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Biopolymeren & verpakking
Ir. Nanou Peelman
Prof. dr. ir. Peter Ragaert
Universiteit Gent
8 november 2012
Leuven
© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Pack4Food
INDUSTRY
65 members
10 RESEARCH INSTITUTES
Filling systems
Resins
Packagingmaterials
Gasses
Food products
Distribution
Food products-composition
-pH-aw
Filling System-standard
-clean-ultraclean
-Hot fill-Aseptic
-In packaging-MAP
Packaging material-barrier
-active-passive
-closure systems
Shelf-life-chemical-microbiological-physical
Sustainability
© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Activities Pack4Food
Advices Research projects
Training / publications
Networking
© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Activities Pack4Food: topics
CONSUMER
Sustainability
Conscious and demanding
Convenience
Delicioushealthy
BioplasticsRecycling
MAPO2-absorbers
Antimicrobial
systems
Intelligent
packaging
Transparancy
Heat resistanceBarrier
Migration
© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
What are bioplastics?
Bio-PE, Bio-PET,…
PLA, starch,
cellulose,…
PE, PP, PET, PS,…
Ecoflex,…
Biobased
Compostable
Non-Biobased
Non-compostable
• From food sources
– Corn, potatoes, sugar cane
• From side streams / waste
– Starch, PHA, whey
• From algae
Diversification resources
Improved properties• Barrier properties: case
• Thermal properties© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
IWT – Collective Research 095062
• Collective Research (IWT) requested byPack4Food: Application of bioplastics for food packaging– Study of the shelf life of different groups of food,
ranging from short (e.g. fresh tomatoes) to long stable shelf life (e.g. biscuits), packaged in various types of bioplastics packaging.
– Inform about the possibilities of the new generation of bioplastics
– Duration: September 2010 – August 2012© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Overview barrier properties
High barrier materials(< 10 cc/m2.d )
Medium barrier materials(10 cc/m2.d <x> 100 cc/m2.d )
Low barrier materials(> 100 cc/m2.d )
Cellulose/starch MPLA 3-layer PLA-blend coex
Mcellulose/starch Paper/AlOx/PLA Multilayer PLA
Cellophane/M/PLA Cellulose/PLA PHB/Ecoflex
Xylan based coating PLA tray
1. O2 -permeability
© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Overview barrier properties
2. H2O - permeability
High barrier materials(< 10 g/m2.d )
Medium barrier materials(10 g/m2.d <x> 100 g/m2.d )
Low barrier materials(> 100 g/m2.d )
Mcellulose/starch Cellulose/starch 3-layer PLA-blend coex
MPLA Cellulose/PLA Multilayer PLA
Cellophane/M/PLA PHB/Ecoflex
Paper/AlOx/PLA Xylan based coating
PLA tray
© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Overview properties
• PLA tray from IWT Era-SME project 0100405: “Realisation of biopolymer based sustainable products by optimization of design, materials, mould making and processing” (HoGent en TUDelft)
• All tested bioplastics between 2 and 4 stars (Vinçotte)
© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Materials
3-layer PLA-blend coexMPLA
Paper/AlOx/PLA
Mcellulose/starchXylan based coating AXylan based coating B© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Materials
Multilayer PLA Cellulose/Starch
Cellulose/PLA
Cellophane/PLA
PHB/Ecoflex Cellophane/M/PLA© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Work package 1
Conclusion:
Considering the variation in film characteristicsdisplayed in the extended table, it can be statedthat multilayered biobased films have propertieswhich make them applicable for use as apackaging material for various types of foods,ranging from short shelf life products, overmedium shelf life to long shelf life products.© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Extensive storage tests: overviewFood Product Selected Films
Short shelf life
(refrigerated storage)
Tomatoes PLA tray + Multilayer PLA
Rumsteak PLA tray + Natureflex/PLA
Medium shelf life
(refrigerated storage)
Ham sausage
Filet de Sax
Cellulose/starch
Mcellulose/starch
PLA tray + Natureflex/PLA
Ham sausage PLA tray + Paper/AlOx/PLA
French fries
Grated cheese
Cellulose/starch
Mcellulose/starch
Long shelf life
(ambient storage)
Potato flakes Xylan based coating (on paper)
Mcellulose/starch
Rice cakes
Tortillachips
Cellophane/M/PLA
Mcellulose/starch
Cellulose/starch
Biscuits Cellophane/M/PLA
Cellulose
Cellulose/starch (home compostable)*
* New version of other cellulose/starch film (not home compostable)© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Example: Ham sausage
0
0,5
1
1,5
2
0 5 10 15 20 25 30 35 40
% O
2
Day
O2-concentration
Reference Cell/starch Mcell/starch
0,0
0,5
1,0
1,5
2,0
0 5 10 15 20 25 30 35 40%
O2
Day
O2-concentration
Reference PLA/AlOx/paper
“O2-concentration in the different packages remained below the limit, applied by the industrial partners”.
© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Overview
Food product Packaging
Parameter
Physico-chemical Microbial Chemical Organoleptic
O2
-per
mea
bili
ty
CO
2
-per
mea
bili
ty
Co
lor
pH
aw
Tota
l pla
teco
un
t
Lact
icac
id
bac
teri
a
Yeas
tsan
d
mo
uld
s
Per
oxi
de
valu
e
FFA
MD
A
Od
or
Co
lor
Tast
e
TomatoesPLA tray + multilayer PLA without perforations X X - - - - - - - - - X V -
PLA tray + multilayer PLA with perforations V V - - - - - - - - - V V -
Rumpsteak PLA tray + Cellulose/PLA film V V ± V V V V V - - - ± ± V
French friesCellulose/starch V V - V V V V V V V V ± V V
Mcellulose/starch V V - V V V V V V V V ± V V
Ham sausage
Cellulose/starch V V V V V V V V V V V V V V
Mcellulose/starch V V V V V V V V V V V X X X
PLA tray + Cellulose/PLA film V V X V V V V V V V V ± ± ±
PLA tray + Paper/AlOx/PLA film V V X V V V V V V V V ± X V
Filet de saxe
Cellulose/starch V V V V V V V V V V V V V V
Mcellulose/starch V V V V V V V V V V V V V V
PLA tray + Cellulose/PLA film V V V V V V V V V V V V V V
Grated cheeseCellulose/starch V V V V V V V V V V - V V V
Mcellulose/starch V V V V V V V V V V - ± V ±
TortillachipsCellulose/starch - - - V V - - - V V V - - V
Mcellulose/starch - - - V V - - - V V V - - V
V = similar or better than reference ± = worse than reference + acceptableX = worse than reference + unacceptable film = preference over reference (taste panel)© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Extensive storage tests
Conclusion:
The tested bioplastics showed sufficient O2 andCO2 barrier to contain the shelf life of the testedfood products, but the moisture barrier limitedthe shelf life of some food products.
An interaction of the food product with thepackaging material was observed, e.g. color.© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Printability and migration
Conclusion:
• Migration: will probably not be a limitating factor, but more tests have to be performed((M)cellulose starch film → conform legislation)
• Printability: films can be printed, but quality needs to be further investigated© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Casestudies @ companies
• Set up
– Selected films were tested on packaging machines at different companies
• Horizontal + vertical flow pack machines
• MAP packaging or packaging under air
– Sealtemperatures were altered to make a goodsealed package
© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Casestudies @ companies
Conclusion:
The different case studies have led to mixedresults. The tested films ran smoothly over mostpackaging machines (did not break), butoptimization of sealpressure, sealtemperatureand sealtime needs further attention.
© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Overall conclusion project
Bioplastics have potential for packaging applications,including MAP packaging, in the food industry andsome could already be used today. Still, several issueslike moisture barrier, brittleness, sealing properties,price,… make that further adjustments are neededbefore bioplastics can compete with the conventionalplastics.
Remark: moisture barrier bigger challenge than gasbarrier → use of bio-PE and bio-PP in these packages?© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Future project: heat resistance of bioplastics
In the framework of VIS-traject
“Sustainable and functional food packaging” (2011 – 2015)
• Aim: characterize and improve the heat resistance of bioplastics for microwave applications, retort applications, catering applications,…
• ‘Buy’ and ‘Make’-strategy– Inventarisation of existing heat resistant bioplastics materials
And/or
– Improving heat resistance properties by changing compositionof bioplastics materials and by different processing techniques© 2012 – Pack4Food
Biopolymeren en verpakking © 2012 – Nanou Peelman - Peter Ragaert8 november 2012
Acknowledgments
• The Collective Research (IWT) on barrier properties of bioplastics was funded for 80% by IWT
• This project was financially supported by 22 companiesfrom the food and packaging industry who activelyparticipated
• Ghent University– ir. Nanou Peelman
– Prof. Dr. ir. Bruno De Meulenaer
– Prof. Dr. ir. Frank Devlieghere
– Elien Verguldt
• University college Ghent, BVI, Packaging Centre, VKC© 2012 – Pack4Food
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