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Packaging materials for bakery products

By,PRASAD REDDY M.N M-TECH (FST)

PACKAGING• Packaging has been defined as a socio-scientific discipline

that operates in society to ensure the delivery of goods to the ultimate consumer of those goods in the best condition intended for their use (Lockhart, 1997).

• Packaging Institute International (Glossary of Packaging Terms, 1988) defined packaging as the enclosure of products, items or packages in a wrapped pouch, bag, box, cup, tray, can, tube, bottle or other container form to perform one or more of the following functions: containment, protection, preservation, communication, utility and performance.

Types of packaging 1) primary package : Eg: metal cans, paperboard cartons, glass bottles and plastic pouches.

2) secondary package: eg: corrugated case or box,

3) Tertiary packaging stretch-wrapped pallet of corrugated cases.

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Functions of Packaging• Protection & preservation• Product information• Promotion of corporate identity• Forms part of sales promotion• Adds to the appeals of the product.

PURPOSES OF PACKAGING

• Physical protection• Barrier protection• Containment or agglomeration• Information transmission• Marketing• Security• Convenience

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Introduction • Bakery is a traditional activity and occupies an important place in

food processing industry • Bakery industry, production of which has been increasing steadily in

the country, is the largest among the processed food industries in India.

• Eg: breads, unsweetened rolls and buns, doughnuts, sweet and savory pies, pizza, quiche, cakes, pastries, biscuits, crackers and cookies.

Bread, biscuits and cake

• The two major bakery industries, viz. bread and biscuit account for about 82% of the total bakery products.

• about 1.3 millions tonnes of the bakery products industry in India is in the organized sector out of 3millions tonnes, rs.

• The annual production of bakery products, which includes bread, biscuits, pastries, cakes, buns, rusk etc., is estimated to be in excess of 3 million tonnes.

• The production of bread and biscuits in the country, both in the organised and unorganised sectors, is estimated to be around 0.44 million tonnes and 11 million tonnes respectively.

• The cake and pastry market estimated at 0.4 million tonnes, is the fast growing market with volume growth of 16%.

Classification of bakery products Categories of Bakery Product

Types within Each Category

Unsweetened goods Bread: sliced, crusty, par-baked, ethnic Rolls: soft, crusty Crumpets English muffins Croissants Pizza base Raw pastry

Sweet goods Large cakes: plain, fruited Pancakes Doughnuts Waffles Cookies Biscuits American muffins Buns Wafers

Filled goods Tarts: fruit, jam Pies: meat, fruit Sausage rolls Pasties Cakes: cream, custard Pizza Quiche

Source: Adapted from Smith, J.P. et al., Crit. Rev. Food Sci. Nutr., 44, 19, 2004

SPOILAGE CONCERNS OF BAKERY PRODUCTS

• 1. Physical spoilage (moisture loss, staling) • 2. Chemical spoilage (rancidity)• 3. Microbiological spoilage (yeast, mold, bacterial

growth) (Hasan, 1997)

DIFFERENT PACAKING MATERAILS

Baking trays are an efficient way to present, protect and cook food products including breads and cakes.

Paper based baking trays are an environmentally friendly alternative to plastic or foil trays.

Made from corrugated, solid board or folding carton,

Suitable for direct food contact, the trays are heat resistant and can be used safely in ovens. This provides maximum convenience for consumers who are able to cook the product in its packaging.

Baking trays:

Biscuit liners

• Biscuit liners provide protection for the transportation, storage and display of biscuits.

• The liner wraps around the biscuits to form a tight protective sleeve between the biscuit and the outer packaging.

• Made from lightweight single face corrugated packaging, 100% recyclable and made from a renewable resource, our biscuits liners offer an environmentally friendly alternative to plastic trays or liners.

Cake base discs• Cake base discs provide a solid base for the

transportation, storage and display of cakes.• For use by industrial cake producers and retailers

who prepare fresh cakes in store. • Paper based cake discs are an environmentally

friendly alternative to polystyrene or plastic cake discs or trays.

• Made from corrugated cardboard our cake discs are 100% biodegradable and made from a renewable resource.

Flexible packaging ( laminates ,wrappers )

These are the most common method of packaging material used to pack bakery products today .

We can find zig zag fisssures at the end of the packs which helps consumer to tear the pack .

Earlier difficult to open now at edge of pack given easy to open

Eg: Good Day , Marie gold , Krack Jack, Parle G

Tins or Metallic Boxes

These are still popular in masses as it was in earlier days.

These can be found for cookies packing which very soft to handle , Hence majority of cookies are packed in Tins .

Eg: Danish Cookies and Britannia s Pure Magic cookies 

Pvc Trays 

• Soft cookies or cakes are arranged in these trays to prevent from any damage at with ease to handle and store .

Eg: Britannia Good day choco chips are packed in pvc trays

Poly bags

Breads are packed in these types of poly bags which are tied through twist n tie bands or stickers .Normal flow wrap packaging is done for Majority of white bread available in market .Eg: Breads by Harvest Gold .

Shrink Wrapped and Over wrapped boxes and trays

• Shrink wrapping is done on boxes to give a attractive look to consumers with additional safety to the products .

• Display boxes can also be shrink wrapped .

Paper Bags Bread  are normally packed  in poly  bags but for 

few artisan bakeries customer prefer more environmental friendly  paper bags .

These paper bags could be  plain or can have printed material  on them .

Paper normally are used for baguette and convenient in carrying such product .

Zip Pouches These are  introduced  with  resealable  pouches

meant for products  to be carried over to a  distance or to be kept for longer period .

These pouches have zip integrated in the pouches so as to open and close it when ever required thus keeping the product crispy and prevents moisture to enter the bag .

Cake Boxes

• Cake boxes  have been  used  for   packing Cakes , Pies  and Swiss rolls  etc  ,these area PET  transparent  with hinged cover and base Consumer can see the products  through transparent cover  

Tube Packaging• Cylindrical Tubes of different height s are used for packaging

bakery products such as cookies , biscuits

Vertical Pouches or Sachet

• These have also been experimented by many bakery manufacturers mainly biscuits, snacky biscuits.

• These can be found for cookies packing which very soft to handle.

• Soft cookies or cakes are arranged in these trays to prevent from any damage at with ease to handle and store .

New technology in bakery products packaging

1.Modified atmosphere packagin (MAP):• CO2 and N2 are the most commonly• Carbon dioxide is soluble in water and fat,

producing carbonic acid and lowering the pH of the product, resulting in changes in the flavour.

• Nitrogen is also very effective but only if the residual oxygen percentage is low.(continued.)

• MAP is especially suited to breads, pastries, and pies

.Active packaging.• Active packaging is the name given to a large

group of packaging modifications that are meant to improve shelf life of the foods.

• It improves shelf life of foods by modifying the environment around the food so that growth of microorganisms is prevented or delayed.

• shelf life of a product can be dramatically extended using oxygen absorbers.

• These absorber generate carbon dioxide replacing the removed oxygen.

• Such absorbers allow natural and safe preservation of food’s original taste and freshness, resulting in extended shelf life without preservatives or additives

Plain cardboard Boxes• These are used by many manufactures to

pack biscuit to differentiate its product from competitors.

• These normal paper boxes which are slightly thicker.

Display Boxes• After primary packing done by flexible wrappers

these packets are arranged in display boxes manually and then these boxes are shrinked wrapped.

• Consumers can see the products through these transparent films.

Conclusion.

• Bakery products include items of different packaging requirements, which are met by arrange of plastic materials in the form of films, laminates and thermoformed trays.

• These materials provide adequate protection against moisture loss/gain, retain the taste and aroma, and are hygienic and safe for food contact.

• These materials provide adequate protection against moisture loss/gain, retain the taste and aroma, and are hygienic and safe for food contact.

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