Active Packaging

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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

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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)



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



Environmental regulations covering reuse, recycling, identification to assist in recycling or the recovery of energy from active packaging materials EU Regulations



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.



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.



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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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.

Documents

Active Packaging