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Food Packaging Innovations- An Overview
Tuesday, 16 February, 2016, 08 : 00 AM [IST]
Prof. Karna B K
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Packaging is everywhere and its specification is based on many factors, including the technical & functional properties of the material, fitness till the consumer satisfaction, purpose, sourcing, functionality, manufacturing capability and cost.
 
It is evident that if packaging is mismanaged, the resulting damaged products or wasted food would probably have far more of an environmental impact than the impact of the packaging.

Food packaging is an important & integral part of the food industry.

3S of Packaging - Safety, Sale and Satisfaction
It has been observed that market of food packaging is one of the largest application segment of the packaging industry, accounting for more than one-third of the global packaging market.

Like other packaged goods, food packaging needs to be in such a manner that it will provide speedy packaging, protection, identification, product quality, display and needs of security.

Advancement in research of food habits development had always been dependent on the packaging technology. Maintaining integrity of foods / processed foods during storage, shipment, and delivery is assured by quality of packaging available.
 
This compiled article reviewing current few food packaging trends and predicting the packaging outcomes in future.

New in Microwave Technology-Thermoformed Tray

The MicVac pasteurisation concept is a microwave technology, with which preparing food involves a thermoformed tray filled with raw food ingredients (meat, poultry, vegetables) and certain partially pre-cooked ingredients such as potatoes. The filled PP-tray is topped and heat sealed with a peelable PA/PP flexible film, after which a patented valve designed to open or close when needed, is added.



Nano-coated ‘killer paper’ extends food shelf life

Israeli scientists have said their new nano-coated “killer paper” could be used in food packaging to combat bacteria such as E.coli to extend product shelf life.





SEM images showing general growth in silver nanoparticles sizes for a 100 mM silver nitrate concentration as a function of sonication time:


(A) Uncoated paper,

(B) 30 min sonication,

(C) 60 min sonication, and

(D) 120 min sonication


The scale bar in (A) and (B) corresponds to 2 µm, while in (C) and (D) it corresponds to 1 µm.



The silver nano-particles are anchored strongly to the surface either by physically embedding them in the surface or by forming chemical bonds or other interactions with the substrate to form a “remarkably sturdy coating.”

The coated paper showed potent antibacterial activity against food-borne disease-causing organisms such as E. coli and S. aureus, killing all of the bacteria in just three hours.

“Developing coated paper with antimicrobial properties of silver nano-particles could be an alternative to other food preservation methods employing radiation, heat treatment, low temperature storage, or the introduction of antimicrobial additives.”

Ready-to-use peel polymers offer resilience and easy opening


Dow Chemicals claims its Sealution polyolefin-based, single pellet formulations offer a raft of advantages compared to conventional resins and blends. The ready-to-use material is suitable for use in blown and cast film applications and with polyethylene (PE) or polypropylene (PP) substrates. They can also be utilised across a broad range of peel seal applications, as Dow claims versatility, seal reliability and easy opening for its new range of peel polymer formulations for food packaging.



New non-aluminium foil packaging for food and drink products



A new transparent, non-aluminium foil barrier film line for stick pack and flow wrapped food and drink applications is launched by Rollprint Packaging Products.


Rollprint said the Overture One lamination is based on the company’s ClearFoil barrier-coated polyester and is coupled with an “aggressive sealant.

The company claims that oxygen barrier levels are available as low as 0.0008 cc/100in2/24 hrs and moisture barrier properties are available down to 0.0008 g/100in2/24 hrs.



Zig Portable Protein Shake


It is this technology that’s used by Luminate Nutrition LLC for its Zig Portable Protein Shake. Protein shakes are a popular choice for pre- or post-workout nutrition and as a healthy snack between meals and using this flexible packaging makes the laminate protein products more convenient for on-the-move consumers.

The lightweight packaging features a built-in mixing mesh design for clump-free shakes, comes packed with a pre-measured portion of protein powder, can easily be transported in a gym back and eliminates the mess of mixing by just allowing consumers to add water directly to the pouch.


Bio-plastics in food packaging






Bio-plastics -a class of polymers are made from renewable resources or enable biodegradability of the products made from this material. In general, raw bio-plastics such as starch, PLA, PHA, PBS and others) are not easy to use so it is blended and compounded into more functional materials - requires special knowledge in the field of additives and a smooth compounding process.


Polylactic acid (PLA) and polyhydroxyalkanoate (PHA) have high rigidity and are unsuitable for applications that require flexibility and toughness. The most common technique to make PLA and PHA flexible is to add a plasticiser or to compound in more flexible polymers. The predominantly used and commercially available resin used for both PLA and PHA is an aromatic/aliphatic co-polyester which is biodegradable, but not at all renewable since it is 100% derived from petroleum.


With further research and development, the heat modifier might make it possible for food or beverage bottles or other containers made from PLA to be “hot-filled,” that is, filled at the food-manufacturing or beverage-bottling plant while the food or beverage is still hot from pasteurisation.


Agriculture waste turned into packaging




German-based companies Zelfo Technology and Upgrading have produced an up-cycled wheat straw based packaging concept. The so called Micro and Nano Fibrillated Cellulose (M/NFC) packaging is made using 100% agriculture waste. They claim that packaging can be manufactured from a mixture of up-cycled plant based M/NFC at various percentages and new cellulose or de-fibred waste material with production times relative to M/NFC quantities used.


World’s first PET bottle made entirely from plants





It is well-known that the Coca-Cola Company, already for some years, is “struggling” to get to its final goal: a 100% plant-based bottle. Apparently they succeeded as they unveiled the world’s first PET plastic bottle made entirely from plant materials at the World Expo in Milan/Italy.

PlantBottle packaging is Coca-Cola’s answer to packaging traditionally made from fossil fuels and other non-renewable materials. The PlantBottle technology converts natural sugars found in plants into the ingredients for making PET plastic bottles. The packaging looks, functions and recycles like traditional PET, but has a lighter footprint.

The PlantBottle can be used for a variety of packaging sizes and across water, sparkling, juice and tea beverage brands. Today, the company uses sugarcane and waste from the sugarcane manufacturing process to create the PlantBottle.



The retortable “Klear Can”







The BPA-free multi-layer, PP “Klear Can” co-injection technology from Kortec, Inc. allows the production of clear PP plastic cans for food packaging. The result, the “Klear Can” provides an attractive alternative to metal cans by providing a clear, see-through PP in a container that features extended shelf life of up to five years.


Kortec, the world’s largest supplier of co-injection systems to the plastics and packaging industries, states that the “Klear Can” is an ideal alternative to metal cans for fruits, vegetables, soups, meats, and other products.


Suitable for retort up to 130°C (265°F), these clear plastic cans have been tested and approved for both retortability and the integrity of the double seam, which was designed to allow the plastic can’s flange to accept traditional (easy open and non-easy open) metal can ends.

Klear Can provides numerous advantages over metal cans, most notably the ability to show the quality of the food products to the consumer at the point of sale. Other advantages include the three-layer plastic construction (PP outer and inner layers, with an EVOH barrier) for a shelf life up to five years and its BPA-free status.

Coloured plastic cans and in-mould labelling are available options.



There are many innovations by using the ultimate in technology to accentuate the brand’s presence on the shelves. Keep in mind that more than two thirds of purchasing decisions are made in the aisle. The competition is decided then and there by what the consumer decides, and it is on the shelves that the brand must make the impact.

At a time when the world faces dramatic challenges on the sustainability and development of its food supply, it needs the scientific and innovative skills of the packaging industry to succeed.

(The author is director, PCRI, Packaging Clinic & Research Institute, Hyderabad. He can be contacted at  pcri.bk@gmail.com)
 
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