Mapúa University

School of Chemical, Biological, and Materials Engineering and Sciences

MODULE REPORT
FSE113 FOOD PACKAGING
Package Development Process
1. Assessment of Product
1.1 Product Information
Lay’s is a potato chip snack. The potato chip is thin, greasy, and quickly crumbles during intake
[1]. Lay’s comes with thirty variants including, original Limon, original chile Limon, wavy ranch,
flamin hot, original bbq, fiery habanero, baked original, flamin hot dill pickle, original sour cream
& onion, wavy hickory bbq, lightly salted bbq, dill pickle original, original salt & vinegar, kettle-
cooked jalapeño, sweet southern heat bbq, original honey bbq, kettle-cooked mesquite bbq,
simply sea-salted, simply bbq, lightly salted original, baked bbq, kettle-cooked sea salt & vinegar,
original lightly salted cheddar, kettle-cooked original, kettle-cooked salt, and pepper, wavy salt &
pepper, kettle-cooked olive oil and herbs, wavy original, kettle-cooked cream cheese & chive,
cheddar and sour cream, and original [2]. It comprises potatoes, vegetable oil, including corn,
canola, sunflower oil, and salt [3].
The potato chip is made to be crispy, light crunch, and airy. They are commonly served as an
appetizer, side dish, and snack. This is produced by first getting the potatoes directly from the
field. The potatoes are stored, and others are shipped for processing chips. It will enter the
washing process, going to the peeling machine to prepare it for cutting. The machine will cut the
potatoes in half for the required size of the chip. It will then go into the slicer machine and will
then be washed after. Following process is frying by automated machine systems. The chips will
go to the conveyor system to add some spices and be sent to the packaging station [4].
Regarding its shelf life, an unopened lay’s chips can stay in their best quality for two to three
months after the said “best buy, best if used by, and best before” date on the package [5]. If the
product is opened but stored properly (tightly closed), it can last about one to two weeks at room
temperature maintaining its best quality [6]. The packaging material is known to be plastic, having
multiple layers of polymer material. On the inside, the material is Biaxially Oriented Polypropylene
(BOPP), Surlyn at the outer layer, and BOPP and Low-Density Polyethene (LDPE) in the middle [7].
The BOPP’s role is to be a moisture barrier and oil and grease resistance. The LDPE’s role is to be
resistant to vegetable oils. For Surlyn and LDPE, it is flexible, strong, and not unbreakable [L8]. The
stable shelf-life of Lay’s chips is due to the packaging as it keeps contaminants and moisture out
and away from the product [8].
The Lay’s potato chips can be damaged if it is squished or crushed during transportation and
storage. If the package is left unsealed and exposed, it will make the chips soggy during intake. If
the contents experience leaching, it can make the products taste and smell bad [8]. The quality of
the product will get soggy as it absorbs moisture coming from the air. Bacteria and insects can
also attack the product if it is not stored correctly.

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 Mapúa University
School of Chemical, Biological, and Materials Engineering and Sciences

Figure 1. Lay’s Potato Chips Classic [1]

Zest-O juice drink is a fruit-flavored ready-to-drink beverage. It comes in 12 variants:

orange, calamansi, guyabano, apple, mango, pineapple, grape, strawberry, mango-lemon-lime,
dalandan, and mango-orange [9]. Its first flavor was orange juice. The main ingredients for orange
juice are water, refined sugar, natural orange flavors, vitamin C antioxidant, E415 stabilizer,
orange concentrate E330 acidity regulator, E211 preservative, vitamin A, palmitate, and zinc
lactate. For other fruit flavors, they also use similar ingredients, just with different fruit extracts.
Zest-O brand became bigger and served broader coverage of beverage and food products,
including chocolate milk drink, carbonated soft drinks, iced tea, etc., throughout the years [10].
Zest-O Ready-to-Drink juices are liquid in the form placed in a doypack with aluminum
material. The packaging promises to be fast cooling, where you can dunk it in cold water for
instant cooling [11]. This is produced by first getting the fruits and other ingredients from their
supplier to be extracted and formulated later. The supply will then be delivered to the
manufacturing location and cleaned before going to the processing location. Then the juice will
be extracted with their provided machine, and soon add the other ingredients. After the
formulation, the product is ready for sterilization and packaging and sent to the market. The
product will be tested regularly to check if they maintain the quality of their product [11]. The
packaging material is films of plastic that are laminated to produce multiple layer structures that
eliminate oxidation from juices, stand as a barrier against environmental impurities, protect from
the sun’s ultraviolet rays, and withstand any rough handling [12].
As for its shelf life, the Zest-O juice drink is known to be shelf-stable. An unopened
doypack Zest-O can last for nine to twelve months. The stable shelf-life of a juice pouch is due to
the packaging material; since fruit juices are known to be susceptible to spoilage caused by
oxidation, the doypack material prevents it from occurring. Also, the packaging material helps to
protect the content from any environmental impurities, ultraviolet rays and keep away from pests
[13].
The Zesto-O Juice Drink can be damaged when heavy pressure squishes it during storage,
transportation, and intake. If the juice pouch is left open or has the tiniest puncture, it allows the

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 Mapúa University
School of Chemical, Biological, and Materials Engineering and Sciences

juice’s sugar to ferment, making the product turn into an alcohol form [14]. Insects can also go in
from the straw to the inside of the juice pouch.

Figure 2. Zest-O Juice Drink [9]

1.2 Market Consideration
There is a wide range of potato chips available in the market. Some use a composite can
packaging with a paperboard material. Some use plastic chip packaging containing polymer
materials. Lay’s chips are available in various sizes. Its sizes are 1 oz (28.3 g), 6.5 oz (184.2 g), and
15.75 oz (446.51 g). 1 oz is the smallest size of the chip, and it is great for school snacks. 6.5 oz is
the regular size of classic chips. 15.75 oz is the biggest size and is perfect for parties. 6.5 and 15.75
oz are great for sharing too. 1 oz and 6.5 oz variations are available in the groceries, supermarket,
and convenient stores. The party size is not seen very often in groceries in the Philippines. This
product is typically bought by mothers, and young adults in retail or some in wholesale. The price
of Lay’s chips is like famous potato chip products [15].
Ready-to-drink juices have wide ranges available in the market. Some juice markets use
juice boxes with a packaging material containing three to six layers of aluminum, paper, and
plastic (75% paper, 20% polyethylene plastic, and 5% aluminum) [16]. Some put juice in a joypack
where the packaging is aluminum, and others put juice in an aluminum can. Zest-O Juice Drink is
available in two packaging sizes. Every box contains ten pieces of 200 mL aluminum juice pouch,
and the other packaging variant is an aluminum can containing 250 mL of juice. Zest-O juice drink
packaging size is available in supermarkets and groceries. Employed and unemployed mothers
commonly buy the product in retail and wholesale. The price range of Zest-O Juice Drink is the
same as other similar products [17].
2. Merchandising Plan
The improvement on the packaging of Zest-O Juice Drink will still be 200 mL and 250 mL.
The improvement on the packaging of Lay’s chips will still be 6.5 oz and 15.75 oz. The market
targets decision-makers of the household, which are usually the mothers, as they know what
children enjoy and love. Even teenagers still enjoy Zest-O juice drinks, as it reminds them of their
childhood while Lay’s chips have always been a comfort snack for any age. Teachers, organizers,
and students mostly choose Zest-O juice drinks when an event is held as it is very affordable. For
Lay’s chips, it is a little expensive, but it promises good quality. According to Alfredo M. Yao, he

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 Mapúa University
School of Chemical, Biological, and Materials Engineering and Sciences

maintains the formulation and packaging material, making the price still the same and like existing
juice product brands, retaining the customers’ loyalty and intense competition. As for Lay’s, they
continue to still sell the original lay’s while selling other variations as well, but still retaining the
customer’s loyalty, and still at the top with other competitors. The target market or outlet is to
make it available in supermarkets and groceries in major cities around Luzon. If it has good
feedback within later months, it will be available to major cities in Visayas and Mindanao. For
further improvement, it can be made available nationwide in later years to test and provide
reviews. Primarily, the product will be transported on land via trucks. Machinery for filling and
packaging will be restricted for some time. If the products volume demand grows, then the
machinery can be expanded.
3. Packaging Requirement
Lay’s Chips
• Regarding containment, the packaging must be strong and intact to handle 6.5 to 15.75
oz of solid potato chips. It must not tear down easily, there must be holes to avoid any
soggy quality of the product and must be kept away from insects.
• In terms of protection, the packaging material used must prevent any moisture to enter.
The packaging must tightly and properly seal the chips to avoid bad quality of chips, and
growth of bacteria resulting to spoilage. The package must also have the capability to
stand, and withstand harsh handling during the process, transportation, and storage.
• The packaging should include a built-in sealed instead of putting a normal clip or rubber
band to the packaging when they are not done eating. The packaging must strongly
handle 6.5 to 15.75 oz variants. The purpose of this packaging is to avoid unproper
storage, moisture, insects attacking the product, and maintain its best qualities.
• Regarding market appeal, the packaging material should maintain the signature logo, logo
name, and graphics for people to easily identify the product. It must also include readable
ingredients, serving instruction, nutritional values, and other information needed for
customers to know.
Zest-O Juice Drink
• Regarding containment, the packaging must be strong and intact to handle 200-250 mL
of liquid juice drinks. The product must not tear down easily, be free from any holes to
avoid leakage and contamination and have barriers to keep away insects.
• In terms of protection, the utilized packaging material must prevent the juice to oxidize.
The material must protect the beverage from harmful ultraviolet rays from the sun. The
packaging must have the capability to stand firm, protect the drink from any damaging
environmental impurities and withstand harsh handling.
• The packaging should include a build-in spout instead of plastic straws so that the product
can be re-closed for both 200- and 250-mL packaging. This will lessen contamination,
waste of beverage when it is spilled due to difficulties in inputting the straw, and improve
the preservation of the product, keeping its freshness until fully consumed.
• Regarding market appeal, the packaging material should maintain the logos size, font, and
graphics for people to identify the product still. It must also include readable ingredients,
serving instruction, nutritional values, and other information needed for customers to
know.
4. Choose Alternative Materials and Design The Packaging
For this section, it presents the materials for the proposed packaging design for Lay’s chips
and Zest-O juice drink.

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 Mapúa University
School of Chemical, Biological, and Materials Engineering and Sciences

Lay’s Chips
As for the body of the packaging, it will contain a layer of Biaxially Oriented Polypropylene
(BOPP), Surlyn Polymer, and Low-Density Polyethylene (LDPE). All materials are one of the traditional
material for packing food, beverage, etc. This kind of packaging provides better shelf life for the product.
To develop the packaging, a sealed will be placed on the top area of the packaging with a polypropylene
material (Figure 3). Adding a seal to the packaging can help to extend the lifespan or quality of the baked
chips. Polypropylene have good quality property for food packaging as it is semi-rigid, good chemical
resistance, good fatigue resistance, integral hinge property, and good heat resistance [18]. The built of
BOPP in the inside layer of the packaging will make a moisture barrier and oil and grease resistance. As
LPDE and Surlyn layer will make the packaging flexible and unbreakable. This will also keep any
contaminants and moisture away from the product. People have been investing resealable packaging
because it is worth it. This is due to its flexibility where resealable packaging can extend shelf life, reduce
waste, adds value, set your brand apart from any competition, and makes homeowner’s life easier [19].
Consumers love to keep food fresh as much as possible as they have seen a impact on the freshness of
their food due to the packagings reclosability. Additionally, plenty of people became more aware
regarding to what they impact to the environment and became more careful in making purchase decisions
to help make the plant clean. Resealing the package does not only less the food waste, but also reduce
secondary waste in packaging such as plastic wraps, storage bags, or foil. As the packaging develops, it
can convince your consumers that what you are providing is worth the money. The second-most
important feature for a flexible packaging is resealability, adding brand value. It can also be easily opened
and help to have the right closure. This can also give the brand an edge over competitors next to your side
of the shelf at the supermarket. Conusmers may not be able to see, taste, feel, or smell the chips right
away, but seeing that your product is resealable, then you have given them the hint of a higher quality
product awaiting for them to consume. Lay’s chips manages wastages to become zero balance waste,
thereby, since all materials are recyclable it can be reused instead of hurting the environment.

(A) (B)
Figure 3. (A) Closed and (B) Open Proposed Resealable Lay’s Chips Packaging Design

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 Mapúa University
School of Chemical, Biological, and Materials Engineering and Sciences

Zest-O Juice Drink

For Zest-O juice drink, the packaging is mostly films of plastics laminated to produce multiple layer
structures. The packaging consist of films of Biaxially Oriented Polypropylene (BOPP), Polyethylene
Terephthalate (PET), Linear Low Density Polyethylene (LLDPE), Cast Polypropylene (CPP), and aluminum.
The BOPP film layer is environmentally friendly. It also light weight, limits damaging of product, difficult
to puncture, has high tendency keeping the product dry, can protect the product from air pollution, toxic
chemicals, and is resistant to oil and grease. BOPP is great for cost, efficiency, and resistant to ultraviolet
rays [20]. The PET film is added as it is hygienic, resistant to microorganisms, strong, no reaction with
beverages and food, and does not biologically degrade. It is also light weight, transports simply, and does
easilty break [21]. As for the LLDPE layer, it is low cost and has adds extra good flexibility and strength.
Before it can be punctured, it will need a tremendous amount of strength [22]. Cast Polypropylene film
layer will make the packaging extra resistant to tear and puncture as it has also great transpareny, extra
heat resistance at high temperatures, blocks any exposure to the atmosphere and moisture, and has high
permeability to water vapor [23]. For aluminum layer, this will protect the juice from any light, oxygen,
moisture, and bacteria to preserve its quality [24]. Based on observation experience during childhood up
til now, a lot are still struggling in puncturing the hole where they usually input the straw. It needs a
specific pressure to get it in, and when it does, leakage from the juice pouch often occur, putting the
product to waste. When people struggle inputting the straw, they use the bottom layer to input the straw.
Thereby, the packaging is easy to puncture with just a straw. In every box of Zest-O juice drink, it contains
a straw as well but is not glued to the packaging of the juice. Sometimes, the straw is not enough, or some
are missing and some can easily break. Instead of using straws for this product, they can use a “twistable
spout” that is connected on the top part of the packaging. The material for the twistable spout will be
Polypropylene (PP) as it is durable, rugged, and hard. With this kind of packaging, consumers can open
and close the pouch, which can extend its shelf-life, lessening the waste of the juice product, ads value,
and makes it easier for consumer to intake the product by squeezing the body of the package (Figure 4).
To protect the twistable spout, a sealing wax will be shrinked to protect the opening of the spout and to
avoid opening it or spill any product. With this kind of portability, consumers such as children can get to
enjoy drinking their juice, avoid spilling, and as well can be beneficial to mothers as it provides less clutter.

(A) (B)
Figure 4. (A) Full and (B) Zoomed In View of Proposed Zest-O Juice Drink Packaging Design

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References:
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UsL5w400_DuNXkZbG5qj5yhFkBYso1AHNbOJZ1eN6U
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corporation/products/zesto-orange-juice-200ml-box-10-pcs

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[18] Polypropylene (PP). (n.d.). British Plastic Federation. Retrieved October 3, 2021, from
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