smart, active & intelligent packaging

8/10/2019 Smart, Active & Intelligent Packaging

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Abirami Nadarajan Active, Intelligent & Smart Packagi

Smartness in Packaging

Broad term covering a number of functionalities

Depending on the product being packaged

Example of current & future functional smartness:

Retain integrity and actively prevent food spoilage (shelf life)

Enhance product attributes ( look, taste, flavor, aroma)

Respond actively to changes in product or package environment

Communicate product information, history or condition to user

Assist with opening and seal integrity

Confirm product authenticity and act to counter theft

Definitions

Passive

They function only as an inert barrier to protect the product against oxygen and moisture

Act as a passive barrier to separate a product from its environment

Active Packaging

Differs from conventional passive packaging in that one or more forms of interaction planned

Active functions beyond the inert passive containment and protection of the product

Interacts directly with the product and/or its environment to improve one or more nutritional, quality and safety factors.

Smart/Intelligent Packaging

Involves the ability to sense or measure an attribute if the product, the inner atmosphere of the package or the shipping environment.

Packaging which senses a situation and provide information such as quality, environment, location, safety, history & etc.

Applications in the current world

Active Packaging

Goals

Extension of shelf life (sea shipments of some fresh produced

Less expensive packaging materials Packaging of limited shelf life product requires enhancement

Simpler processing Additional MO hurdles allows MAP to be achieved without expensive equipments

Reduction or removal of preservatives from food formulations

Difficult to handle productsOxygen can be removed from tightly packaged product such as cheese

Allowing particular packages to be used retortable plastic packages with multilayer shelf lifes, PET wine bottles

PresentationHeating by microwave suseptors & other adjuncts has allowed packaging innovation for convenience foods


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Active Packaging

System Explanation/Mechanism/Examples

Moisture Absorber

In the form of sachets & pads

Liquid water can accumulate as a result of temperature fluctuations in high moisture packages, drip of tissue flesh foods and

transpiration of horticultural products

If this water is allowed to build up Growth of bacteria & mold , Fogging of the films

Drip absorbent pad: Consisting of granules of superabsorbent polymer sandwiched between 2 layers of a microporous or

non-woven polymer, which is sealed at the edges

Used in flesh food to absorb water

Desiccant: Hygroscopic substance in a porous pouch or sachet, placed inside a sealed package Extend shelf life of moisture sensitive foods

Oxygen Scavenger

Use powdered iron or ascorbic acid to reduce the oxygen concentration in the headspace

Small packets or sachets containing powdered iron

Bread, caked, cooked rice, biscuits, pizza, pasta, cheese, cured meats and fish, coffee, snack foods, dried foods and beverage

Bottle Closuresincluded in the seal liner to absorb oxygencreating a vacuum headspace

CO2absorbers or

emitters

Sachets that absorb only carbon dioxide

Contains Ca(OH)2in addition to iron powder, so they absorb both oxygen & CO2

Application in roasted or ground coffee

Fresh roasted coffee releases CO2 , unless its removed, It can cause bursting or swelling

Emitters : Ascorbic acid & ferrous carbonate/ sodium bicarbonate that absorbs oxygen, releasesCO2

Avoiding package collapse & development of partial vacuum

Ethylene

Scavengers

Plant hormone produced during ripening + / - effect

-effectincreasing the respiration ratesoftening of fruit tissue & accelerated senescence, degrading chlorophyll and

promoting a number of post harvest diseases

Potassium permanganate, which oxidizes C2H4in a series of reaction which at last results in CO 2& H2O

Palladium Catalyst on activated carbonabsorbs C2H4 and catalytically breaks it down

Activated EarthAdsorb ethylene ; open pores within the plastic which alter the gas exchange properties of the bag

Fruits & Vegetable mainly

Ethanol Emitters

EthanolAntimicrobial agentAntimold Atmosphere

Sachets : Contains ethanol (55%) & water (10%) which are adsorbed onto silicone dioxide powder (35%) and filled into a

paper-EVA copolymer sachets

To mask the alcohol flavor, some may even contain vanilla or other flavors

Absorb moisture from food, release ethanol vapor

Useful for high water activity baked goods

Pizza crust, cakes, breads, biscuits, fish & bakery products

Flavor /Odor

Absorber

Volatile amines usually formed by the breakdown of protein in fish muscle

Can be neutralized by various acidic compounds

Commercial bags, made from film containing ferrous salt & organic acid such as citric or ascorbic acid oxidizes amine and

other odor causing compounds as they absorbed by the polymer

Odor (aldehydes) release due to oxidation of fats & oilsremoved by active packaging

Removal of bitter compounds using a plastic bottle coated internally with cellulose acetate-butyrate to absorb limonin &

immobilization of naringinase in cellulose triacetate film to hydrolyze naringin

Antioxidant

Release

Incorporated in plastic films to stabilize polymerprotect it from oxidative degradation

Past : BHA/BHT in plastic liner of breakfast cereal and snack products

But monomer migrationadverse effect on health

Now: Vitamin E is used as a replacement

Antimicrobial

Release

Prevent growth of MO on food surface

Ensures that only low levels of preservatives come into contact with the food

Incorporated within the film or coated on the surface

Sorbic acid in cheese packaging retards mold growthextends shelf life

Very less commercial application Inhibitory activity is said to be lost when the antimicrobial in combination with polymeric materials results in incompatibilit

or heat lability during extrusion

Eg: Silver ion, organic acids, sulphur dioxides

Microwave

susceptors

Packaging materials that absorb microwave energy and convert it into heatsusceptors

Enhance performance of the package by achieving localized effects such as browning and crisping of food


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Intelligent Packaging

Goals

Improve product quality & product value, for example quality indicators, temperatures and TTIs and gas concentration indicators

Provide more convenience, for example quality, distribution and preparation/cooking methods

Provide protection against theft, counterfeiting & tampering

Intelligent Packaging

System Explanation/Mechanism

Quality Indicators

Indicate if the quality of the product has become unacceptable during storage, transport, retailing and in consumers homes

Undergo color change that remains permanent and is easy to read & interpret by consumers Kimchi Freshness Indicatorcolor indicator developed to monitor the ripeness of commercial kimchi products during

distribution & sales

RipeSenseEnable consumers to choose fruits that best appeals to their taste

It detects aroma compounds given off by the fruit as it ripens, changing the label on the package through a range of color from

red (firm) through orange to yellow (juicy).

Pears was trialed first, as its very hard for consumers to assess the ripeness of pears

Time-

Temperature

Indicators

Device that shows an irreversible change in a physical characteristics (color/shape) in response to temperature history

Small adhesive labels attached onto shipping containers or individual consumer packages

Provide visual indications of temperature history during distribution & storage, which is particularly useful for warning of

temperature abuse in chilled or frozen food products.

Monitors perishable foods such as fish, fruits and vegetables

Gas

ConcentrationIndicators

Indicate the presence or absence of gas

Most common oxygen indicator is pink when the oxygen concentration is < 0.1 %

Turning blue when the oxygen concentration is > 0.5% Such indicators indicates effective absorption of all oxygen and to warn if there is a breakdown in oxygen barrier

Thermochromic

Inks

Temperature sensitive inks

Printed onto labels or containers that are to be heated or cooled prior to consumption to indicate ideal drinking temperature o

the product

Inkschange colorhidden messages such as drink now or too hot become visible

Microbial Growth

Indicators

Rapid microbiological indicators and sensors

Biosensors : Uses biomolecular recognition antigen-antibody, Phage capturespores, bacteria

Highly specific

Others: Respond to amine and sulfide from spoilage

Use colorimetrically signal seafood MO spoilage ( Commercial)

Leakage indicator

Attached to the packaging to ensure the integrity of the package in the distribution chain

Normally used in MAP of meat product

Provide information about the oxygen & carbon dioxide leakage in meat products

Self Heating/Self

Cooling

Uses the reaction of quicklime & a water based solution to create heat

Sake, coffee, tea & ready meals

Self-coolingutilizes endothermic reaction based on dissolution of ammonium nitrate & ammonium chloride in water

Intelligent packaging in short:

Indicator Principle/reagents Give information about Application

Time-temperature

indicator

Mechanical, chemical,

enzymaticStorage conditions

Food stored under

chilled and frozen

conditions

Oxygen indicatorRedox dyes ,pH dyes

enzymes

Storage conditions

package leak

Foods stored in

packages with reduced

oxygen concentration

Indicator of CO2 chemicalStorage conditions

package leak

Foods package in MAP

or CAP

Microbial growth

indicators MO

Freshness indicators

pH dyes,

All dyes reacting with

certain metabolites

Microbial quality of

foods (i.e. spoilage)

Perishable foods such

as meat, fish, poultry.

Pathogen indicators

(int.)

Various chemical and

immunochemical methods

reacting with toxins

Specific pathogenic

bacteria such as

E. coliO157

Perishable foods such

as meat, fish, poultry.


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Modified Atmosphere Packaging

Food packaging technologies that rely on mixtures of the atmospheric gases ; oxygen, carbon dioxide, nitrogen in concentration different that

those in air

Sometime, add: Carbon monoxide, ethanol, sulfur dioxide and argon

Rely on gases that are safe, common, cheap, readily available & usually not considered as chemical additives

Proper marriage of food, gas mixture & package type is crucial

To retard the deterioration processes in foods

Maintain the foods in a fresh state From extended distribution marketing chains

Rigorous temperature control often necessary ; cold chain management

The benefits of MAP technology to the manufacturer, retailer as well as consumer far outweigh the drawbacks. Nevertheless some critical points shoul

considered in this technology. The following l ist some advantages and disadvantages of MAP.

Advantage Disadvantage

Increased shelf-life allowing lesser frequency of loading of retail

display shelves.

Improved presentation of the product

Hygienic stackable pack sealed and free from product drip and odor

Shelf-life can be increase by 50 to 400%.

Reduction in production and storage costs due to better utilization of

space and

equipment

Capital cost of gas packaging machinery

Increased pack volume increases transport costs and retail display

space

Cost of gases and packaging materials

Temperature control is of critical importance and, by itself, has a

greater impact than atmosphere modification for most products

Potential growth of food borne pathogens due to non-maintenance

required storage temperature by retailers and consumers.

Type of gases used in MAP

Gases How does it affect food?

Oxygen

Most degradative reaction in food constituents involves oxygen

Fats & OilsRancidity

Spoilage MORequires O2to growOff odors in the presence of sufficient oxygen & thus food spoilage

Normal respiratory metabolism of fresh fruits & vegetable & normal atmp concentration of O 2senescence & degradation of

produce quality

Implicated with staling of bakery goods & pasta

Oxidation of meat pigments; Red Brown

But in the absence of O2, meat will become purple

Carbon Dioxide Found in atmp at low levels ~0.03%

CO2 Dissolve in waterAntimicrobial effectSuppress the growth of MO

Suppress the respiration of some fresh fruits & vegetablesExtends shelf life

CO2 > 1%, render plant tissue insensitive to the ripening hormone slow down senescence & deterioration

But too muchdamages plant tissue

Largely depends on the tolerance levels of plants, and it varies

Nitrogen

Abundant in air (78%)

Physiologically inert

Used as a filler gas and to exclude some other reactive gases

Carbon Monoxide Colorless, tasteless & bland but very toxic

Concentration as low as 1%, CO will inhibit growth of many bacteria, yeast & mold

Delay oxidative browning in fruits & vegetable when + with low O 2concentration (2-5%)

CO in red meat packagesmaintain their natural appearance throughout shelf life

CO reacts with myoglobincarboxymyoglobin, bright red pigment that masks the natural aging & spoilage of meats

Sulfur Dioxide

Control growth or mold & bacteria on a number of soft fruits, eg Grapes & dried fruits Also in fruit juices, wine, shrimp, pickles and some sausages

SO2+ H2OSulfite compound solutioninhibitory to bacteria in acidic condition

HypersensitivitySulfite allergy

Ethanol

Antifungal activity

Baked goods in Japan to reduce MO spoilage

Enhance freshness of tomatoes

Act as flavor enhancer for other fruits

Argon Noble gas

May have antimicrobial effect


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MAP OF RED MEAT

Deterioration of Fresh Meat Oxidative color deterioration & MO deterioration

Meat pigment: Myoglobin, red color and largely determined by oxidative state

Reduced formDeoxymyoglobinPurple color

Oxygenated MyoglobinBright red colorAssociated with freshness

Atmp O2 slowly converts myoglobin into metmyoglobin Dull brownPoor quality

Contaminated during slaughtering process

Presence of O2 encourages growth of Pseudomonasputrid & malodorous compounds

Vacuum Packaging

Exclusion of atmp O2 prevents :Oxidation og myoglobin to metmyoglobin Suppress the growth of Pseudomonas

Applied to 2-9 kg of primal & subprimal meat cuts for distribution in stores

Beef of normal pH and kept chill T can be stored for 1012 weeks

Lamb : more neutral pH exterior adipose tissue than beef, so 6-8 weeks

Case Ready Meats Packaged at plants and delivered to ready to be placed in the retail case

Combination of MAP: Vacuum packaging , low & high O2 MAP

Poultry, beef, veal, pork, ground meat products

High O2 MAP

40-80% O2Extend color stability

2030% CO2Delay MO spoilage

Presence of O2Rancidity and off odor

So not suitable for prolonged storage of red meats

Low O2 MAP Low O2 + High CO2 : gas flushing of packages

Absence of O2 retard formation of brown metmyoglobin

The CO2 suppresses the growth of spoilage bacteria

CO2 very solublePackage collapse

So need N2 to rescue, in the headspace

Such packages results in shelf life of 3-4 months for lamb & pork

MAP of BAKERY & PASTA PRODUCTS

Subject to moisture loss, oxidative rancidity, MO breakdown due to mainly molds.

MO spoilage

Aw > 0.86 , predominant mold is Penicillum

Aw< 0.86 , predominant mold is Aspergillus (more sensitive to CO2)

Chemical preservatives such as: Calcium & sodium propionate, sorbic acid, potassium sorbate used by the bakery industry

But the trend towards foods free of preservative opens up opportunities for MAP

To prevent deterioration and extend shelf life

Vacuum Packaging : Remove headspace of O2, inhibit oxidative rancidity and growth of aerobic spoilage MO

N2 + CO2 Suppress growth of bacteria and molds due to the presence of CO2

Ethanol emitters

used in JAPAN to extend shelf life of baked goods

Powerful bactericide & effective antifungal agent

Pizza sprayed with 2% ethanolincrease in shelf life by 5 fold

Exclusion of O2 is so crucial, packaging material must provide good barrier to O2.

Rigid trays with nylon/LDPE/ PVC/PVDC lid stock

Laminated films made from Nylon/polyethylene, nylon/PVDC/PE or nylon/EVOH/PE have also been used

50-100% CO2 + 0.5% N2shelf life extension up to several months


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MAP OF FRESH HORTICULTURE PRODUCTS/PRODUCE

Problem

(Summary)

Fresh producesusceptible to diseases because increase in the respiration rate after harvesting

Shelf life at ambient conditions are very limited

Can be extended by retarding physiological , pathological and physical deteriorative processes

Important quality aspect : Freshness

Maintaining freshness during the entire supply chain is a challenge

Respiration

(Detail problem)

Involves oxidation of starch & sugars to simples molecules : CO2 & H2O

H20 remains in the tissue, but CO2 escapes

Rate of respirationgood index for storage lifeHigher the rate, shorter the shelf life or VV

Low T give a slow respiration rateEthylene ( Ripening)

Detail problem)

Fruit & Vegetable expels ethylene

A gas which accelerates ripening process in F&V

Even in small quantities

Climateric / Nonclimacteric

Climatericthose in which ripening associated with a distinct increase in respiration and C2H4 production

Results in color changes, softening, increased tissue permeability and development of aroma

Ethylene liberation & sensitivity of ethylene varies from product to product

Low temlow ethylene liberation

Transpiration

(Detail problem)

Continue to loss water after theyre harvested

Lose their freshness when the water loss is 3-10%

If not retarded, it induces wilting, shrinkage, loss of firmness, crispness and succulence

Respiration generates heat, which is dissipated through direct heat transfer to the environment and evaporation of water

Post-Harvest Decay

(Detail problem)

One MOproliferatesecrete enzymesdeterioration

Fungi : Alternaria, botrytis, Penicilium, Rhizopus

Bacteria : Erwinia & Pseudomonas

DevelopmentFavored by high T & high RHcondensationspore germination

Other preservation

technique

Respiration of F&V can be reduced by low temperature, canning, dehydration, freeze drying, controlled atmosphere, hypoba

and modified atmosphere

MAP in Vegetable Preservation techniqueair surrounding the food in the package is change to another composition

The mixture of gases depends on the type of products, packaging material and storage temperature

Packaging F&V : Lowered level of O2 & Heightened level of CO2

But the suppression of O2 continues until its 2-4%, then fermentative metabolism replaces normal aerobic metabolism & off-

flavors, off-odors and undesirable volatile are produced

More than 10% CO2, the growth of many bacteria & fungi are retarded

GOAL: To create an equilibrium package atmosphere with low O2 and high CO2 to be beneficial to the produce and not injuri

Ehtylene is halved at O2 levels of around 2.5 %

Active & passive method of creating MA conditions

Passive MArelies on the respiration of the produce and the gas permeability properties of the film to achieve desired MA

The produce is put in a bag, if the permeability of the bag is properly matched with the respiration of the produce, the ideal

atmp will evolve inside the sealed bag

Active MA (Common) gas flushing and gas scavenging technology by adding CO2 and N2 or removing O2 during package

The produce is put inside in a bag and the air in the bag is replaced with air that has the proper mixture of O2 & CO2

Time required to increase CO2 & decrease O2 for active MA shorter than passive MA

Examples Storage of grapes in 80% O2 or 40% O2 + 30% CO2 improved berry hardness, springiness, chewiness, flavors over controlled

stored in air

Avacado, showed potential for long term storage ==> up to 9w weeks under MAP in commercial application

Bananareducing O2 (2.5-5%) & increasing CO2 suppressed respiration rate of banana

As a result of MAP Slows down the respiration of the product

Thus increases shelf life, increase freshness

Retards produce ripening by inhibiting both the production & action of ethylene

Factor affectingMAP

Temperature control is important as produce are sensitive to temperatures: Biological reaction rises 2-3 fold for every 10C risT.

Film permeability increases as Temperature increases

Low RH increase transpiration damage & lead to desiccation, increased respiration

High in package humidity condensation on the filmdriven by T

smart, active & intelligent packaging

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