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Food Packaging

Introduction

Packaging is a process of covering/wrapping of goods into a package.

It also involves designing and producing packaging materials.

Packaging is an essential for providing safe and secure goods to consumers.

It is a $2 billion industry per year in Australia.

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Food Packaging

Food packaging is essential and pervasive:

●Essential, because without packaging the safety and quality of food would be compromised,

●Pervasive because almost all food is packaged in some way.

In the last 200 years the package evolved from being a container for the product, to becoming an important element of total product design, eg.

Example: Packing tomato sauce in glass bottles has evolved to squeezable co- extruded multi-layer plastic bottles with oxygen barrier layer for long shelf life

Self-lubricating surfaces http://liquiglide.com/

General types of packaging

Consumer packaging

Designed for consumer convenience and appeal.

The major emphasis is on marketing.

Industrial packaging

Designed to focus on the handling convenience and protection during transportation.

The main focus is on logistics.

1. 2. 3. 4.

Functions of packaging

Protection

Containment

Communication/Information

Convenience

A good package can not only preserve the food quality but also significantly contribute to a business profit.

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Protection

The quality of the food product can deteriorate biologically and chemically as well as physically, during distribution, .

Food packaging contributes to extending the shelf life and maintaining the quality and safety of food products.

Food packaging reduces food waste and spoilage during distribution, and decreases the cost of preservation facilities.

Protection

The requirement for protection is determined by the nature of the food and the type of protection needed.

●The product needs for protection ●Physical environment

● impact, compression, abrasion, tearing, puncture ●Climatic environment

● Oxygen, Moisture, Light, Taints and odours

●Biological environment ● Pests - insects & rodents; ● Microbiological - bacteria, mould

The climatic environment

Coles, McDowell and Kirwan 2003; Chap1 page 14

The physical environment

Coles, McDowell and Kirwan 2003; Chap1 page 14

The biological environment

Coles, McDowell and Kirwan 2003; Chap1 page 15

Material loss by pilferage and tampering

● Security in distribution for protection against pilferage, tampering and counterfeiting

● lids may have plastic over-seal;

● perforated lid which breaks when opened;

● blister package sealed to a large paperboard backing;

● holographic packaging to reduce counterfeiting.

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Containment

Food products must be contained before they can be moved from one place to another.

Packaging facilitates handling, storage and distribution

Packaging has enabled the modern food distribution system, the development of supermarkets and the global food chain.

Includes both primary & secondary packages Package choices are based on:

Þ Dimension & Configuration requirements

Þ Material cost Þ Strength Þ Stability

Food Processing Plant Corporate video 1’40” http://www.youtube.com/watch?v=I4EbS36TQYQ

Three levels of packaging

primary pack: in direct contact with the food or beverage, eg. bottle and cap, carton

secondary or transit package: contains and collates primary packs, eg. a shrink-wrapped corrugated fibreboard tray or case

tertiary package, eg. pallet, roll cage, stretch-wrap.

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Packaging for transport

Communication /Information

Consumers make purchasing decisions using numerous clues provided by the graphics, colours and distinctive shapes of packaging.

Packages also need to communicate information about the product ●identity, quantity, instructions for storage and use

●labelling information as required by FSC 1.2 (nutrition, ingredient information, allergen warnings, country of origin, use-by date etc. )

●Universal Product Code (bar code) read accurately and rapidly using modern scanning equipment.

Communication for informed decision-making

Communicate information to end-user as required by legislation, ANZ Food Standards Code 1.2, ACCC and Department of Fair Trading

●Product brand names and descriptions; ●Manufacturer's name and address, ●Quantity/ net weight, ●Use-by dates/ best before date ●Ingredient listing,

●Nutrition information panel ●Directions for storage and cooking instructions; ● Warnings and allergen advice ●Recycling or disposal of package

Marketing – to sell food

Self-selection impact – silent salesman how getting the customer to select your product over all the others in the supermarket.

Marketing trends - increasing emphasis on the look, sales appeal and quality of retail packaging.

High quality graphics and promotional links between graphics and advertising to support brand identities, plus the ability to reflect current consumer trends and images.

Interactive marketing - new APPS to inform and educate the consumer, eg.

iAllergens, FoodSwitch, Traffic Light Food, Woolworths, Coles, Shop Ethical!, ShopWell, Frugal, ACCC recalls

Design Aesthetics & Marketing

"The Coke bottle is the most perfectly designed package in the world." The original contour of the "Mae West" bottle was designed in 1915. The bottle has undergone several redesigns in its 100-years.

Bar-codes

UPC bar code QR code

Micro QR Code

https://www.gs1.org/standards/barcodes

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Pallet, carton and bar-coding

A different barcode for each level of package, carton, etc.

Print important information, including use-by date

Each level treated as a product and scanned on receipt, etc.

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Convenience

Packaging plays an important role in allowing products to be used conveniently by the consumer.

Size – manageable for the consumer (small, regular, bulk)

Shape and proportions - variety of pack sizes, designs and pack types

Unitizing - primary package discrete units packed into secondary packages (multipacks)

Package design for the consumer use – easy to hold, portable, easy opening, re-close, dispense or pour, squeezable, spray, microwavable, recyclable, biodegradable, etc.

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Convenience

Packaging also plays an important role in allowing products to be handled, stored and efficiently distributed by the manufacturer

cartons pallets shipping containers

https://www.packworld.com/trends-and-issues/traceability- authentication-serialization/video-track-and-trace-serialization

Environmental considerations

Australian Packaging Covenant

http://www.packagingcovenant.org.au/

Initially launched in 1999, with 3x 5 year cycles of review. On July 1st 2010, an open-ended Australian Packaging Covenant commenced.

an agreement between companies in the supply chain and all levels of government to reduce the environmental impacts of consumer packaging, by:

https://www.youtube.com/watch?v=6qGZYPOLAos example: https://www.packagingcovenant.org.au/documents/item/1088 ●design packaging that is more resource efficient & more

recyclable;

Henderson Island

North Pacific gyre (Pacific trash vortex) https://www.youtube.com/watch?v=lLbJZjYyXAs

http://coastalcare.org/2009/11/plastic-pollution/

Types of plastic & recycling options

New Scientist 19 May 2018

Australasian Recycling Label

https://www.environment.gov.au/protection/waste-resource-recovery/plastics-and-packaging

New Scientist 19 May 2018

Packaging types and selection

Day in the Life of a Food Packaging Professional

http://www.youtube.com/watch?v=uXa-yqP9e3Q

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Selection of packaging

The design and development of appropriate packaging for food, one needs to consider:

The product’s characteristics : physical, chemical, biochemical and microbiological nature,

Mechanism by which it can deteriorate, It’s fragility in distribution Possible interactions with packaging materials

Coles, McDowell and Kirwan 2003; Chap1 page 13

Nature of the product

Physical nature

Gas, liquid, viscous liquid, solid blocks, granules, free-flowing powders, emulsions, pastes etc

Chemical or biochemical nature

Ingredients, chemical composition, nutritional value, corrosive, sticky, volatile, perishable, odorous etc.

Dimensions

Size and shape

Volume, weight & density

Method of fill, dispense, accuracy, legal obligation etc.

Damage sensitivity

Mechanical strength properties or fragility/weaknesses

Product deterioration

Intrinsic mechanisms including changes in:

Organoleptic qualities

Taste, smell, colour and texture

Chemical breakdown

Vitamin C breakdown in orange juice, riboflavin loss from milk in light, Maillard browning of dried milk

Physio-Chemical changes

staling of bread, crystallisation of lactose in ice cream or condensed milk

Biochemical changes

enzymatic browning, cheese ripening, respiration in fruit & vegies

Microbiological status

bacterial or mould growth

Product shelf-life requirement

Average shelf life needed Use-life needed

Changes in packaged food during storage

The processes by which food quality is lost often involve interaction with the environment – either from substances taken up or loss through the packaging.

Type of Change

Food product impacts

Moisture loss

Drying – a problem in frozen food; wilting of vegetables,

Moisture uptake

Softening of crisps, biscuits; lumping of powders,

Oxygen uptake

Oxygen causes oxidation rancidity – fats and oils,

Light

Light initiated oxidation of fats; bleaching /colour loss

Packing material options

● Glass

● Tinplate

● Aluminium

● Paper and paperboard

● Plastics

Primary Packages

GLASS

METALS

PAPER

PLASTICS

COMPOSITE

RIGID & SEMI-RIGID CONTAINER

Bottle Jug Jar Tumbler Vial

Cans - Fe/Sn Alumin. Cans

Metal boxes (Slip lid, Lever lid, Hinged)

Trays Drum

Boxes Cartons

Form-in-line (cup, tub, tray)

Egg box

Bottle Jug Jar Tub Cup Tray Thermoform

Drum Laminated cartons IBCs

FLEXIBLE WRAPS, BAGS, POUCHES & SACHETS

Tube Foil

Vegetable parchment Folded wrap Sealed wrap Bags

(plain, treated)

Preformed Form-in-line FIBCs

Foil laminates Laminated pouches

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Cost of packaging

Packaging is a major cost in the retail price

Direct cost of package plus indirect costs for empty as well as full packages, including handling, storage, transport, insurance, management

The ‘added value’ of the Package should exceed costs ! to remain competitive and innovative

Weight of packages and different package options

Weight

Milk 12 L

Beer 9 L

Wine 6L

Bottles

7500 g

6840 g

Cartons

340 g

Steel can

1300 g

Aluminium can

580 g

Cask

400 g

Glass

● Inert with respect to foods

● Transparent to light and may be coloured

● Impermeable to gases and vapours

● Rigid

● Can be easily returned and reused

● Brittle and breakable

● Needs a separate closure

● Widely in use for both single & multi-trip packaging

Coles, McDowell and Kirwan 2003; Chap1 page 17

Tinplate can

Aluminium can

Tinplate and aluminium

● Rigid material

● Steel can – high density, suited to retort canning process

● Aluminium can - low density, suited for canned drinks

● Good tensile strength

● An excellent barrier to light, liquids and foods

● Needs closures, seams and crimps to form packs

● Used in many packaging applications: food and beverage cans, aerosols, tubes, trays and drums

● Can react with product causing dissolution of the metal Coles, McDowell and Kirwan 2003; Chap1 page 17

Paper and paperboard

● Low-density materials

● Poor barriers to light without coatings or laminations

● Poor barriers to liquids, gases and vapours unless they are coated, laminated or wrapped

● Good stiffness

● Can be grease resistant

● Absorbent to liquids and moisture vapour

● Can be creased, folded and glued

● Tears easily, Not brittle, Moderate tensile strength

● Excellent substrates for inexpensive printing

Coles, McDowell and Kirwan 2003; Chap1 page 17

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Plastics

Wide range of barrier depending on type of polymer

Permeability to gases and vapours to varying degrees

Always consider oxygen and water vapour transmission when selecting film, with respect to the likely spoilage mechanisms of the food.

Range of physical and optical properties flexible or rigid opaque or transparent variable tensile and tear strengths

Functional over a wide range of temperatures depending on the type of plastic polymer

Coles, McDowell and Kirwan 2003; Chap1 page 17

Packing film selection

Wide range of plastic polymer materials.

Each polymer has differences in permeability to air, water and light, rigidity/flexibility.

Different foods have different requirements;

●Foods susceptible to drying but not affected by oxygen (e.g. bread) need high moisture barrier [LDPE ]

●Foods susceptible to moisture pick-up and affected by oxygen (e.g. crisps) need high moisture barrier and high oxygen barrier, [ OPP ]; plus laminate with Aluminium foil will further prevent light and oxygen.

●Food requiring containment (liquid foods) need rigid plastic.

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Plastic (polymeric) packaging materials – examples of applications

Low density polyethylene (LDPE) – squeezy bottles and shopping bags

High density polyethylene (HDPE) – rigid bottles, carboys

Polypropylene (PP) – rigid

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Common packaging polymers

1. PET – Polyethylene Terephthalate (e.g. soft drink bottles, peanut butter jars). 2. HDPE – High-Density Polyethylene (e.g. milk bottles, yoghurt cups).

3. PVC – Polyvinyl Chloride (e.g. some types of cling wrap for meat, fish, cheese, vegetables; clear plastic containers for fresh fruit or takeaway sandwiches).

Common packaging polymers

4. LDPE – Low-Density Polyethylene (e.g. some grocery bags; bags used for bread and frozen foods; some types of cling wrap).

5. PP – Polypropylene (e.g. bottle caps, yoghurt and margarine containers, food storage boxes).

6. PS – Polystyrene (e.g. plastic cutlery; drinking cups and yoghurt cups; lightweight foam trays used to package meat and vegetables).

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Thermoplastic vs thermoset Packaging polymers may be classified into thermoplastics and

thermosets, depending on whether crosslinks are present.

Thermoplastics

Soften and melt when heated, but resolidify upon cooling

Can be easily shaped by heat and pressure (e.g. films, bottles, etc.)

Support hot-forming methods such as injection-moulding.

Heated in several cycles, polymers are melted and cooled to become solid without significant loss of properties.

Recyclability: Easier to recycle.

Typical polymers: Acrylics, Nylons, Polyethylene, Polypropylene, Polystyrene

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Thermoset polymers

Change irreversibly when heated.

The change usually involves cross-linking (setting) which strengthens the polymers.

They are often made from multi-part compounds and formed before setting (e.g. epoxy resin).

Setting accelerates with heat, or for some polymers with UV light.

Thermosets will not melt, and have good heat resistance.

Heating does not soften the materials, but severe heating irreversibly destroy covalent bonds (decomposition).

Much harder to recycle.

Examples: Phenolics, epoxies, silicones, some polyesters, polyurethanes and elastomers

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Heat seal strength

The strength of the bond formed by heat sealing is important in heat sealable plastic packaging.

This property related to a film’s ability to make a peel-resistant seal.

Measured by testing the sealed samples under controlled temperature, pressure and dwell-time (time during which heat is applied).

Then measure the seal’s resistance to peeling on a tensile tester.

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Plastic Laminates

Since no single film can satisfy all packaging requirements, several different films may be combined by lamination or coextrusion.

Lamination of plastic films can be done using an adhesive, Or If the two plastic films each have heat-sealing properties, they may be joined together by passing the films through a heated roller

Laminates can include layers of different plastic films, paperboard and metal (aluminium), achieving barrier properties with the summation of all the different components.

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Polymer coatings and laminates

Polymers are also used to coat other materials; for example, paper coffee cups are often coated with a thin layer of polyethylene, which makes them hard to recycle.

Polymers are also used in laminates (multilayer films), either with another polymer, or paper or metal.

Different components may serve as barriers to light, moisture, oxygen, taste and aroma compounds.

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Tetra Pak - laminated paperboard

Coatings

Coatings are applied to the surfaces of plastic films to improve heat-sealing, barrier and printing properties

Acrylic coatings – glass clear, hard, heat sealable, very glossy PVdC coatings may be modified to produce either a good heat-sealing polymer or

a high-barrier polymer

Direct vacuum metallising with aluminium on plastic films results in a significant increase in barrier properties

SiOx applied by vacuum deposition. SiOx coated PET film is used in the retort pouch laminates, is transparent, retortable, recyclable and has excellent barrier properties.

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Water vapour transmission

The steady state rate at which water vapour permeates through a film at specified conditions of temperature and relative humidity.

This is a measure of a film’s ability to retain freshness, preventing the escape of moisture from moist products, or preventing dry products from picking up moisture from outside.

The moisture passing through the film in a given time is reported as water-vapour transmission rate (WVTR) in g/m2/24 hours.

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Gas permeability

The ability of a gas or other volatile substance to penetrate and pass through a material.

Gases include oxygen, nitrogen, carbon dioxide and various volatile compounds found in foods.

This property is associated with the retention of colour, flavour and odour.

Permeability is expressed as cc (mL) of gas permeated per 1 square metre of film in 24 hours.

A material is considered as ‘high oxygen barrier’ if its Oxygen transmission Rate (OTR) is < 15.5 cc/m2/24 hr.

Coles, McDowell and Kirwan 2003;

0 = Not suitable, * = short life, ** =medium life, *** = long life, MAP = modified atmosphere pack.

Coles, McDowell and Kirwan 2003;

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Important properties in storage

The product/package interaction.

Permeability to gases and vapours.

Resistance to ‘scalping’ of flavour and aroma components, which may be lost by dissolving in the polymer.

Alternatively, packaging components may diffuse into the product, causing contamination, off-flavours, etc.

Innovative packaging

Modified Atmosphere Packaging (MAP) – employs gas mixtures to reduce enzymatic and microbial changes during storage

Active Packaging, inclusions with added functionality: Antimicrobial, Oxygen scavenger, Ethylene oxidation, Odour removal,

Intelligent Packaging, sensing and informing; eg. indicator for ripeness or freshness.

Han, J. 2005.

Gases and food quality effects

Nitrogen is an inert and tasteless gas, no antimicrobial activity. It is not very soluble in water, and it is primarily used to displace oxygen and prevent package collapse.

Oxygen inhibits the growth of anaerobic micro-organisms, but promotes the growth of aerobic microbes. Oxygen is responsible for some undesirable reactions in foods, including 63

Modified Atmosphere Packaging (MAP)

Retail food product

CO2

Raw red meat

70%

30%

Raw white fish, other seafood

30%

40%

30%

Cooked, cured, processed meat fish poultry, Ready cook chill

30%

70%

Fresh pasta, Bakery products

50%

Dairy products

100%

Dried foods, Liquid foods & drinks

100%

Air Products. 1995

Active Packaging

Active Scavenging systems remove undesirables such as oxygen, excess water, ethylene, carbon dioxide, taints and others ............... ABSORBERS

Active Releasing systems add desirables such as carbon dioxide, water, antioxidants and preservatives................ EMITTERS

Diagram of active packaging systems

Intelligent Packaging

Intelligent or smart packaging include time-temperature indicators (TTIs), gas indicators, microwave doneness indicators, radiofrequency identification (RFID).

● Clever, smart, interactive

● Indicator must be easily activated

● Must show measurable, reproducible changes

● Must be irreversible

● Easily correlated to food quality

Insignia Embedded Colour Changing Labels - 40s http://www.youtube.com/watch? v=k0kpOoe-42g

Smart packaging – oxygen exclusion/absorption https://www.youtube.com/watch? v=VH_SdO9u0nA

Intelligent Plastics – ripeness & freshness indicator

Packaging Innovations

CES 2011 - Interactive and intelligent food packaging 4’ 34’’ http://www.youtube.com/watch? v=MpKukF48Tac

New 2011 NutriSmart embeds RFID tags directly within food 1’ 50’’

http://www.youtube.com/watch?v=N3_EjOecfOA

Cook-chill Meal https://www.youtube.com/watch?v=KbMdaj5owBU https://www.youtube.com/watch?v=zwobWIEl3f0

Amazon go 1’50”

https://www.youtube.com/watch?v=NrmMk1Myrxc

Future trends in food packaging

Development of new materials that possess very high barrier properties, thus reduce the total amount of packaging materials.

Convenience is a "hot" trend” ; in either productivity, processing, warehousing, traceability, display qualities, tamper-resistance, easy opening, and cooking preparation.

Safety another important trend, related to public health microbiological control or security against bioterrorism.

Forth issue is the trend to natural and environmentally friendly. Substitution of artificial chemical ingredients with natural ingredients. Increase in recyclable and reusable (refillable).

Edible packaging https://www.youtube.com/watch?v=hLEWeP3WJ8M

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