active packaging
DESCRIPTION
pengemasanTRANSCRIPT
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Active Packaging & Intelligent Packaging
Food Science & Technology
Brawijaya University 2014
Indria Purwantiningrum
Food Storage and Packaging
Overview
Introduction
Active vs Intelligent
Types of Active /int packaging
Issues related to active/int packaging
Conclusion
References
Introduction
Additives incorporation
Within packaging
Extend/ maintain shelf life
Active Packaging
has been used with many food products
Scavenging oxygen ; adsorbing carbon dioxide, moisture, ethylene
and/or flavour/odour taints; releasing ethanol, sorbates, antioxidants and/or
other preservatives; maintaining temperature control.
Introduction
capable of sensing and providing information can provide assurances of pack integrity, tamper
evidence, product safety and quality, utilised in applications such as product
authenticity, anti-theft and product traceability
time-temperature indicators gas sensing dyes microbial growth indicators physical shock indicators tamper proof anti-counterfeiting and anti-theft technologies
Smart Packaging
devices
Active vs Intelligent
Active packaging
changes the condition of the packed food
extend shelflife
improve safety or sensory properties
maintaining the quality of the packaged food.
Intelligent packaging
monitor the condition of packaged foods
give information about the quality of the packaged food during transport and storage.
Oxygen Scavenger
Oxygen detrimental effects on foods.
Oxygen scavengers help: maintain food product quality by decreasing
food metabolism,
reducing oxidative rancidity,
Inhibiting oxidation of pigments and vitamins,
controlling enzymic discolouration
inhibiting the growth of aerobic microorganisms
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Oxygen Scavenger
Market : Japan, USA, Europe Usage : polyethylene terephthalate (PET) bottles, bottle
caps and crowns for beers and other beverages Form : small sachets containing various iron based
powders combined with a suitable catalyst. Mechanism : the chemical systems react with water
supplied by the food produce a reactive hydrated metallic reducing agent that scavenges oxygen within the food package 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 that is labelled Do not eat.
Oxygen Scavenger
The main advantage of using such oxygen scavengers is that they are capable of reducing oxygen levels to less than 0.01% which is much lower than the typical 0.33.0% residual oxygen levels achievable by modified atmosphere packaging (MAP). Oxygen scavengers can be used alone or in combination with MAP
Their use alone eliminates the need for MAP machinery and can increase packaging speeds
common commercial practice to remove most of the atmospheric oxygen by MAP and then use a relatively small and inexpensive scavenger to mop up the residual oxygen remaining within the food package
Oxygen Scavenger
Disadvantage : risk of being swallowed/ accidentally digested by consumer
Solution : oxygen scavenging adhesive labels that can be applied to the inside of packages and the incorporation of oxygen scavenging materials into laminated trays and plastic films have enhanced and will encourage the commercial acceptance of this technology
Oxygen Scavenger : Application
Marks & Spencer Ltd (first UK retailer to use oxygen scavenging adhesive labels ) sliced cooked and cured meat and poultry products
coffee, pizzas, speciality bakery goods and dried food ingredients
cakes, breads, biscuits, croissants, fresh pastas, cured fish, tea, powdered milk, dried egg, spices,
herbs, confectionery and snack food Toyo Seikan Kaisha Ltd marketed a laminate
containing a ferrous oxygen scavenger which can be thermoformed into an Oxyguard tray used commercially for cooked rice
Sour
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Oxygen Scavenger : Alternatives
Oxygen scavenger materials : Iron based
High aw/ wet condition loss of scavenging capability
Non-iron based : non-metallic reagents & organo-metallic agents Have the same affinity as iron
Speed & capacity is lower than iron-based materials
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Carbon dioxide scavengers/ emitters
Carbon dioxide scavengers particularly applicable for fresh roasted or ground coffees produce significant volumes of carbon dioxide.
Fresh roasted or ground coffees absorb moisture and oxygen and lose easily desirable volatile aromas and flavours
Solution : use packaging with patented one-way valves that
will allow excess carbon dioxide to escape. use a carbon dioxide scavenger or a dual-action
oxygen and carbon dioxide scavenger system.
CO2 Scavenger :Materials
Mixture of calcium oxide and activated charcoal in polyethylene coffee pouches
Dual-action oxygen and carbon dioxide scavenger sachets and labels common & commercially used for canned and foil pouched coffees in Japan and the USA contain iron powder for scavenging oxygen, and
calcium hydroxide which scavenges carbon dioxide. commercially available:
Ageless type E and Fresh Lock (Mitsubishi ) Freshilizer type CV (Toppan Printing Co Ltd.)
CO2 Emitter
Carbon dioxide emitting sachet and label devices can either be used alone or combined with an oxygen scavenger
An example of the former is the Verifrais package manufactured by SARL Codimer (Paris, France) extending the shelf life of fresh meats and fishconsists of a standard MAP tray but has a perforated false
bottom under which a porous sachet containing sodium bicarbonate/ascorbate is positioned.Mechanism : when exudate MAP meat or fish contacts
the sachets contents, carbon dioxide is emitted and this antimicrobial gas can replace the carbon dioxide already absorbed by the fresh food, so avoiding pack collapse
CO2 Emitter : Problems & Solution
Problems ; Pack collapse development of a partial vacuum
Solution : Use of dual action oxygen scavenger/carbon dioxide
emitter sachets and labels Mechanism: absorb oxygen and generate an equal
volume of carbon dioxide. These sachets and labels usually contain ferrous
carbonate and a metal halide catalyst although non-ferrous variants are available. Commercial manufacturers
CO2 Emitter : Application
Commercial manufacturers : Mitsubishi Gas Chemical Co. Ltd (Ageless type
G), and
Multisorb Technologies Inc. (Freshpax type M).
Food applicaions : snack food products, e.g. nuts and sponge cakes
Ethylene scavengers
Ethylene (C2H4) = plant growth regulator accelerates the respiration rate and subsequent senescence of horticultural products such as fruit, vegetables and flowers.
Important effects in plants: induction of flowering in pineapples, colour development in citrus fruits, bananas and
tomatoes, stimulation of root production in baby carrots and development of bitter flavour in bulk delivered
cucumbers, but in most horticultural situations Undesirable effects should be removed
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Ethylene scavengers
Materials : potassium permanganate (KMnO4) immobilised
on an inert mineral substrate such as alumina or silica gel
Titanium dioxide
Activated carbon-based scavengers with various metal catalysts
Minerals (ground & incorporated into packaging material)
Ethylene scavengers
Mechanism : KMnO4 oxidises ethylene to acetate and ethanol
in the process changes colour from purple to brown indicates its remaining ethylene scavenging capacity.
Available in sachets to be placed inside produce packages
inside blankets or tubes that can be placed in produce storage warehouses
Ethanol emitters
Ethanol = use as antimicrobial agent Function :
effective against mould inhibit the growth of yeasts and bacteria.
Application can be sprayed directly onto food products just prior
to packaging. mould-free shelf life of bakery products can be
significantly extended after spraying with 95% ethanol (0.51.5% (w/w)
More practical & safer method : films and sachets
Ethanol emitters: Commercial app
Ethicap, Antimold 102 and Negamold (Freund Industrial Co. Ltd),
Oitech (Nippon Kayaku Co. Ltd), ET Pack (Ueno Seiyaku Co. Ltd) Ageless type SE (Mitsubishi Gas Chemical Co.
Ltd). Contain absorbed or encapsulated ethanol in a
carrier material which allows the controlled release of ethanol vapour.
Ethanol emitters:in practice
Ethicap (most commercially popular ethanol emitter in Japan) consists of food-grade alcohol (55%) and water (10%) adsorbed onto silicon dioxide powder (35%) and contained in a sachet made of a paper and ethyl vinyl acetate (EVA) copolymer laminate.
To mask the odour of alcohol, some sachets contain traces of vanilla or other flavours.
The sachets are labelled Do not eat contents and include a diagram illustrating this warning.
Negamould & Ageless type SE dual-action sachets scavenge oxygen & emit ethanol vapour
Ethanol emitters:Mechanism
Consider food weight, aw, desired shelf life size and capacity of the ethanol-emitting sachet
Principles of mechanism : moisture is absorbed by the food ethanol vapour is releaseddiffuses into the package headspace
Usage in bread inhibit mould growth and staling effect
Also widely used in Japan for extending the shelf life of semi-moist and dry fish products
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Preservative releasers
potential use of antimicrobial and antioxidant packaging films preservative properties for extending shelf life
some antimicrobial and antioxidant films have been marketed but the majority have failed to be commercialised because of doubts about their effectiveness, economic factors and/or regulatory constraints
Preservative releasers : materials
Synthetic silver zeolite to allow slow release of antimicrobial silver ions into the surface of food products
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 antifungal agents, e.g. imazalil and benomyl.
Preservative releasers : Applications
Meats
Fish
Bread
Cheese
Fruit
Vegetables
Source: Coles, et al. 2003
Preservative releasers : Alternative Applications
In the UK Microban (USA) kitchen products such as chopping boards, dish cloths and bin bags Triclosan antibacterial aromatic chloro-
organic compound also used in soaps, shampoos, lotions, toothpaste and mouth washes
methyl salicylate into RepelKote paperboard boxes by Tenneco Packaging Antimicrobial, insect repellent
Interest in preservatives
releaser packaging
Two influences have stimulated interest : Consumer demand for reduced antioxidants and
other additives in foods. Interest of plastic manufacturers in using natural
approved food antioxidants, e.g. vitamin E for polymer stabilisation instead of synthetic antioxidants developed specifically for plastics
For example, the cereal industry in the USA : previously used BHA & BHT in waxed paper. Nowadays use of -tocopherol (vitamin E)
Moisture absorbers
desiccants such as silica gel, calcium oxide and activated clays and minerals
dual-action purposes, these sachets may also contain activated carbon for odour adsorption or iron powder for oxygen scavenging
high aw foods such as meats, fish, poultry, fruit and vegetables
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Moisture absorber
Basic mechanism : two layers of a microporous non-woven plastic film, such as polyethylene or polypropylene, between which is placed a superabsorbent polymer which is capable of absorbing up to 500 times its own weight with water.
Typical superabsorbent polymers : polyacrylate salts, carboxymethyl cellulose (CMC) and starch copolymers which have a very strong affinity for water.
Placed under packaged product to absorb tissue drip Larger sheets and blankets are used for absorption of
melted ice from chilled seafood during air freight transportation, or for controlling transpiration of horticultural produce
Moisture absorber
Alternative approach : Intercept the moisture in the vapour phase
Reduces in-pack RH
Example: Pichit film (Showa Denko Co Ltd.) consists of
a layer of humectant carbohydrate and propylene glycol sandwiched between two layers of polyvinyl alcohol (PVOH) plastic film
Flavour/odor adsorbers
Undesirable flavour/ odor : amines breakdown of fish muscle proteins, and
Aldehydes auto-oxidation of fats and oils.
Volatile amines, such as trimethylamine, associated with fish protein (usually alkaline)
Can be neutralised by various acidic compounds
Flavour/odor adsorbers :
commercials Anico bags ferrous salt and an organic acid such as citrate or
ascorbate. Oxidise amines as they are adsorbed by the polymer film
Duponts Odour and Taste Control (OTC) technology Removal of aldehydes such as hexanal and heptanal from package headspaces Based upon a molecular sieve with pore sizes of around five
nanometres Removes or neutralises aldehydes although evidence for this is lacking snack foods, cereals, dairy products, poultry and fish
BMH powder developed by Swedish company EKA Noble in co-operation with Dutch company Akzo synthetic aluminosilicate zeolites adsorb odorous gases within their highly porous structure. can be incorporated into packaging materials, especially paper-
based pack
Temperature control packaging
use of innovative insulating materials, self-heating and self-cooling cans
to guard against undue temperature abuse during storage and distribution of chilled foods, Thinsulate (3M Company, USA)
to increase the thermal mass of the food package so that it is capable of withstanding temperature rises, Cool Bowl (Adenko, Japan)
TTI : Commercials
Self-heating aluminium and steel cans and containers for sake, coffee, tea and ready meals heated by an exothermic reaction occurs when lime and water positioned in the base are mixed.
In the UK, Nestl Nescaf coffees in self-heating insulated cans use the lime and water exothermic reaction.
Self-cooling cans in Japan raw sake. The endothermic dissolution of ammonium nitrate and chloride
in water used to cool the product. Chill Can (The Joseph Company, USA)
usehydrofluorocarbon ( HFC) gas refrigerant. The release of HRC gas is triggered by a button set into the
cans base and can cool a drink by 10C in two minutes. Environmental impact of HFCs
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Food safety & Regulatory issues: Food contact approval establishment prior using Environmental regulations The need for labelling, if consumer confusion may
rise Effects on microbial ecology & safety of foods
Food safety, consumer
acceptability and regulatory issues
aims to evaluate the safety, effectiveness, economic and environmental impact and consumer acceptance of active and intelligent packaging
Actipack project (EU funded)
Food safety, consumer
acceptability and regulatory issues
active packaging
affect foods
Component migration
intended
unintended
antioxidants, ethanol and antimicrobial preservatives
their identity,concentration and possible toxicology effects
metal compounds
identification and quantification
Food safety, consumer
acceptability and regulatory issues
Environmental regulations covering reuse, recycling, identification to assist in recycling or the recovery of energy from active packaging materials EU Regulations
Food safety, consumer
acceptability and regulatory issues
Food labelling currently required to reduce the risk of consumers ingesting the contents of oxygen scavenger sachets or other in-pack active-packaging devices.
Some active packages may look different from their passive counterparts.
Therefore it may be advisable to use appropriate labelling to explain this difference to the consumer even in the absence of regulations.
Food safety, consumer
acceptability and regulatory issues
Very important for food manufacturers to consider the effects on the microbial ecology and safety of foods.
Regarding the use of antimicrobial films, it is important to consider what spectrum of microorganisms will be inhibited.
Antimicrobial films which only inhibit spoilage microorganisms without affecting the growth of pathogenic bacteria will raise food safety concerns.
Food safety, consumer
acceptability and regulatory issues
In the USA, Japan and Australia, active packaging concepts are already being successfully applied.
In Europe, the development and application of active packaging is limited because of legislative restrictions, fear of consumer resistance, lack of knowledge about effectiveness and economic and environmental impact of concepts
No specific regulations exist on the use of active packaging in Europe. Active packaging is subjected to traditional packaging legislation
The food industrys main concern about introducing active components to packaging seems to be that consumers may consider the components harmful and may not accept them.
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Food safety, consumer
acceptability and regulatory issues
So far, research has mainly concentrated on the development of various methods and their testing in a model system, but not so much on functioning in food preservation with real food products.
Furthermore, the benefits of active packaging need to be considered in a holistic approach to environmental impact assessment.
Discussion
What aspect should be considered when choosing active/ intelligent packaging? Please Explain in brief.
Compare each type of active packaging mentioned above in terms of food application, materials/ technology used, principles of mechanism, purpose of usage
References
Coles, R., D. McDowell, M.J. Kirwan. 2003. Food Packaging Technology. Cp. 10. CRC Press
Ahvenainen, R. 2003. Novel Food Packaging Technique. CRC Press
Rooney, M.L. 1995. Active Food Packaging. Chapman & Hall.