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Food Packaging FDSC 319  Functions of Food Packaging Containment - Loss and pollution Protection - Outside environment influences Convenience - Aid customers in the use of the product Communication - Recognition, universal product code (UPC) scanning and educate the consu...

Food Packaging FDSC 319  Functions of Food Packaging Containment - Loss and pollution Protection - Outside environment influences Convenience - Aid customers in the use of the product Communication - Recognition, universal product code (UPC) scanning and educate the consumer (nutritional information and usage)  Package Role in Preservation Protect the product from physical damage Inject nitrogen in potato chip bags Protect the product from the environmental contamination: Dirt, insects and air Limit the oxygen around the product – Vacuum packaged products Microbial growth and oxidation (rancidity) Limit the loss of moisture in the product – Prevents the surface dehydration of foods  Convenience Aid Customers in the use of the Product Food packaging with features to make the product easier to use Re-closeable features Zip-lock Screw caps Pre-sliced products …. etc.  Communication Educate the Consumer Package identifies the product to the consumer. Convincing customers to buy the product, i.e., a silent salesman. Inform consumers about how to: Prepare, use or store the product Contents or amount of product contained Ingredients Nutritional content  Requirements for Food Packaging ▪ Non-toxic ▪ Protect against contamination and ingress of odors ▪ Barrier to moisture and oxygen ▪ Filter out harmful UV light ▪ Provide resistance to physical damage ▪ Tamper-resistant ▪ Easy to open have dispensing & resealing features ▪ Meet size, shape and weight requirements ▪ Have appearance, printability features ▪ Readily disposable ▪ Low cost ▪ Compatible  Levels of Packaging Primary package o In direct contact with the contained product o Retail unit that you buy, compatible with the food Secondary Package o Corrugated case or box contains a number of primary packages No direct contact with the food directly ‫الحزمة األولية‬ ‫ على اتصال مباشر مع املنتج املتضمن‬O Tertiary package ‫ متوافقة مع الطعام‬،‫ وحدة البيع بالتجزئة التي تشتريها‬O ‫ الحزمة الثانوية‬ Made of number of secondary packages ‫تحتوي العلبة أو الصندوق املموج على عدد من العبوات األولية ال يوجد اتصال مباشر بالطعام مباشرة‬ ‫ حزمة تالياري‬ ‫ مصنوع من عدد من الحزم الثانوية‬  Package Environments Physical Environment ✓ The environment in which a physical damage can be caused to the product, e.g., Shocks (drops, falls & bumps), vibration, compression & crushing during transportation & storage. Ambient Environment ✓ The environment that surrounds the package, e.g., gases, water, light, temperature, microorganisms, macro-organisms, and dirt. Human Environment ✓ The environment in which the package is handled by people, e.g., the interaction with people (communication and physical handling).  Types of food packaging materials Glass Metals Foils Paper, paperboard and fiberboard Composites and laminates Polymers (synthetic and natural)  WHY FOODS ARE PACKAGED DIFFERENTLY? Foods have different composition/ingredients Foods spoil/deteriorate differently Foods are packaged in certain ways to have the longest shelf life possible. ISO 1156 – Framework for design & evaluation of packages (www.iso.org/standard/50175.html) – Guideline for universal design (UD) HOW DIFFERENT FOODS ARE PACKAGED  Meat Packaging Red meats such as beef is packed in: Styrofoam tray wrapped with thin film Gas atmospheres (mixture of oxygen, carbon dioxide and nitrogen) Meat Packaging (cont.) How the following meat products are packed? ▪ Sausages ▪ Poultry ▪ Seafood  Fruits and Vegetables Canned - shelf stable Jars - especially baby food Frozen - bags in a box Edible coated Gas flushed plastic bags Cereals and Cereal Products Oatmeal in paperboard Most breakfast cereals in waxed or plastic bags inside a paperboard box. Bread and bakery items are packaged in a plastic bag. Crackers are packaged in waxed or plastic bags within a paperboard box.  Chips Most chips in a gas filled bag Some chips in paper bags Why bags are filled with gas? What is the type of the gas used? Chips are typically packaged in specific ways to ensure freshness and longevity. Here’s how and why: ### 1. **Most Chips in a Gas-Filled Bag** Most chips are packaged in bags made of plastic or aluminum foil with a gas filling, especially in large-scale commercial production. ### 2. **Some Chips in Paper Bags** While less common, some smaller brands or artisanal chips are packaged in paper bags, often for environmental or branding reasons. Paper bags might be lined with materials to preserve the chips, but they generally don't protect the chips from air as effectively as plastic or foil. ### 3. **Why Bags Are Filled with Gas** The gas filling inside the bag is essential to: - **Prevent Oxidation**: Chips are prone to getting stale and rancid when exposed to oxygen. The gas displaces oxygen to slow down the oxidation process, which extends the shelf life of the chips. - **Cushion the Chips**: The gas also acts as a cushion to protect the chips from being crushed during transport. ### 4. **What Type of Gas Is Used?** The gas used is typically **nitrogen (N₂)**. Nitrogen is an inert, non-reactive gas that: - Doesn't interact with the chips, unlike oxygen which could cause them to spoil. - Is harmless and makes up about 78% of the Earth's atmosphere. Using nitrogen ensures that the chips stay fresh and crispy for longer.  Dairy Products Originally in glass jugs Later came wax coated paperboard Now, still some wax paperboard but changing over to plastic jugs Cheese, yogurt, cottage cheese, etc., in plastic containers. Ice cream, butter come in wax coated paperboard or plastic containers.  Beverages Most soft drinks in aluminum cans Some juices sold in plastic jugs/bottles Coffee sold in glass jars, plastic jars and metal or plastic cans  Eggs Usually sold in paperboard or plastic containers Understanding Food Shelf Life The shelf life of food products is a critical concept in food technology, referring technology, referring to the period during which a food maintains acceptable acceptable quality for consumption. It encompasses the time from production production through retail purchase and consumer storage. Factors affecting affecting shelf life include product characteristics, environmental conditions conditions during distribution and storage, and packaging properties. properties. Understanding and accurately determining shelf life is essential for essential for food manufacturers to ensure product safety, quality, and and consumer satisfaction. by Akmal Nazir Defining Shelf Life IFT Definition The Institute of Food Technologists defines shelf life as the period between manufacture and retail manufacture and retail purchase during which a product maintains satisfactory quality in terms of in terms of nutritional value, taste, texture, and appearance. IFST Definition The Institute of Food Science and Technology defines it as the period during which a food product food product remains safe, retains desired characteristics, and complies with nutritional data when nutritional data when stored under recommended conditions. Consumer-Focused Definition Another definition considers shelf life as the duration between packing and the end of consumer quality, determined by the percentage of displeased consumers. Primary vs Secondary Shelf Life Primary Shelf Life Primary shelf life refers to the duration a product retains acceptable quality when stored under ideal conditions, typically in a warehouse or distribution center. Secondary Shelf Life Secondary shelf life refers to the time a product maintains quality after the package has been opened, where conditions such as temperature and humidity can significantly affect the product's quality.  ‫‪Regulatory Perspectives on Shelf Life‬‬ ‫‪1‬‬ ‫‪EU Directive 2000/13/EC‬‬ ‫‪Required prepackaged foods to bear a date of "minimum durability" or "use‬‬ ‫‪by" date for highly perishable foods.‬‬ ‫‪2‬‬ ‫‪Commission Regulation (EC) No. 2073/2005‬‬ ‫‪Provided the first legal definition of shelf life in EU legislation.‬‬ ‫وجهات النظر التنظيمية حول العمر االفتراضي‬ ‫‪3‬‬ ‫‪Current Labeling Practices‬‬ ‫‪1‬‬ ‫توجيه االتحاد األوروبي ‪EC/2000/13‬‬ ‫‪"Best before," "Use by," and "Best by" dates are now commonly used, with‬‬ ‫األطعمة املعبأة مسبقا املطلوبة لتحمل تاريخ "الحد األدنى من املتانة" أو تاريخ "االستخدام بحلول" لألطعمة شديدة التلف‪.‬‬ ‫‪some manufacturers opting for "born on" dates.‬‬ ‫الئحة املفوضية األوروبية رقم ‪2073/2005‬‬ ‫قدم التعريف القانوني األول للمدة االفتراضية في تشريعات االتحاد األوروبي‪.‬‬ ‫ممارسات وضع العالمات الحالية‬ ‫تستخدم اآلن تواريخ "األفضل قبل" و"االستخدام من قبل" و"األفضل من قبل" بشكل شائع‪ ،‬حيث يختار بعض الشركات املصنعة تواريخ "الوالدة في"‪//.‬‬ Factors Controlling Shelf Life 1 Product Characteristics Intrinsic factors such as pH, water activity, enzymes, microorganisms, and reactive compounds influence shelf life. 2 Environmental Factors Extrinsic factors like temperature, relative humidity, light exposure, and gas pressures affect product deterioration. 3 Packaging Properties The package's ability to control mass and heat transfer significantly impacts food preservation. Product Categories Based on Shelf Life Perishable Foods Semiperishable Foods Shelf Stable Foods Require chill or freezer temperatures. Contain natural inhibitors or undergo Considered "nonperishable" at room Examples: milk, fresh meats, minimally mild preservation. Examples: some temperature. Examples: cereal grains, processed foods. cheeses, root vegetables, pasteurized nuts, canned foods, dry mixes. milk. Impact of Distribution and Storage Environment Temperature Control Humidity Management Light Exposure Fluctuations in storage temperature Relative humidity influences moisture transfer Light can catalyze oxidation reactions, significantly affect deterioration rates of through packaging, impacting food quality. affecting color and nutrient content of foods. packaged foods. Packaging Materials and Their Properties Material Permeability Protection Level Metal Cans Impermeable High Glass Containers Impermeable High Paper-based Permeable Low Plastics Varying Medium to High Moisture Content and Shelf Life Initial Moisture The starting moisture content of a food product influences its shelf life potential. Equilibrium Moisture The moisture content a food reaches when exposed to a specific relative humidity affects stability. Time to Critical Moisture Shelf life can be determined by the time taken to reach a critical moisture content. Oxygen and Its Effects on Food Quality Microbial Growth Oxygen can promote the growth of aerobic microorganisms, leading to spoilage. Color Changes Oxygen exposure can cause discoloration in fresh and cured meats. Lipid Oxidation Oxygen contributes to rancidity in fats and oils, affecting flavor and nutritional quality. Fruit and Vegetable Senescence Oxygen plays a role in the aging process of produce, impacting texture and appearance. Package-Product Interactions 1 Tin and Iron Dissolution Metal ions from cans can dissolve into acidic foods, affecting flavor over time. ‫تفاعالت الحزمة واملنتج‬ 2 Plasticizer Migration ‫ إذابة القصدير والحديد‬-1.‫ مما يؤثر على النكهة بمرور الوقت‬،‫يمكن أن تذوب األيونات املعدنية من العلب في األطعمة الحمضية‬ Compounds from plastic packaging can migrate into foods, potentially ‫هجرة امللدنات‬ exceeding legal limits..‫ مما قد يتجاوز الحدود القانونية‬،‫يمكن للمركبات من العبوات البالستيكية أن تهاجر إلى األطعمة‬ ‫نكهة سلخ فروة الرأس‬.‫ وتغيير خصائصها الحسية‬،‫يمكن ملواد التعبئة والتغليف امتصاص النكهات من األطعمة‬ 3 Flavor Scalping Packaging materials can absorb flavors from foods, altering their sensory properties. Methods of Shelf Life Determination 1 Direct Methods Involve storing products under normal conditions and evaluating quality over time. 2 Accelerated Shelf Life Testing (ASLT) Uses elevated environmental conditions to speed up deterioration processes. 3 Predictive Modeling Utilizes mathematical models to estimate shelf life based on known parameters. Accelerated Shelf Life Testing (ASLT) Principle Applies chemical kinetics to quantify effects of extrinsic factors on deterioration rates. Methodology Subjects food to controlled environments with higher-than-normal stress levels. Calculation Uses acceleration factors to estimate true shelf life under normal conditions. Pros & Cons of ASLT Advantages: Allows for faster evaluation of product, process, or packaging changes without waiting for normal shelf life periods. Data Limitations Methodology Ignorance Industry Skepticism Lack of basic data on extrinsic factors' Limited understanding of required Doubts about the advantages and effects on deterioration rates. procedures for effective ASLT. reliability of ASLT procedures. May introduce unrepresentative reactions at very high temperatures; not applicable in tropical climates where ambient conditions are already extreme. Criteria for Sample Failure in Shelf Life Testing Sensory Panel Scores Significant changes in mean sensory evaluation scores indicate product failure. Microbial Deterioration Growth of microorganisms rendering the product unsafe or unsuitable for consumption. Consumer Acceptability Changes in odor, color, texture, or flavor that make the product unacceptable to consumers. Statistical Considerations in Shelf Life Determination Distribution Knowledge Understanding the statistical distribution of observations is crucial for accurate analysis. Mean Time to Failure Accurate estimation of mean time to failure and standard deviation is essential. Failure Probability Predicting the probability of future failures helps in shelf life estimation. Data Analysis Models Appropriate models are needed to handle skewed distributions and unfailed data. Predictive Modeling in Microbial Shelf Life 1 Model Development Creation of sophisticated predictive models for microbial growth in foods. 2 Application Use of models to determine shelf life of perishable foods like meat, fish, and milk. 3 Limitations Recognition that models should complement, not replace, microbial testing and expert judgment.