Food Packaging Technology

CURRENT RESEARCH AND ADVANCEMENT IN

PACKAGINGN TECHNOLOGY WITH

SPECIAL APPLICATION TO FOOD

BY

RUSSLY ABDUL RAHMAN

DEPT OF FOOD TECHNOLOGY/DEPT OF PROCESS AND FOOD ENGINEERING

UNIVERSITI PUTRA MALAYSIA

INTERNATIONAL SYMPOSIUM

ON CURRENT ADVANCEMENT AND RESEARCH

IN TEXTILE AND PACKAGING TECHNOLOGY

14th December 2009

Universiti Tun Hussein Onn Malaysia (UTHM)

More Sophisticated Consumers

Increase of Working Woman, Single Parent & Dual Income HouseholdChange in Lifestyle (Health & Weight Conciousness)Aging PopulationKnowledgeable & Educated Citizens (Food Safety, Nutrition, Labelling) Desire of Ethnic Cuisine Among Various Ethnic GroupsDemand for Halal Recognition Among Muslim Community

INTRODUCTION

TRENDS

IN

TECHNOLOGIES

TECHNOLOGIES FOR

BEVERAGE PACKAGING

PET laminated container forming system

Super lightweight forming technology

Sterilized can forming system

Panel forming system

Dual co-extrusion coating system

Aseptic filling system

Induction heating system

Foam printing system

Less environmental impact lacquer and its coating system

Heat-resistant, pressure-resistant and pressure & heat resistant PET bottle

Two-mold blow PET bottle production system

High barrier plastic container production system

Multi-layer co-injection PET bottle production system

Oxygen scavenging plastic container production system

Multi Layer PET Bottles

The multi layer bottles are made from PET /

N-MXD6. A typical bottle will have 5 layers

namely PET / N-MXD6 / PET / N-MXD6 /

PET. It has excellent CO2 and O2 retention

in the bottle as compared to the ordinary

PET bottle. Also the multi layer gives

greater strength and rigidity to the bottle.

TECHNOLOGIES

FOR FOOD PACKAGING

Full aperture easy open end production system

Co-extrusion technology

Easy-open plastic container production system

Eco-friendly bottle cap design

In-cap induction heating seal

Press forming system for ultra thin steel

Large size cup & pouch production system

Eco-friendly lamination

Induction heating system

Multi-layer plastic container production system

Extra-functioned end production system

Microwavable container production system

Oxygen or moisture scavenging technology for plastic containers

Structure of Lid

(1) PET/NY/Al/PP

(2) PET/EVOH/NY/PP （Transparent Type）EVOH ; Ethylene-vinylalcohol Copolymer

Lid

EVOHAdhesive

PP

Structure of Oxygen Barrier Cup

(Lamicon Cup)

Cup with Iron foil for retort

Characteristics(1) Food storage ability at the same level as a metal can

(2) Superior heat resistance

(3) Use for Retort sterilization

Oxygen barrier type lid

Iron foil

White PP

Paper Container (Renjicco)

This is a versatile paper based plastic

laminated normally of PET. It can withstand

freezing temperature on one hand and oven

temperature on the other hand. Being

microwavable and ovenable, it provides

convenience and can be used as a serving

container as well. The container is also

environmental friendly.

TECHNOLOGIES FOR

TOILETRIES & COSMETICS PACKAGING

Double structure aerosol can

Glossy bottle production system

Frosted bottle production system

In-mold labeling (IML) system

Partly injected extrusion molding system

Pump dispenser production system

Extra-functioned cap production system

Easy-to-refill plastic containers

Collapsible plastic containers

Oxygen scavenging plastic containers

Various decoration technologies:

Mat printing, metallic printing, pearl-tone printing,

hot stamping, silk screen printing, frosting

High corrosion-resistant internal coating system for can

Fe

Fe2O3

Fe

O2

PP

Oxygen

Barrier

Oxygen

Absorption

PP

O2

Outside ; PP/Oxygen barrier/Oxygen Absorption/PP ; Inside

Outside Inside

Oxygen Absorption Cup

(Oxyguard Cup)

TECHNOLOGIES FOR

HOUSEHOLD & INDUSTRIAL CHEMICALS PACKAGING

Solvent-resistant technology

Powder lacquer and its coating system

Co-extrusion (window stripe) system

In-mold labeling (IML) system

Measuring dispensing closure

Trigger dispenser production

Collapsible plastic container

Easy-to-refill plastic container

Easy open plastic container

Various decoration technologies

Spouted Pouch

There is an increasing trend in the use of

pouch with spout. Compared with plastic

bottles, the amount of plastics in pouch is

much lower and therefore more

environmental friendly. With the spout in

place, it is reclosable as in plastic bottle.

However, it has disadvantages such as

slower filling speed and difficult to display

on shelves.

TECHNOLOGIES FOR

HEALTHCARE PACKAGING

Biaxially oriented blow molding system (BOB)

2-port blown bag production system

Production system for stopper with rubber disc

Total engineering for fill/seal/autoclave

Aseptic filling system

Oxygen or moisture scavenging plastic container

production system

Improper use prevention system for IV bag

Trends in

Functional Packaging Materials

• Light Barrier Film (U-SAVE)

• Non-heating Packaging Materials for

Microwave Oven

• Moisture Absorbing Material

• Self Heating / Cooling Containers

• Biodegradable Plastics (Bionolle)

TRENDS IN FUNCTIONAL PACKAGING MATERIALS

Light Barrier Film (U-SAVE)

U-SAVE is a plastic sheet composed of

several plastic films laminated by special

adhesive which can shade more than 95% of

ultraviolet rays while it transmits more than

80% of visible light. It has been developed as

an ideal packaging material which meets the

requirement to show the contents while

shading ultraviolet rays.


Non-heating Packaging Materials for

Microwave Oven

The non-heating Packaging Materials for

Microwave Oven is a new package for

microwave oven that prevents heating

using aluminium foil and thus able to

prevent spark from occurring. This can be

achieved by special design in such a way

that no aluminium foil exists at edges.


Moisture Absorbing Material

The material consists of highly water absorbentresins sandwiched between plastic film and paper. Itis capable of absorbing and retaining moistureseveral hundred times its own weight. It serves aspowerful absorber and water retainer, while allowingthe retained moisture to disperse as water vapour.One such example is the ‘Total-Dry’ which is abarrier packaging material which has moistureabsorbing function by having drying agent to theinternal layers of laminated films. It preventsdeterioration of moisture and maintains stable long-term quality contents.


Self Heating / Cooling Containers

With consumers preference to have their drinkseither warm or cold, the self heating or coolingcontainers were developed. Essentially suchcontainer will have a separate compartment in thecontainer consisting of two chemicals separatedfrom each other which upon mixing will giveeither exothermic or endothermic reactions. Thereaction can be activated by having a simplemechanism such as a plastic needle to piercethrough a layer separating the chemicals. Atypical example is having CaO to react with waterwhich gives out heat in the reaction.


Biodegradable Plastics (Bionolle)

More and more biodegradable plastics are being

researched and developed. One such example is

Bionolle which is a biodegradable aliphatic

polyester. Like wood and paper, Bionolle is stable in

the atmosphere but biodegrades in compost, moist

soil, water with activated sludge and in sea where a

large number of microorganisms is present. It can be

incinerated with less problem to the furnace as its

combustion heat is relatively low and does not

generate toxic or acid gases.

TRENDS IN

RESEARCH ACTIVITIES

•Oxygen Scavenging

•Ethylene Scavenging

•Antimicrobial Films

•Sulphur Dioxide Emitting Films

•Freshness Indicators

•Improving Food by Food-Film Interaction

Use of oxygen-scavenging technology can

lower oxygen levels further, or can be

used to permit the use of a cheaper

packaging film. Oxygen-scavenging

chemistry can be incorporated into films,

adhesives, printing inks or lid seals, and

so can be adapted to almost any type of

package.

TRENDS IN RESEARCH ACTIVITIES

Oxygen Scavenging

The ripening and ageing processes of

many fruits and vegetables are stimulated

by ethylene. Removal of ethylene is an

attractive way of extending the storage

life. By incorporating the ethylene

scavenging system into the packaging

film (rather than adding a sachet to the

package) the removal of ethylene is

enhanced by the large surface area of the

film.


Ethylene Scavenging

Antimicrobial agents can be incorporated

into a packaging film rather than in the food

itself. The film can be configured to allow

controlled release thereby extending shelf

life. Films, both edible and inedible, based

on biopolymers are being investigated.


Antimicrobial Films


Freshness Indicators

Since many foods lose their

`freshness’ by oxidative reactions,

films that change colour in

response to the level of oxygen

within a package can be used to

indicate freshness.

Some Examples

of

Current Researches

AN ACTIVE-SMART PLASTIC FILMS

FOR APPLICATIONS IN PACKAGING

USING A SMART BIO-SWITCH

CONCEPT

DR. IDA IDAYU MUHAMAD

DEPARTMENT OF BIOPROCESS ENGINEERING

FKKKSA, UTM SKUDAI

AMI+™

THE IDEA

The term ‘active packaging’ preserves the condition of the packed

food to extend shelf life, to improve safety or sensory properties.

Whilst a ‘smart packaging’ system monitors the condition of packed

foods to give information about the quality of the packed food during

transport and storage.

An active-smart packaging using a bio-switch concept is a combination

technology of biodegradable polymer, antimicrobial control releaser and

pH-colour indicator from Anthocyanidin extracts.

It is developed to detect (I) the degree of continuous natural

fermentation in food products or (2) the spoilage of non-fermented food

by microorganisms/chemical reaction by pH changes.

THE PRODUCT

i.The Plastic Film – biodegradable from starch based formulation

ii.Encapsulated colourant – natural, from plant extract

iii.Antimicrobial Substances – varies e.g. essential oils, lysozyme, nisin

and lauric acid

Inhibition of E. coli by the antimicrobial film in liquid culture medium at 37oC

THE PRODUCT

iii. Anthocyanidin Group

controls the colour of the pigment

one of the things that change the color is the level of acid or alkali

the molecules are affected by the pH of the environment

antioxidant component neutralizes free radicals

THE PRODUCT

Antimicrobial effects

of film

In blow molded plastic sheets In thermoformed plastic

As container layerOn-cap label film Use for dipping or coating

With AMI+®

THE MECHANISM

This system consists of two main mechanisms:

i. The first mechanism is the bioactive substances (antimicrobial)

protect the food from external microbial contamination.

ii. The second mechanism is the colour changes of the developed

indicator represented properly the quality of the internal packed

food and sustainability of the bioactive substances.

Project TitleSusceptor Packaging Material for Differential

Heating In Microwave with Special Application for

Microwave Reheating Of Frozen Foods

Project Leader

Russly bin Abd Rahman

Project Team Members

- Nor Mazlana Main

- Yus Aniza Yusof

- Nor Amaiza Mohd Amin

- Chin Nyuk Ling

- Coskan Ilicali

Preparation of susceptor packaging

***put a pair of

susceptor board

at the top and

bottom surfaces

in rigid box

Susceptor board

Rigid box

MATERIALS & METHODS

Preparation of puffs

Conventional baking

Microwave

baking

Microwave oven (EM-

B756A, SANYO

Electric Co, Ltd., UK)

Conventional Oven

(UM 200-800,

MEMMERT

GmbH+Co.KG,

Germany)

Puffs for

testing

Quality testing

Sensory evaluation-30 untrained panelist

Colour changes at the top &

bottom surfaces

Minoltra Colour

Reader (CR-10,

Japan)

using

Figure 1: Puffs baked in (a) conventional oven,(b) susceptor packaging in microwave oven and

(c)microwave oven

(b) (c)(a)

RESEARCH CONCLUSIONS

**Microwave baking without packaging application had some quality

defects such as lack of desirable, colour, become soggy, shrinked and

brittle when cold.

**When susceptor was used, ΔE values increased, showing that the

colour of puffs were getting brown and darker, more than the control

colour. Besides, it formed a texture similar to the conventionally baked

ones at three level of power used.

**In this study, the best conditions for baking puffs in microwave oven

using susceptor packaging were 270s, 285s and 300s at 340W; 165s and

180s at 500W; and 105s and 120s at 790W. When susceptor packaging

was applied for this condition, it reduced conventional baking time to

about 75%-91%.

Production of Colloidal Silver Nanoparticles by

Chemical Reduction Using Polyethylene Glycol (PEG)

and Antimicrobial Effect on E.coli O157:H7

Russly Abd. Rahman*, Maryam Joukar*, Nor Azowa Bt Ibrahim ,

Luqman Chuah Abdullah , Tan Chin Ping

Faculty of Food Science and Technology

University of Putra Malaysia (UPM), Serdang, Selangor Malaysia

Introduction

Silver containing composites have been extensively studied

because of their strong , stable and wide spectrum

antibacterial activity. Silver ions can react with cell

membrane proteins by combining the thiol(-SH) groups ,

change the membrane permeability, generate free radicals

and subsequent free radical-induced membrane damage.

Silver nanoparticles (Ag-NPs) are of interests due to their

unique physicochemical and antibacterial characteristics

and become one of the most quickly developing area in

current research .

Materials and Methods

AgNo3 + PEG

(solvent , Reducing Agent and stabilizer )

Reduction of Ion (Ag+)

to nanoparticle (Agº)

Characterization

TEM , UV-vis Spectroscopy , XRD , FTIR

Antimicrobial Efficiency

Escherichia coli 0157:H7

Results

Peaks confirmed to metallic silver references

0

10

20

30

40

50

60

70

80

90

100

Cum

ula

tive d

istr

ibution Q

3 / %

0

1

2

3

4

5

6

7

sta

ndard

devia

tion / %

0.5 1 5 10 50 100 500 1000 5000 10000

particle size / nm

Particle size : 3.27±0.36 nm

Treatment

Counts of colonies

(*107)

Inhibitory reduction

(percentage%)

Control 257.5 ± 159a -

10 ppm (µg/ml) of AgNPs 106.3 ± 27b 58.75%



Colloidal solution 18.5 ± 8c 92.99%

PEG 58.3 ± 16c 77.43%

MICROBIAL INHIBITION

This study presented a simple and inexpensive

method for preparation of silver nanoparticles,

well defined in size and nano-responding

properties and have excellent antibacterial activity

against Escherichia coli. It has high potential for

application in food packaging polymers currently

under research.

Research Conclusion

Reinforced Biocomposite using Kenaf Fiber:

A Study on Its Mechanical Properties

Russly Abdul Rahman, Behjat Tajeddin,

Luqman Chuah Abdulah, Nor Azowa Ibrahim and Yus Aniza Yusof

Universiti Putra Malaysia

METHODS

The cellulose processing was carried out according to

Standard Test Method, ASTM No.D1103-60. Biocomposite

formulation was processed for HDPE with 0, 30, 40 and 50% of

cellulose and 0, 5 and 7% of PEG as plasticizer. In order to

make each HDPE/Cellulose/PEG sample sheet, predetermined

amount of materials were mixed using Thermo Haake

PolyDrive R600/610 blending machine. Blending was carried

out at 145 oC with rotor speed 30 rpm in 12 minutes. Then,

composites obtained from melt blending were compressed

using the Hot Press Machine for preparation of composite

sheets with thickness of 1 and 3 mm.

Impact Strength of cellulose & PEG content in HDPE matrix

SOUS VIDE PROCESSING

Sous vide is an interrupted catering system in which raw or par-cooked food is sealed into a vacuumized laminated plastic pouch or container, heat treated by controlled cooking, rapidly cooled and then reheated for service after a period of chilled storage

Sous vide Advisory Committee, U.K.

SOUS VIDE (FRENCH) MEANS “UNDER EMPTY”“UNDER VACUUM” “WITHOUT AIR”

Sous vide or vacuum cooking technology is an emerging processing technology in Asia and an established one in Europe since the 1980s due to its high nutritional and flavor retention

SOUS VIDE RESEARCHES IN UPM

• Storage Stability of Sous Vide Beef Satey• Effects of Sous Vide Processing on Chicken Tom Yam• Storage of Vacuum Packed Cook-chilled Ginger Chicken

Soup• Storage of Vacuum Pack Cook-chilled Fried Kai Lan• Storage of Vacuum Packed Cook-chilled Maggie Goreng• Effects of Sous Vide Processing on Nasi Goreng• Storage of Vacuum Packed Cooked-Chilled Spaghetti and

Bolognaise Meat Sauce• Storage of Vacuum Packed Cook Chilled Wantan Mee• Sous Vide Processing of Rendang• Preparation of Sous Vide Chicken Rice and Chicken Keel

STEPS IN SOUS VIDE PROCESSING

INITIAL PREPARATION

(mixing, cooking, blanching, etc.)

PACKAGING(weigh, assemble, place in package)

AIR EXTRACTION &

HERMETIC SEALING

COOKING & PASTEURIZATION

RAPID CHILLING

REFRIGERATION

Preparation of Sous Vide Chicken Rice & Chicken Keel

• Time-temperature profiles and process time for sous vide chicken rice and chicken keels were obtained through heat penetration test for 5D and 13D processes using the General Method. In slow heating (75°C) of chicken keel, the process time for 5 D and 13 D processes were 26.7 and 38.3 min whereas for the fast heating (90°C), were 16.5 and 19.2 min, respectively

• Sous vide products showed their benefits as better retention. in aroma and flavour, lower cook loss, juicier and more tender compared to the traditionally cooked products

• Better aroma and flavour retention were obtained in the sous vide products compared to the traditional cooked products over 4 weeks storage

Research on standards

Department of Standards M’sia (DSM)

SIRIM

- Technical Committees

- Working Group

Example of Standards being Developed;

• Transport packaging for dangerous goods

• Packaging and storage of pesticides

• Sacks made from thermoplastic flexible film

•Linear bar code for product packaging

• Child resistant packaging

• Steel drums

STANDARDS ON

PACKAGING OF WET CARGO

STANDARDS ON

PACKAGING OF CUT FLOWERS

The modern consumers are changing

continuously. Fresh opportunities are evolving

all the time. Technological advances in science

and technology coupled with good packaging

technologies will shape the future and continue

to meet the needs of the consumers.

CONCLUSION

For a dual income family, after a hard day’s work at the office, who will go to the kitchen to prepare dinner?

Question

Answer

A. Husband B. Wife

Traditionally ……. this is what happens

THANKYOUAcknowledgement:

Jamilah Bakar

Ida Idayu

Mazlana Main

Stella Johan

Maryam Jokar

Behjat Tajeddin

Toyo Seikan