen or more layers.

In cold seal packaging, adhesives are coated onto plastic films or substrates, forming layers that strongly bond when pressure is applied. This adhesive is applied in a wet form to the substrate using a revolving gravure cylinder, then dried in an extended oven before being reeled up at the end of the press. One interesting facet is that the adhesive is applied in a specific pattern that enables seal formation without the need for heat. Recent advancements involve the use of copolymers of vinyl acetate and ethylene combined with rubber latex, sometimes without the inclusion of natural rubber latex.

Making the Right Choice Between Heat Seal and Cold Seal Packaging

The choice between heat seal and cold seal packaging hinges on various factors, primarily the specific needs and requirements of your products. Considerations include machine speed and capacity, barrier properties (e.g., moisture, oxygen, UV light), and seal strength. For some products, a high-integrity heat seal might be the ideal choice, while for others, the convenience and efficiency of a cold seal adhesive might be more appropriate.

The sealing method you select plays a pivotal role in preserving product freshness, quality, and safety. It’s essential to weigh the pros and cons of heat seal and cold seal packaging carefully, ensuring that your choice aligns with the unique demands of your products. Ultimately, the right seal can make all the difference in delivering a superior packaging solution that protects your goods and enhances user experience.

Leading Flex Pack Provider

When it comes to flexible packaging, PPS stands out as a leading provider of comprehensive solutions. As a prominent player in the realm of contract packaging, we offer a wide array of secondary packaging services, including flexible packaging, to businesses of all sizes. Our commitment to excellence has earned us recognition in the industry, making us the go-to choice for companies seeking high-quality packaging, wrapping, filling, and bagging services.

Unmatched Expertise and Cutting-Edge Technology

At PPS, we leverage the latest in automated equipment to streamline our packaging processes. Our modern equipment includes auto bag filling, auto labeling, heat sealing, heat tunnel technology, shrink sleeve applications, and vertical continuous band sealing, complete with a stand and hot stamp imprinter. This cutting-edge equipment, combined with a trained and dedicated staff, ensures efficient and precise packaging solutions for your products.

With over 80 years of industry experience, PPS has earned its reputation as a leader in secondary packaging solutions. Our range of production solutions extends beyond packaging to include wrapping, kitting, assembly, commercial sewing, and more. Contact us today to learn how we can collaborate to improve your packaging solutions and help you choose the best method of sealing, whether heat seal or cold seal packaging.

Secondary, Primary & Tertiary Packaging Explained -Infographic