Smart packaging: The future of food preservation

With the global population steadily rising and over two-thirds expected to live in urban areas by 2025, the demand for fast, convenient, and value-added food is projected to grow significantly. Meeting these evolving needs calls for innovations not just in food processing but also in food packaging. 

Following the advent of smart devices like smartphones, smart watches, and smart TVs, it is now time for smart food packaging to take center stage. But what exactly is smart packaging? Let’s explore how this cutting-edge technology is poised to revolutionize the food industry in the years to come.

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India, one of the largest producers of food and agro-based products, faces significant challenges with 20% of its produce wasted due to the lack of adequate processing and packaging infrastructure. The food processing sector holds immense potential, with the ability to attract investments of US$ 18.12billion (₹1,50,000 crores) over the next decade and generate employment for 9 million people.

Currently, India’s packaging industry is growing at an annual rate of 12%, supported by approximately 22,000 companies ranging from raw material manufacturers to machinery suppliers.

Post-harvest conditions play a critical role in determining the shelf life of food products. Factors such as storage temperature, relative humidity, and gas concentrations directly influence the spoilage of perishable items. Storage requirements vary depending on the type of food, as the surrounding atmosphere significantly impacts shelf life. For instance, reducing oxygen levels helps preserve certain foods by slowing discolouration in cured meats, preventing rancidity in nuts, and maintaining quality in powdered milk. However, high carbon dioxide and low oxygen levels can accelerate spoilage in fresh produce due to anaerobic metabolism, leading to rapid decay. Conversely, carbon dioxide can have antimicrobial benefits for products like fresh and processed meats, cheeses, and baked goods.

The success of a food packaging system goes beyond selecting the most suitable package; it also involves effectively communicating the internal conditions of the package to consumers. This growing demand is being addressed through innovative technologies like smart packaging, which is poised to revolutionize food preservation and enhance consumer trust.

Chandrakant Salunkhe, Founder & President, Packaging Industry Association of India (PIAI) believes that Smart packaging has a long way to go as it is revolutionizing the food industry by ensuring product safety, enhancing shelf life, and providing a seamless consumer experience.

He further says – “As global markets demand sustainable and technology-driven solutions, smart packaging offers the perfect blend of innovation and practicality. Indian exporters must leverage these advancements to build trust, increase value, and compete on the international stage.”

Smart packaging in India – key drivers and types

India’s smart packaging market is projected to grow from USD 3.64 billion in FY2023 to USD 7.05 billion by FY2031, with a CAGR of 8.6% during FY2024-FY2031. This growth is fueled by technological innovations, eco-friendly solutions, rising incomes, increasing consumer demand for interactive experiences, and the expansion of e-commerce.

Key drivers of this transformation include advancements in technology, evolving consumer preferences, and intensifying market competition, all of which are shaping the future of packaging in India.

Smart packaging is categorized into two types based on the technology used:

Active Packaging: Active packaging has been in use for several years and plays a vital role in interacting with the product to enhance its health properties and extend its shelf life. It can be applied in two distinct ways:

Internal Element Placement: An active element is placed directly inside the package to prevent moisture, absorb oxygen, or act as an antibacterial agent.

Embedded Active Elements: The active element is integrated into the smart package itself, typically through printing or lamination. This method is more popular as it eliminates the need for unfamiliar objects inside the package.

For example, incorporating an oxygen scavenger into the packaging of cooked or sliced meat products prevents discoloration.

Key Advantages of Active Packaging:

• Extends product shelf life, enabling long-distance transportation while maintaining freshness.
• Reduces food waste.
• Prevents oxidation.
• Preserves the product’s original taste, aroma, and color.

Intelligent Packaging: Although not yet widely commercialized, this technology can sense changes in the product or its packaging. It monitors the product’s condition, detects breaches in quality during transport or storage, displays temperature, and indicates freshness.

Intelligent packaging system use external or internal indicators that can determine these conditions. These indicators can be split into three parts –

• Indicators that are placed outside of the package which shows the temperature of the product.
• Indicators placed inside the package that provide information about oxygen leak, carbon dioxide or presence of salmonella.
• Indicators that allow consumers to easily communicate with the product/brand, also known as connected packaging.

The intelligent packaging systems consists of three major components, they include:

• Time-Temperature indicators (TTIs): This system uses indicators to monitor temperature variations in the product during storage. When perishable food products are stored above their optimal temperature, rapid microbial growth can occur, leading to spoilage before the estimated “use-by” date. TTIs are attached to the package surface and track the cumulative time-temperature history throughout the distribution chain. These indicators provide indirect information about product quality by displaying a visual color change to signal potential spoilage. Commercially available TTIs, such as Thermax and Warmmark, use color movement as a clear indication of temperature abuse, helping ensure product safety and quality.
• Biosensors: A biosensor is an analytical device combining a biological sensing element with a transducer to generate a signal proportional to the analyte concentration. The signal, triggered by changes like proton concentration, gas exchange, or light interaction during target compound metabolism, is converted into a measurable response (e.g., current or potential). This response can be amplified, processed, and stored for analysis, making biosensors a vital part of intelligent packaging systems.
• Radio-frequency identification systems (RFID): RFID tags are advanced data carriers consisting of a microchip with an antenna, a reader that exchanges radio signals with the tag, and middleware connecting the system to enterprise applications. They enable long-distance communication, store numerous codes, and enhance product identification and traceability.

Connected Packaging: Connected Packaging refers to smart packaging equipped with QR codes, NFC tags, or similar communication technologies that activate specific functions. This packaging type is favored by brands as it offers customers a seamless way to access additional product information. By scanning the QR code or NFC tag with a smartphone, users can instantly view detailed product details and even purchase related items digitally.

Challenges in India

Smart food packaging in India faces several challenges despite its potential for revolutionizing the industry. These challenges stem from environmental, technological, and economic factors.

1. Sustainability Issues: While there is growing demand for eco-friendly packaging, including biodegradable and recyclable materials, the high costs associated with developing such packaging are a significant barrier. Additionally, the infrastructure for recycling, especially for multilayered materials used in food packaging, remains inadequate in many parts of India​. Consumers increasingly prefer sustainable options, but the cost of transitioning to such packaging can be a challenge for many businesses.
2. Consumer Behavior: There is a shift towards sustainable and smart packaging, but many consumers are still accustomed to traditional packaging solutions. Smart packaging, which may include features like real-time food monitoring or interactive elements, can be seen as an added expense, and some consumers may be hesitant to embrace these innovations​.
3. Technological Integration: The implementation of smart packaging technologies, such as sensors for tracking freshness or interactive labels, requires significant investment in R&D. Many companies, especially smaller businesses, may struggle to afford these technologies. Furthermore, integrating such technologies into existing production processes poses logistical challenges​.
4. Regulatory Hurdles: The Indian government has started enforcing stricter regulations on packaging waste, pushing for more sustainable solutions. However, the regulatory environment is still evolving, and businesses often face uncertainties regarding compliance with new laws​.
5. Market Education: There is a need for greater consumer awareness about the benefits of smart packaging. Although it enhances convenience, safety, and sustainability, many consumers are unfamiliar with its advantages, which can slow its adoption​.

While smart food packaging holds immense promise in revolutionizing the Indian food industry, overcoming the associated challenges is key to its widespread adoption. The high costs, technological integration issues, and regulatory uncertainties can hinder progress, but the growing demand for sustainability and innovation creates a strong case for continued investment. Addressing these obstacles through collaborative efforts between businesses, consumers, and policymakers will be essential for realizing the full potential of smart packaging. By overcoming these challenges, India can lead the way in eco-conscious and technologically advanced food packaging solutions.