PACKAGING SYSTEM

TPF 469 Packaging

Packaging systems are integral components of product design and Science and
distribution, serving multifaceted roles that extend beyond containment. Technology
They are critical in preserving product integrity, enhancing shelf life,
ensuring regulatory compliance, and conveying branding messages to
consumers. This abstract explores the diverse aspects of packaging
systems, encompassing materials, sustainability considerations, and
emerging technologies. It highlights the significance of a holistic approach
that balances functionality, aesthetics, and environmental impact to
meet evolving consumer demands and industry standards. As the global
packaging landscape continues to evolve, innovation and sustainability
will remain at the forefront of packaging system development.
 Packaging systems
1 Aseptic packaging

Aseptic packaging is a method in which food is sterilized or commercially sterilized outside

of the can, usually in a continuous process, and then aseptically placed in previously
sterilized containers which are subsequently sealed in an aseptic environment. After cooling,
the sterile food product is pumped to an aseptic packaging system where the food is filled and
hermetically sealed into previously sterilized containers. Aseptically processed foods can be
packaged in the same types of containers used for retorted foods. However, another
advantage of aseptically processed foods is that they can be packaged in containers that do
not have to survive the conditions of a retort. These include LDPE/Pb/LDPE/AL/LDPE
laminate cartons and multilayer plastic flexible packaging that has cost and convenience
advantages. The disadvantage of these packages is that they are not as easily recycled as
metal and glass containers. Aseptic filling systems have also been developed for HDPE and
PET bottles. Aseptic filling of PET containers may have a cost advantage over hot filling of
heat-set PET containers. Another advantage of aseptically processed foods is that they can be
filled into drums, railroad tank cars, tank trucks and silos that have been previously sterilized
with steam. The food can be later reprocessed and packaged to meet market demands. The
sterilization agents available for aseptic packaging include heat, chemical treatment with
hydrogen peroxide and high energy irradiation (UV light or ionizing (gamma) irradiation). A
combination of hydrogen peroxide and mild heat is most commonly used with plastic and
paperboard-based laminate packaging.

The most commercially successful form of aseptic packaging utilizes paper and plastic
materials which are sterilizes, formed, filled and sealed in continuous operation. The package
may be sterilized with heat or combination of heat and chemicals. In some cases, the
disinfectant property of hydrogen peroxide (H2O2) is combined with heated air or ultra violet
light to make lower temperatures effective in sterilizing these less heat resistant packaging
materials.

Aseptic packaging is also used with the metal cans as well as large plastic and metal drums or
large flexible pouches. Great quantities of food materials are used as intermediates in the
production of further processed foods. This frequently requires packaging of such items as
tomato paste or apricot puree in large containers. The food manufacturer then may use the
tomato paste in the production of ketchup or the apricot puree in bakery products. If such
large volumes were to be sterilized in drums, by the time the cold point reached sterilization
temperature the product nearer the drum walls would be excessively burned. Such items can
be quickly sterilized in efficient heat exchangers and aseptically packaged.

2 Modified Atmosphere Packaging

Modified atmosphere packaging (MAP) is a procedure which involves replacing air inside a
package with a predetermined mixture of gases prior to sealing it. Once the package is sealed,
no further control is exercised over the composition of the in-package atmosphere. However,
this composition may change during storage as a result of respiration of the contents and/or
solution of some of the gas in the product. Vacuum packaging is a procedure in which air is
drawn out of the package prior to sealing but no other gases are introduced. This technique
has been used for many years for products such as cured meats and cheese. It is not usually
regarded as a form of MAP.

The gases involved in modified atmosphere packaging, as applied commercially are carbon
dioxide, nitrogen and oxygen. Carbon dioxide reacts with water in the product to form
carbonic acid which lowers the pH of the food. It also inhibits the growth of certain
microorganisms, mainly moulds and some aerobic bacteria. Lactic acid bacteria are resistant
to the gas and may replace aerobic spoilage bacteria in modified atmosphere packaged meat.
Most yeasts are also resistant to carbon dioxide. Anaerobic bacteria, including food poisoning
organisms, are little affected by carbon dioxide. Consequently, there is a potential health
hazard in MAP products from these microorganisms. Moulds and some gram negative,
aerobic bacteria, such as Pseudomonas spp, are inhibited by carbon dioxide concentrations in
the range 5–50%. In general, the higher the concentration of the gas, the greater is its
inhibitory power. The inhibition of bacteria by carbon dioxide increases as the temperature
decreases.

Nitrogen has no direct effect on microorganisms or foods, other than to replace oxygen,
which can inhibit the oxidation of fats. As its solubility in water is low, it is used as a bulking
material to prevent the collapse of MAP packages when the carbon dioxide dissolves in the
food. This is also useful in packages of sliced or ground food materials, such as cheese,
which may consolidate under vacuum. Oxygen is included in MAP packages of red meat to
maintain the red colour, which is due to the oxidation of the myoglobin pigments. It is also
included in MAP packages of white fish, to reduce the risk of botulism. Other gases have
antimicrobial effects. Carbon monoxide will inhibit the growth of many bacteria, yeasts and
moulds, in concentrations as low as 1%.

However, due to its toxicity and explosive nature, it is not used commercially. Sulphur
dioxide has been used to inhibit the growth of moulds and bacteria in some soft fruits and
fruit juices.

Argon, helium, xenon and neon, have also been used in MAP of some foods. MAP packages
are either thermoformed trays with heat-sealed lids or pouches. With the exception of
packages for fresh produce, these trays and pouches need to be made of materials with low
permeability to gases (CO2, N2, and O2). Laminates are used, made of various combinations
of polyester (PET), polyvinylidene chloride (PVdC), polyethylene (PE) and polyamide.

3. Controlled Atmosphere Packaging (CAP)

Material written in during lecture

4. Active packaging

Active packaging refers to the incorporation of certain additives into packaging film or within
packaging containers with the aim of maintaining and extending product shelf life. Packaging
may be termed active when it performs some desired role in food preservation other than
providing an inert barrier to external conditions. Active packaging includes additives or
‗freshness enhancers‘ that are capable of scavenging oxygen, adsorbing carbon dioxide,
moisture, ethylene and/or flavor/odor taints, releasing ethanol, sorbates, antioxidants and/or
other preservatives and/or maintaining temperature control. The shelf life of packaged food is
dependent on numerous factors, such as the intrinsic nature of the food (e.g. pH, water
activity, nutrient content, occurrence of antimicrobial compounds, redox potential, respiration
rate, biological structure) and extrinsic factors (e.g. storage temperature, relative humidity,
surrounding gaseous composition). These factors directly influence the chemical,
biochemical, physical and microbiological spoilage mechanisms of individual food products
and their achievable shelf life. By carefully considering all of these factors, it is possible to
evaluate existing and developing active packaging technologies and apply them for
maintaining the quality and extending the shelf life of different food products.
 Modern Packaging Systems

Introduction

Various terms for new packaging methods can be found in the literature, such as active,
smart, interactive, clever or intelligent packaging. The definitions of active and intelligent
packaging are

 Active packaging changes the condition of the packed food to extend shelflife or to improve
safety or sensory properties, while maintaining the quality of the packaged food.

 Intelligent packaging systems monitor the condition of packaged foods to give information
about the quality of the packaged food during transport and storage.

Active packaging

Active packaging refers to the incorporation of certain additives into packaging film or within
packaging containers with the aim of maintaining and extending product shelf life. Packaging
may be termed active when it performs some desired role in food preservation other than
providing an inert barrier to external conditions. Active packaging includes additives or
‗freshness enhancers‘ that are capable of scavenging oxygen, adsorbing carbon dioxide,
moisture, ethylene and/or flavor/odor taints, releasing ethanol, sorbates, antioxidants and/or
other preservatives and/or maintaining temperature control.

Active packaging techniques for preservation and improving quality and safety of foods can
be divided into three categories; absorbers (i.e. scavengers, releasing systems and other
systems. Absorbing (scavenging) systems remove undesired compounds such as oxygen,
carbon dioxide, ethylene, excessive water, taints and other specific compounds. Releasing
systems actively add or emit compounds to the packaged food or into the headspace of the
package such as carbon dioxide, antioxidants and preservatives. Other systems may have
miscellaneous tasks, such as self-heating, self-cooling and preservation. The main active
packaging systems are as follows:

1 Oxygen scavenger: The most common oxygen scavengers take the form of small sachets
containing various iron-based powders containing an assortment of catalysts. These chemical
systems often react with water supplied by the food to produce a reactive hydrated metallic
reducing agent that scavenges oxygen within the food package and irreversibly converts it to
a stable oxide. The iron powder is separated from the food by keeping it in a small, highly
oxygen permeable sachet.

2 Carbon Dioxide Scavengers/Emitters: There are many commercial sachet and label
devices that can be used to either scavenge or emit carbon dioxide. The use of carbon dioxide
scavengers is particularly applicable for fresh roasted or ground coffees that produce
significant volumes of carbon dioxide. Fresh roasted or ground coffees cannot be left
unpackaged since they absorb moisture and oxygen and lose desirable volatile aromas and
flavors.

3 Ethylene Scavengers : Ethylene (C2H4) is a plant hormone that accelerates the respiration
rate and subsequent senescence of horticultural products such as fruit, vegetables and flowers.
Many of the effects of ethylene are necessary, e.g. induction of flowering in pineapples and
colour development in citrus fruits, bananas and tomatoes, but in most horticultural situations
it is desirable to remove ethylene or to suppress its effects. Effective systems utilize
potassium permanganate (KMnO4) immobilized on an inert mineral substrate such as
alumina or silica gel. KMnO4 oxidizes ethylene to acetate and ethanol and in the process a
change colour from purple to brown and hence indicates its remaining ethylene-scavenging
capacity. KMnO4-based ethylene scavengers are available in sachets to be placed inside
produce packages or inside blankets or tubes that can be placed in produce storage
warehouses.

4 Ethanol Emitters: The use of ethanol as an antimicrobial agent is well documented. It is

particularly effective against mould but can also inhibit the growth of yeasts and bacteria.
Ethanol can be sprayed directly onto food products just prior to packaging. The size and
capacity of the ethanol-emitting sachet used depends on the weight of food, aw of the food
and the shelf life required. When food is packed with an ethanol-emitting sachet, moisture is
absorbed by the food and ethanol vapor is released and diffuses into the package headspace.

5 Preservative Releasers: One most commonly used preservative releaser is a synthetic

silver zeolite that has been directly incorporated into food contact packaging film. The
purpose of the zeolite is apparently to allow slow release of antimicrobial silver ions into the
surface of food products. Many other synthetic and naturally occurring preservatives have
been proposed and/or tested for antimicrobial activity in plastic and edible films. These
include organic acids, e.g. propionate, benzoate and sorbate, bacteriocins, e.g. nisin„ spice
and herb extracts, e.g. from rosemary, cloves, horseradish, mustard, cinnamon and thyme,
enzymes, e.g. peroxidase, lysozyme and glucose oxidase, chelating agents, e.g. EDTA,
inorganic acids, e.g. sulphur dioxide and chlorine dioxide, and anti-fungal agents, e.g.
imazalil and benomyl. The major potential food applications for antimicrobial films include
meats, fish, bread, cheese, fruit and vegetables.

6 Moisture Absorbers: Excess moisture is a major cause of food spoilage. Soaking up

moisture by using various absorbers or desiccants is very effective at maintaining food
quality and extending shelf life by inhibiting microbial growth and moisture-related
degradation of texture and flavor. Moisture absorber sachets for humidity control in packaged
dried foods, several companies manufacture moisture drip absorbent pads, sheets and
blankets for liquid water control in high aw foods such as meats, fish, poultry, fruit and
vegetables are available.

7 Flavour/Odor Adsorbers: The interaction of packaging with food flavors and aromas has
long been recognized, especially through the undesirable flavor scalping of desirable food
components. Two types of taints amenable to removal by active packaging are amines, which
are formed from the breakdown of fish muscle proteins, and Aldehydes that are formed from
the autoxidation of fats and oils. Volatile amines with an unpleasant smell, such as
trimethylamine, associated with fish protein breakdown are alkaline and can be neutralized
by various acidic compounds. The bags that are made from film containing a ferrous salt and
an organic acid such as citrate or ascorbate are claimed to oxidize amines when they are
absorbed by the polymer film. Odor and Taste Control (OTC) technology removes or
neutralizes aldehydes.

Intelligent packaging

Intelligent packaging includes indicators to be used for quality control of packed food. They
can be so-called external indicators, i.e., indicators which are attached outside the package
(time temperature indicators), and so-called internal indicators which are placed inside the
package, either to the head-space of the package or attached into the lid.

1 Time temperature indicator (TTI): A time temperature indicator (TTI) can be defined as
a simple device that can give the idea about easily measurable, time-temperature dependent
change which affects full or partial temperature history of a food product to which it is
connected. The principles of TTI operation are based on mechanical, chemical,
electrochemical, enzymatic or microbiological irreversible change.
2 Freshness indicators: Two types of the changes can take place in the fresh food product
i.e. (i) Microbiological growth and metabolism resulting in pH changes, formation of toxic
compounds, off-odors, gas and slime formation, (ii) Oxidation of lipids and pigments
resulting in undesirable flavors, formation of compounds with adverse biological reactions or
discoloration. A freshness indicator indicates directly the quality of the product. The
indication of microbiological quality is based on a reaction between the indicator and the
metabolites produced during growth of microorganisms in the product. An indicator that
would show specifically the spoilage or the lack of freshness of the product, in addition to
temperature abuse or package leaks, would be ideal for the quality control of packed
products.

3 Pathogen indicators: Commercially available Toxin GuardTM is a system to build

polyethylene-based packaging material, which is able to detect the presence of pathogenic
bacteria with the aid of immobilized antibodies. As the analyte (toxin, microorganism) is in
contact with the material it will be bound first to a specific, labelled antibody and then to a
capturing antibody printed as a certain pattern. The method could also be applied for the
detection of pesticide residues or proteins resulting from genetic modifications.