When Manufacturing Moves from Liquids to Powder Products
As brands create powder-concentrate versions of their popular liquid products, they need to keep many operational differences in mind.
More food, beverage, and home-care brands are looking at switching from liquid formulations to concentrated powders in response to costs, changing consumer preferences, and a desire for more sustainable products and packaging.
Successful powder products in these categories — some newly formulated, and others long established — include Crush-brand beverages, baby formula, protein shakes, electrolyte drinks, pool chemicals, dishwasher and laundry pods, and even a foaming-powder toilet cleaner.
Moving to a powder formulation, or adding one to an existing product line, prompts many manufacturing, packaging, and logistics changes. Manufacturers must consider the effect on: filling and packing; outsourcing; supply chains; storage and transportation of ingredients and finished product; packaging design; and marketing, including ecommerce.
To understand these differences, we questioned five experts with expertise ranging from explosion safety to contract packaging. They are:
• Jeff Davis, senior explosion safety consultant for Fike Corp., which provides products and services for explosion and fire protection;
• Michael Keplinger, managing partner and director of testing and insights at branding agency SmashBrand;
• Neil Kozarsky, CEO of T.H.E.M., a packaging products and services provider;
• Scott Robison, vice president of business development at GreenSeed Contract Packaging; and
• Todd Smith, manager at Kansas State University’s Bulk Solids Innovation Center (KSU BSIC).
The panel’s answers, slightly edited, train a light on what it takes to make the move to powder products.
What are the impacts on packaging operations when switching from a liquid product to a powder product? What should a brand owner or contract packager be aware of when planning the switch?
Kozarsky (T.H.E.M.): When products change from liquid to dry, the packaging operations are very different, with the possible exception of secondary packaging. Primary packaging equipment for liquids is either incompatible with the packaging of powders or requires extensive change parts.
Microbiologically unstable liquid products typically need to be blended on-site, and liquid packaging operations often require thermal processing and hot or aseptic filling, which adds complexity and cost.
While relative humidity is not a big concern in a liquid operation, it is a major issue in powder-filling operations. Pumps and sanitary piping are replaced by hoists and/or pneumatic conveying when dealing with powders. Dry products subjected to moisture will run slower on many filling lines and have the potential to create seal-quality challenges. If the relative humidity is really askew, many products won’t run at commercially feasible rates.