WELCOME

Topic- Packaging materials and systems for liquid, concentrated, dried, frozen and fat-rich dairy products.

Course Code: AHD - 411

Guided by-Dr. Anuj Gautam

Presented by:Shreya Rai

R-13042

Packaging MaterialsPaperboardPaperboard is the main material in our cartons. It provides stability, strength and smoothness to the printing surface.

PolyethylenePolyethylene protects against outside moisture and enables the paperboard to stick to the aluminium foil.

Aluminium foilAluminium foil protects against oxygen and light to maintain the nutritional value and flavours of the food in the package in ambient temperatures.

PACKAGING MATERIAL

RETORT PACKAGINGA retort pouch is a flexible package in which prepared food is hermetically sealed for long term unrefrigerated storage. Retort is a process that uses heat and pressure to cook food in sealed packages.It is the most acceptable form of food preservation in rigid, semi rigid and flexible packaging system.

AIMS OF RETORT PACKAGING:

•To destroy microorganisms by heating.•Thermal processing of food with package itself.•To protect the food from chemical enzymes.•To make commercially sterile food.

Benefits:• Offer greater shelf appeal as there’s a larger area for graphics and text.• Can be manufactured in numerous sizes and shapes

• Selection of the correct packaging material provides superb product protection, optimal chemical resistance and an oxygen barrier

• Offer high temperature resistance, toughness and printability • Products have a longer shelf-life

• Easier to distribute and therefore have lower transportation costs

• Heat sealable and sterilisable

• Easy opening and reclose

• Easy storage

• Larger surface area for marketing information

• No refrigeration required

• Microwavable

RETORT PACKAGING

PACKAGING OF FAT- RICHDAIRY PRODUCTS

TYPES 1.Cream Cream is a yellowish component of milk, rich in fat globules, that rises to the surface naturally if milk is allowed to stand. a. Low fat cream containing milk fat not less than 25% by weight.b. Medium fat cream containing milk fat not less than 40% by weight.c. High fat cream containing milk fat not less than 60% by weight.

2. ButterButter may be defined as fat concentrate, which is obtained by churning cream, gathering the fat into a compact mass and then working it. Butter consists of 80-90% fat with maximum of 16% water.

3. Fat SpreadsFat spreads are solid plasticized foods of water in fat type of emulsion which by principle contain an aqueous phase as well as fats and oils.

4. GheeGhee means the pure heat clarified fat derived solely from milk or curd or from desi (cooking) butter or from cream to which no colouring matter or preservative has been added. It contains 99-99.5% fat.

5. Butter oilButter oil and Anhydrous Milk fat / Anhydrous Butter oil means the fatty products derived exclusively from milk and/ or products obtained from milk by means of process which result in almost total removal of water and milk solids not fat.

Packaging of CreamThe exclusion of light is important as light can initiate auto oxidation of milk fat resulting in the production of rancid flavors.

Cream may be tainted by the absorption of odors from various sources and packaging material must, therefore, be impermeable to gases.The absorption of moisture can cause the quality of cream to deteriorate and packaging must, therefore, be impermeable to both.

The design of the container can also influence product quality. With some creams serum separation may occur during storage and the ability to shake the contents to ensure mixing can be important to consumer acceptability.

Table cream: Table cream is packaged for retail sale in units similar to those for milk such as glass bottle, paper carton, low density polyethylene sachet, plastic bottles etc. When table cream is produced for the purpose of coffee whitening, UHT processing is combined with aseptic packaging.

PACKAGING FOR PASTEURIZED CREAM Retail packaging:Pasteurized cream is packaged in cartons and bottles for retail sale with package size usually being in the range of approximately 100-1000 ml.

The most common form of packaging used is the injection moulded polystyrene pot, or flat topped round container.

To improve the barrier properties of plastics packaging for fresh cream, multilayer materials may incorporate an ethylene vinyl alcohol (EVOH) layer. Once filled, the containers are closed with a heat sealed polyethylene/ aluminum foil laminate.

Bulk packaging:It may be used for catering or institutional use. Normally plastic (e.g. polythene) bags contained in plastic crates or cardboard cartons are used for bulk packaging. In this case package size ranges from 5 to 25 liters.

Packaging of Sterilized Cream In case of retort sterilized cream, tin cans and glass bottles are used for packaging.

Sterilization takes place in a retort or hydrostatic sterilizer using temperature time regimes of 110-120°C for 10-20 min.

A calcium sequestering agent, such as sodium citrate or a sodium phosphate, may be added to make more casein available for stabilizing the emulsion.

The unit packaging volumes have to be relatively small (400 ml) because of the restriction on heat transfer with larger volumes

Packaging of UHT CREAM•Aseptic canning

•Plastic (polythene), paper and foil laminate cartons and Plastic (polystyrene or polypropylene).

•Lacquered aluminum or tin plate cans are used for Aerosol cream.

•Preformed pots or with laminates.

•Plastic ( polythene) bag contained within a cardboard carton is used for bulk packaging of UHT cream with unit volumes are in the range 5-1000L.

Packaging of ButterPackaging material for butter should have excellent barrier properties such as: · It should be moisture proof· It should be grease proof· It should be impervious to light· It should have good strength

Some of the packaging materials used for butter packaging are:i) Parchment paper – also known as butter paper.ii) wax coated paperiii) cellophaneiv) cardboard boxes and teak wood drums lined with food grade plasticv) Aluminium foil laminatesvi) Lacquered tin cans

Techniques of packaging1.Manual moulding and wrapping

2. Mechanical moulding and hand wrapping

Packaging of Ghee Requirements for packaging material:1 .Good fat resistance 2. Barrier properties against oxygen and moisture. 3. It shall be temper proof.

A major portion of ghee is packed in lacquered tinplate containers of capacities ranging from 250 litres to 15 litres / kilograms. Since the product is very sensitive to oxygen, the tinplate containers are filled to the brim without any air gap.

For shorter shelf-life, 200 ml, 500 ml and 1 litre capacity pouches made of polyethylene film, multi – layer co-extruded films of LDPE/HDPE are used.For long – term storage, stainless steel containers or tinplate cans are desirable.

Ghee is also marketed in lined cartons with flexible laminated plastics as inner liner materials, laminates and Bag - in - Box containers. The bag is vacuum filled and inserted manually into the box. Seven layer Nylon containing self standing pouch with closure is also used.

Another form is consisting of a multi-ply collapsible bag with a tap which can be housed in a rigid outer container. The container can be a box, a crate or a drum whose capacity varies between 3 and 200 liters.

LIQUID DAIRY PRODUCTS

Includes milk products like Butter milk, Whey, Lassi, and different types of milk like, Recombined milk, Toned milk, Vitaminised milk etc.PackagingPaper Based - Paper-based packaging is lightweight and low cost, but it’s susceptible to moisture and tearing.

Plastic - Plastic is used to hold fresh and pasteurized milk. Some of the drawbacks of plastic containers include becoming fragile at low temperatures and melting at high temperatures.

Glass - Glass bottles are still used today by some dairy manufacturers, not as widely used as plastic or paper-based packaging. While glass is heat resistant, it is also heavy and fragile.

Metal - Both aluminum and tin are used to make cans for milk products, such as evaporated milk and sweetened condensed milk. Advantages are the strength of the material, grease-proof qualities, and the barrier properties. One drawback to aluminum is its vulnerability to acids. Tin tends to be heavy and expensive.

Wood - Barrels made from wood are used for bulk packaging of such milk products as sweetened condensed milk and buttermilk. It avoids tainting the milk.

Different types of packaging of Liquid Dairy products

PACKAGING OF CONCENTRATEDDAIRY PRODUCTS

Evaporated milkEvaporated milk is a concentrated milk product with a dry matter content of at least 25%.

Heat desiccated milk products include-

•Khoa- It is a partially dehydrated whole milk product prepared by the continuous heating of milk in a karahi over a direct fire while also constantly stirring cum scraping by using a khunti till it reaches its semi solid consistency(Pat). Types of Khoa- Pindi: Moisture- 31-33% Dhap: Moisture- 37-44% Danedar: Moisture- 35-40% •Rabri- It is a concentrated and sweetened whole milk product containing several layers of clotted cream. It contains 30% moisture.

Condensed milkCondensed milk is a concentrated milk product with sugar. The product usually contains not more than 27% of water , 43–46% of sugar and at least 28% of dry matter of milk. Condensed milk has a pale yellow colour, smooth consistency and high viscosity and is a sweet milk product.

Packaging of Concentrated milk productsDoy-pack packaging- The Integrated Plant offers the largest choice of condensed milk in Doy-Pack pack among Ukrainian manufacturers. The barrier properties of the pack are the same as those of the tin can and by convenience of opening exceed it – each pack is provided with threaded cover.

DOY PACK PACKAGING

Polyamide hose- It is the ideal solution for confectionary enterprises and shop. The advantage of this pack is convenience in removal of product, no bulky reusable containers, inexpensive packing, convenience of disposal.

Industrial containers- Condensed milk in industrial containers is the optimum solution for large confectionaries. Various industrial containers, both by weight and shape, make it possible to choose the alternative suitable for the production. Condensed milk is also delivered in tank trucks with capacity of 4 to 30 t.Depending on kind of condensed milk and packaging, this product can be stored for 5 to 12 months.

PACKAGING OF DRIEDMILK PRODUCTS

It is a manufactured dairy product made by evaporating milk to dryness. The purpose of drying milk is to preserve it; milk powder has a far longer shelf life than liquid milk and does not need to be refrigerated, due to its low moisture content. Another purpose is to reduce its bulk for economy of transportation.

Powdered milk and dairy products include such items as:•Dry whole milk•Nonfat (skimmed) dry milk•Dry buttermilk•Dry whey products •Dry dairy blends.

PACKAGING Milk powders readily take up moisture from the air, leading to a rapid loss of quality and caking or lumping. Packaging is chosen to provide a barrier to moisture, oxygen and lightMilk powder is packed into either plastic-lined multi-wall bags (25 kg) or bulk bins(600 kg).They are often packed under nitrogen gas to protect the product from oxidation and to maintain their flavour and extend their keeping quality. Packaging is chosen to provide a barrier to moisture, oxygen and light. Bags generally consist of several layers to provide strength and the necessary barrier properties.

PACKAGING OF FROZENDAIRY PRODUCTS

Ice cream is a frozen dairy product made by suitable blending and processing of cream and other products, together with sugar, flavor with or without stabilizer, colour with incorporation of air during the freezing process.Types of Icecreams- Plain- Colour and flavouring ingredients amount less than 5%.

Chocolate- Flavoured with cocoa or chocolate

Fruit- Containing fruits like strawberry, pineapple. etc.

Nut- Containing nuts like almond, walnut, cashewnut etc.

Milk ices or Milk lollies- Contains milk fat not more than 2%, protein not less than 3.5%, T.S. not less than 20%.

Ices- Made from fruit juice, sugar, stabilizer etc. No any dairy product.

Sherbet- Similar to ices but used dairy product, instead of water.

Novelties- It is the ice cream having specially shape, size and colour.Soft icecream- Sold as drawn from the freezer without hardening.

Packaging Of Ice creamsIce-cream sticks and ice-cream cones are the most common types.

Ice-cream sticks come individually in flowpack bags. The ice-cream sticks in flowpack bags are packaged into cartons which are then case-packed for distribution.

In the case of ice-cream cones, subsequent to the freezing process, these are presented on trays with various units which are later packed into cartons Once the trays have been completed they are wrapped using flowpack machinery where an inert gas may be injected to preserve the product before they are boxed.

There are 2 types of Packaging-

•Multiservice (Tinned/ Steel can)•Single service (Carton)

NOVELTY CARTON ICE CREAM RETAIL CUPS

PLASTIC FLUTED ICE CREAM CUPS

SINGLE SERVE ICE CREAM CUPS

Impacts of Packaging materialsThe principal roles of food packaging are to protect food products from outside influences and distribution damage, to contain the food, and to provide consumers with ingredient and nutrition information. Package design and construction play significant roles in determining the shelf life of a food product. The right selection of packaging materials and technologies maintains product quality and freshness during distribution and storage.

Negative health effects

PVC (polyvinyl chloride) The World Health Organization's International Agency for Research on Cancer (IARC) has recognized the chemical used to make PVC, adipates and pthalates as a known human carcinogen.

Vinyl chloride monomer a known human carcinogen that causes a rare cancer of the liver.

Dioxins are a global health threat because they persist in the environment and can travel long distances. At very low levels, dioxins have been linked to immune system suppression, reproductive disorders, a variety of cancers, and endometriosis

Polycarbonates, whose primary building block is bisphenol A (BPA), a hormone disrupter that releases into food and liquid and acts like estrogen. A more recent animal study suggests that even low-level exposure to BPA results in insulin resistance, which can lead to inflammation and heart disease.

Negative effects on environmentPlastics are durable and degrade very slowly.

In some cases, burning plastic can release toxic fumes.

The manufacturing of plastics often creates large quantities of chemical pollutants.

Unfortunately, recycling plastics has proven difficult. The biggest problem with plastic recycling is that it is difficult to automate the sorting of plastic waste, and so it is labor intensive.

Residual toxic compounds likely to be transferred to food through plastics

Monomers and oligomers: Polymers have very high molecular weight and hence not assimilated by the body. Monomers being small may be assimilated by the body and therefore may pose health problems.

Polymerization residues: There may be presence of catalysts, solvents, emulsifiers and wetting agents having low molecular weight

During film container manufacturing a variety of processing aids are added which are: a. Antioxidantsb. Antiblock agentsc. Antistatic agents Absence of antistatic agents may lead to: 1. Fire/spark hazard 2. Dust attraction and 3. Difficulty in Derolling

d. Plasticizerse. Lubricantsf. Slip agents

FUTURE GOALS IN MAKING PACKAGING MATERIALS

1. Use of new migration resistant plasticizers.

2. Improvement in formulation to reduce greatly their use.

3. Surface treatment of finished plastic products to reduce plasticizer migration (U.V. light, laser radiation treatments given).

4. Plasticizers related to cancer by International Agency for Research on Cancer are:DEHA- BIS-2-Ethyl Hexyl Adipate BBP: Butyl Phenyl Methyl or Butyl Benzyl PhthalateDEHP- Bis-2- Ethyl Myxyl or Di-Ethyl Hexyl Phthalate.

5. To use biodegradable plastics as far as possible.

Thank You