FDE 418 Food Packaging: Intelligent Packaging PDF

FDE 418 Food Packaging : Intelligent Packaging Definition of Intelligent Packaging Packaging systems that monitor the conditions packaged food during its life cycle to communicate (i.e. indicate) the quality of the packaged product.  Intelligent Packaging Monitor product quality factors...

FDE 418 Food Packaging : Intelligent Packaging Definition of Intelligent Packaging Packaging systems that monitor the conditions packaged food during its life cycle to communicate (i.e. indicate) the quality of the packaged product.  Intelligent Packaging Monitor product quality factors or environmental conditions by sensors or indicators. Expensive, highly perishable foods Limited shelf life Devaluation caused by quality deterioration High wastage  Intelligent Packaging RFID, or Radio Frequency Identification, is a technology that uses small electronic tags attached to products or packaging to transmit information via radio waves. This information can be read by an RFID reader and used for various purposes, including product identification and tracking. RFID technology is useful to prevent fraud, improve economic losses, and optimize transportation, handling, and storage conditions but is not considered as IP itself since they are not responsive to and informative about the kinetic changes related to the quality of food products. RFID can further enhance the performance of IP when used alongside a sensor by providing location-specific information and only the regarded as IP. Conventional use of RFID in food industry Supply Chain Management ❖ Throughout the supply chain, real-time tracking of things using RFID tags makes sure they are always handled and kept correctly. Inventory Management ❖RFID tags allow automated inventory management, eliminating the need for manual counting and record-keeping. Intelligent Packaging IP is generally classified based on the type of sensor used as TTIs, gas sensors, and biosensors. TTI is the earliest and the most commercialized form of IP technology. Conventionally, the shelf life of food products or their freshness is determined based on selected marker substances, such as vitamins, color or flavor change, enzyme activity, etc., through predictive models based on accelerated shelf-life tests. However, in reality, thermal fluctuations and unpredicted events do not often obey the predictions, which may significantly alter the quality of the food product. TTI are often used as stickers on packages, in which a thermo-sensitive material mimics the rate of loss of a quality factor to produce a color or color contrast to a reference scale to indicate the level of freshness or the ‘actual’ shelf life of the product. Intelligent Packaging Two types of TTI are available in the market. Full-history TTIs store the information of cumulative time–temperature history of the package. In this case, the response rate of the indicator (e.g., color change) as a function of temperature needs to match that of the selected quality marker (i.e., rate constant and activation energy of the famous Arrhenius equation). Frozen foods, fish, and meat products require cold-distribution chains to ensure microbial stability and expected quality. Partial-history TTIs, in which the colorogenic reaction occurs above a determined threshold temperature, indicate only if the product is exposed to abusive temperatures. More sophisticated systems can also be developed by designing an array of partial-history TTI systems with varying threshold temperatures to provide information about at what temperature and how long the product stayed. Intelligent Packaging The major types of commercialized TTI systems can be classified as Diffusion-based TTIs (i.e., diffusion of colored esters forms color contrast alongside a reference scale), Enzymatic TTIs (i.e., certain enzymatic reaction changes the environmental conditions, such as pH, which then causes color change), Polymer-based TTIs (i.e., polymerization reaction forms a color contrast with a reference scale). All TTIs commonly require an activation step to start the sensing process at the same time when the product enters the package. Diffusion based TTI Time-temperature-indicator, or integrator (TTI), can be used for the visual display of food product safety information for consumers. A prototype isopropyl palmitate (IPP) diffusion-based TTI system was characterized and evaluated for monitoring the microbial quality of non- pasteurized angelica (NPA) juice based on temperature abuse. Intelligent Packaging: Diffusion δϕ J = −D δx E − a D = D0 exp RT Enzyme based TTI Enzymatic TTIs, an adhesive label contains two different film pouches that are separated by a thin and breakable mechanical seal barrier. One pouch contains the solution of lipolytic enzyme or lipase. The other one is filled with the aqueous solution of a lipid substrate (for example, tricaproin) and pH indicator. Once the barrier seal is broken by pressing, the substrate encounters the enzyme, and the TTI device is activated. The controlled and irreversible enzymatic hydrolysis leads to the generation of fatty acids (like caproic acid), thus reducing the pH and inducing color change more intensely as the enzymatic reaction proceeds over time. Enzyme based TTI In the TTI, a suitable pH-sensitive dye changes the color of the label from orange to yellow to pink. The yellow color is printed on the tag as the reference color, indicating the shelf-life. The orange color on the label signifies the activation of TTI; yellow represents that the product is near its expiry. The pink color indicates that the food has already expired. These reactions are very sensitive to temperature, and the thermal sensitivity of the reaction is characterized by the activation energy (EA, kJ mol−1). Intelligent Packaging: −Ea Polymerization k d = k0 exp( ) RT Intelligent Packaging: TTI Mechanisms Polymerization Diffusion-based Enzymatic reaction based  Intelligent Packaging Gas sensors, which are sensitive to changes in gas levels selected as a quality marker inside the package, are the other commercially available IP systems. They can be used to detect gas formation (e.g., carbon dioxide, secondary metabolites, etc.) due to microbial contamination, or fruit ripening by the formation of aromatic volatiles and extent of fermentation (e.g., in kimchi) by the formation of organic acids. They often enjoy the use of binding reactions or redox reactions, pH change, or luminescent dyes to produce color (i.e., easy to interpret by the consumer) controlled by the change in the target gas concentrations. The electrochemical sensors are also being developed, but they are expensive systems and are not commercially available yet. Intelligent Packaging The easier and more common approach to detect microbial spoilage is by following the formation of secondary metabolites, such as volatile nitrogen compounds, sulfide indicators, ethanol, organic acids, etc., as explained in gas sensors. Such analyte-specific receptors can be designed based on enzymes, pH- responsive dyes, antigens, microorganisms, nucleic acids, or hormones. An ideal biosensor for IP applications, however, needs to be detected selectively. The direct detection of pathogenic bacteria is often challenging due to lack of desired sensitivity, selectivity, reliability, quick response time, and compliance with user and applicability as a label to the conventional packaging. Therefore, contrary to extensive research in the area, they are not fully commercialized for IP applications yet.  Colorimetric film Recognition molecule Food pigments-natural, giving color of fruits and vegetables cheap easy to extract some great pH indicator BIOMATERIALS FOR SMART FOOD PACKAGING  Smart label scheme BIOMATERIALS FOR SMART FOOD PACKAGING SMART FOOD PACKAGING Yildiz et al., 2021 SMART FOOD PACKAGING Kilic et al., 2022 SMART FOOD PACKAGING Kilic et al., 2022 SMART FOOD PACKAGING Kilic et al., 2022 SMART FOOD PACKAGING Kilic et al., 2022 SMART FOOD PACKAGING Oktay et al., 2023 SMART FOOD PACKAGING Oktay et al., 2023 SMART FOOD PACKAGING Oktay et al., 2023 SMART FOOD PACKAGING Oktay et al., 2023 Challenges Economically not feasible Instability of biomolecules SMART FOOD PACKAGING Aseptic Packaging This technology creates a package that is virtually free from fertile microorganisms via separate treatment of the product and the package. Thus, a sterile product and a sterile package are combined in the filling step and directly closed afterwards to avoid recontamination. Aseptic packaging gives less thermal load to the filled product than conventional retorting, allowing for several months of shelf life. Aseptic Packaging Aseptic packaging is the filling of sterile containers with commercially sterile products under aseptic conditions and then sealing the containers so that reinfection is prevented; that is so that they are hermetically sealed. The term aseptic implies the absence or exclusion of any unwanted microorganisms from the food, container, or other specific areas, whereas the term hermetic (strictly air-tight) is used to indicate suitable mechanical properties to exclude the entrance of microorganisms into a package and gas or water vapor into (or from) the package. The term commercially sterile is generally taken to mean the absence of microorganisms capable of reproducing in the food under nonrefrigerated storage and distribution conditions. Aseptic Packaging Aseptic Packaging Aseptic packaging can include rigid containers such as metal cans, glass bottles, and jars; paperboard containers consisting of paper, foil, plastic, and preformed cartons; semi- rigid plastic containers such as preformed cups, tubs, trays, and bottles; and flexible plastic containers such as pouches. Aseptic Packaging Three main sterilization processes for packaging material are in common use, either individually or in combination: irradiation, heat, and chemical treatments. Irradiation involves ionizing radiation using gamma rays from cobalt-60 or cesium-137. The use of intense and short-duration pulses of broad-spectrum ‘white’ light (200–1000 nm) that generate high power levels can also sterilize aseptic packaging material and has recently been commercialized. UV radiation is most effective in terms of microbial destruction between 248 and 280 nm (the so-called UV-C range), with an optimum effectiveness at 253.7 nm. However, UV-C irradiation is generally only used commercially in combination with hydrogen peroxide (H2O2). Aseptic Packaging Heat sterilization processes can involve either steam (moist heat) or dry heat. For example, saturated steam at 165 °C and 600 kPa for up to 2 s is used to sterilize plastic containers. Hot air at a temperature of 315 °C has been used to sterilize paperboard laminate cartons where a surface temperature of 145 °C for 180 s is reached. A mixture of hot air and steam has been used to sterilize the inner surfaces of cups and lids made from PP, which is thermally stable up to 160 °C. The lethal effect of H2O2 on microorganisms (including resistant spores) has been known for many years and is widely used to sterilize food packaging materials. When UV irradiation and H2O2 are used together they act synergistically, and the overall lethal effect is greater than the sum of the individual effects of peroxide and irradiation; the optimum effect is at a relatively low peroxide concentration of between 0.5% and 5%. Peracetic acid (PAA) is a liquid sterilant, which is particularly effective against spores. It is used for sterilizing filling machine surfaces as well as packaging materials such as PET bottles before aseptic filling, with the PET bottles being rinsed with sterile water rather than hot air. Aseptic Packaging Assessment of package integrity is one of the most critical issues in the aseptic packaging of foods, and package integrity must be maintained to ensure the safety and quality of the product. There is increasing interest in non-destructive (or noninvasive) package integrity testing, which allows the online testing of every package produced, while leaving both product and package intact. However, the availability of commercially viable, non-destructive package integrity testing equipment is still very limited. Retort Packaging The advances in dairy packaging technologies that leverage high-heat sterilization also are extending to retort systems, in which food is filled into a pouch or metal can, sealed, and then heated to high temperatures, rendering the product commercially sterile. Improved the taste, texture, and appearance of dairy-based beverages while preventing degradation or loss of the nutritional values of proteins and sugars, UHT vs Pasteurized Milk Packaging 941 × 332