Abirami Nadarajan

Active, Intelligent & Smart Packaging

Smartness in Packaging

Broad term covering a number of functionalities

Depending on the product being packaged

Example of current & future functional smartness:

Retain integrity and actively prevent food spoilage (shelf life)
Enhance product attributes ( look, taste, flavor, aroma)
Respond actively to changes in product or package environment
Communicate product information, history or condition to user
Assist with opening and seal integrity
Confirm product authenticity and act to counter theft
Definitions

Passive
They function only as an inert barrier to protect the product against oxygen and moisture
Act as a passive barrier to separate a product from its environment

Active Packaging
Differs from conventional passive packaging in that one or more forms of interaction planned
Active functions beyond the inert passive containment and protection of the product
Interacts directly with the product and/or its environment to improve one or more nutritional, quality and safety factors.

Smart/Intelligent Packaging
Involves the ability to sense or measure an attribute if the product, the inner atmosphere of the package or the shipping environment.
Packaging which senses a situation and provide information such as quality, environment, location, safety, history & etc.

Applications in the current world

Active Packaging
Goals
Extension of shelf life (sea shipments of some fresh produced
Less expensive packaging materials Packaging of limited shelf life product requires enhancement
Simpler processing Additional MO hurdles allows MAP to be achieved without expensive equipments
Reduction or removal of preservatives from food formulations
Difficult to handle products Oxygen can be removed from tightly packaged product such as cheese
Allowing particular packages to be used retortable plastic packages with multilayer shelf lifes, PET wine bottles
Presentation Heating by microwave suseptors & other adjuncts has allowed packaging innovation for convenience foods

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System

Moisture Absorber

Oxygen Scavenger

CO2 absorbers or
emitters

Ethylene
Scavengers

Ethanol Emitters

Flavor /Odor
Absorber

Antioxidant
Release

Antimicrobial
Release

Microwave
susceptors

Active, Intelligent & Smart Packaging

Active Packaging
Explanation/Mechanism/Examples
In the form of sachets & pads
Liquid water can accumulate as a result of temperature fluctuations in high moisture packages, drip of tissue flesh foods and
transpiration of horticultural products
If this water is allowed to build up Growth of bacteria & mold , Fogging of the films
Drip absorbent pad : Consisting of granules of superabsorbent polymer sandwiched between 2 layers of a microporous or
non-woven polymer, which is sealed at the edges
Used in flesh food to absorb water
Desiccant: Hygroscopic substance in a porous pouch or sachet, placed inside a sealed package
Extend shelf life of moisture sensitive foods
Use powdered iron or ascorbic acid to reduce the oxygen concentration in the headspace
Small packets or sachets containing powdered iron
Bread, caked, cooked rice, biscuits, pizza, pasta, cheese, cured meats and fish, coffee, snack foods, dried foods and beverages
Bottle Closures included in the seal liner to absorb oxygen creating a vacuum headspace
Sachets that absorb only carbon dioxide
Contains Ca(OH)2 in addition to iron powder, so they absorb both oxygen & CO2
Application in roasted or ground coffee
Fresh roasted coffee releases CO 2 , unless its removed, It can cause bursting or swelling
Emitters : Ascorbic acid & ferrous carbonate/ sodium bicarbonate that absorbs oxygen, releases CO2
Avoiding package collapse & development of partial vacuum
Plant hormone produced during ripening + / - effect
- effect increasing the respiration rate softening of fruit tissue & accelerated senescence, degrading chlorophyll and
promoting a number of post harvest diseases
Potassium permanganate, which oxidizes C2H4 in a series of reaction which at last results in CO2 & H2O
Palladium Catalyst on activated carbon absorbs C2H4 and catalytically breaks it down
Activated Earth Adsorb ethylene ; open pores within the plastic which alter the gas exchange properties of the bag
Fruits & Vegetable mainly
Ethanol Antimicrobial agent Antimold Atmosphere
Sachets : Contains ethanol (55%) & water (10%) which are adsorbed onto silicone dioxide powder (35%) and filled into a
paper-EVA copolymer sachets
To mask the alcohol flavor, some may even contain vanilla or other flavors
Absorb moisture from food, release ethanol vapor
Useful for high water activity baked goods
Pizza crust, cakes, breads, biscuits, fish & bakery products
Volatile amines usually formed by the breakdown of protein in fish muscle
Can be neutralized by various acidic compounds
Commercial bags, made from film containing ferrous salt & organic acid such as citric or ascorbic acid oxidizes amine and
other odor causing compounds as they absorbed by the polymer
Odor (aldehydes) release due to oxidation of fats & oils removed by active packaging
Removal of bitter compounds using a plastic bottle coated internally with cellulose acetate-butyrate to absorb limonin &
immobilization of naringinase in cellulose triacetate film to hydrolyze naringin
Incorporated in plastic films to stabilize polymer protect it from oxidative degradation
Past : BHA/BHT in plastic liner of breakfast cereal and snack products
But monomer migration adverse effect on health
Now: Vitamin E is used as a replacement
Prevent growth of MO on food surface
Ensures that only low levels of preservatives come into contact with the food
Incorporated within the film or coated on the surface
Sorbic acid in cheese packaging retards mold growth extends shelf life
Very less commercial application
Inhibitory activity is said to be lost when the antimicrobial in combination with polymeric materials results in incompatibility
or heat lability during extrusion
Eg: Silver ion, organic acids, sulphur dioxides
Packaging materials that absorb microwave energy and convert it into heat susceptors
Enhance performance of the package by achieving localized effects such as browning and crisping of food

Abirami Nadarajan

Active, Intelligent & Smart Packaging

Intelligent Packaging
Goals
Improve product quality & product value, for example quality indicators, temperatures and TTIs and gas concentration indicators
Provide more convenience, for example quality, distribution and preparation/cooking methods
Provide protection against theft, counterfeiting & tampering

System

Quality Indicators

TimeTemperature
Indicators
Gas
Concentration
Indicators
Thermochromic
Inks

Microbial Growth
Indicators

Leakage indicator
Self Heating/Self
Cooling

Intelligent Packaging
Explanation/Mechanism
Indicate if the quality of the product has become unacceptable during storage, transport, retailing and in consumers homes
Undergo color change that remains permanent and is easy to read & interpret by consumers
Kimchi Freshness Indicator color indicator developed to monitor the ripeness of commercial kimchi products during
distribution & sales
RipeSense Enable consumers to choose fruits that best appeals to their taste
It detects aroma compounds given off by the fruit as it ripens, changing the label on the package through a range of color from
red (firm) through orange to yellow (juicy).
Pears was trialed first, as its very hard for consumers to assess the ripeness of pears
Device that shows an irreversible change in a physical characteristics (color/shape) in response to temperature history
Small adhesive labels attached onto shipping containers or individual consumer packages
Provide visual indications of temperature history during distribution & storage, which is particularly useful for warning of
temperature abuse in chilled or frozen food products.
Monitors perishable foods such as fish, fruits and vegetables
Indicate the presence or absence of gas
Most common oxygen indicator is pink when the oxygen concentration is < 0.1 %
Turning blue when the oxygen concentration is > 0.5%
Such indicators indicates effective absorption of all oxygen and to warn if there is a breakdown in oxygen barrier
Temperature sensitive inks
Printed onto labels or containers that are to be heated or cooled prior to consumption to indicate ideal drinking temperature of
the product
Inks change color hidden messages such as drink now or too hot become visible
Rapid microbiological indicators and sensors
Biosensors : Uses biomolecular recognition antigen-antibody, Phage capture spores, bacteria
Highly specific
Others: Respond to amine and sulfide from spoilage
Use colorimetrically signal seafood MO spoilage ( Commercial)
Attached to the packaging to ensure the integrity of the package in the distribution chain
Normally used in MAP of meat product
Provide information about the oxygen & carbon dioxide leakage in meat products
Uses the reaction of quicklime & a water based solution to create heat
Sake, coffee, tea & ready meals
Self-cooling utilizes endothermic reaction based on dissolution of ammonium nitrate & ammonium chloride in water

Intelligent packaging in short:

Indicator

Principle/reagents

Give information about

Application

Time-temperature
indicator

Mechanical, chemical,
enzymatic

Storage conditions

Food stored under

chilled and frozen
conditions

Oxygen indicator

Redox dyes ,pH dyes

enzymes

Storage conditions
package leak

Foods stored in
packages with reduced
oxygen concentration

Indicator of CO2

chemical

Storage conditions
package leak

Foods package in MAP

or CAP

Microbial growth
indicators MO
Freshness indicators

pH dyes,
All dyes reacting with
certain metabolites

Microbial quality of
foods (i.e. spoilage)

Perishable foods such

as meat, fish, poultry.

Pathogen indicators
(int.)

Various chemical and

immunochemical methods
reacting with toxins

Specific pathogenic
bacteria such as
E. coli O157

Perishable foods such

as meat, fish, poultry.

Abirami Nadarajan

Active, Intelligent & Smart Packaging

Modified Atmosphere Packaging

Food packaging technologies that rely on mixtures of the atmospheric gases ; oxygen, carbon dioxide, nitrogen in concentration different that
those in air
Sometime, add: Carbon monoxide, ethanol, sulfur dioxide and argon
Rely on gases that are safe, common, cheap, readily available & usually not considered as chemical additives
Proper marriage of food, gas mixture & package type is crucial
To retard the deterioration processes in foods
Maintain the foods in a fresh state From extended distribution marketing chains
Rigorous temperature control often necessary ; cold chain management

The benefits of MAP technology to the manufacturer, retailer as well as consumer far outweigh the drawbacks. Nevertheless some critical points should be
considered in this technology. The following list some advantages and disadvantages of MAP.
Advantage
Increased shelf-life allowing lesser frequency of loading of retail
display shelves.
Improved presentation of the product
Hygienic stackable pack sealed and free from product drip and odor
Shelf-life can be increase by 50 to 400%.
Reduction in production and storage costs due to better utilization of
space and
equipment

Disadvantage
Capital cost of gas packaging machinery
Increased pack volume increases transport costs and retail display
space
Cost of gases and packaging materials
Temperature control is of critical importance and, by itself, has a
greater impact than atmosphere modification for most products
Potential growth of food borne pathogens due to non-maintenance of
required storage temperature by retailers and consumers.

Type of gases used in MAP

Gases
Oxygen

Carbon Dioxide

Nitrogen

Carbon Monoxide

Sulfur Dioxide

Ethanol

Argon

How does it affect food?

Most degradative reaction in food constituents involves oxygen
Fats & Oils Rancidity
Spoilage MO Requires O2 to grow Off odors in the presence of sufficient oxygen & thus food spoilage
Normal respiratory metabolism of fresh fruits & vegetable & normal atmp concentration of O 2 senescence & degradation of
produce quality
Implicated with staling of bakery goods & pasta
Oxidation of meat pigments; Red Brown
But in the absence of O2, meat will become purple
Found in atmp at low levels ~0.03%
CO2 Dissolve in water Antimicrobial effect Suppress the growth of MO
Suppress the respiration of some fresh fruits & vegetables Extends shelf life
CO2 > 1%, render plant tissue insensitive to the ripening hormone slow down senescence & deterioration
But too much damages plant tissue
Largely depends on the tolerance levels of plants, and it varies
Abundant in air (78%)
Physiologically inert
Used as a filler gas and to exclude some other reactive gases
Colorless, tasteless & bland but very toxic
Concentration as low as 1%, CO will inhibit growth of many bacteria, yeast & mold
Delay oxidative browning in fruits & vegetable when + with low O2 concentration (2-5%)
CO in red meat packages maintain their natural appearance throughout shelf life
CO reacts with myoglobin carboxymyoglobin, bright red pigment that masks the natural aging & spoilage of meats
Control growth or mold & bacteria on a number of soft fruits, eg Grapes & dried fruits
Also in fruit juices, wine, shrimp, pickles and some sausages
SO2 + H2O Sulfite compound solution inhibitory to bacteria in acidic condition
Hypersensitivity Sulfite allergy
Antifungal activity
Baked goods in Japan to reduce MO spoilage
Enhance freshness of tomatoes
Act as flavor enhancer for other fruits
Noble gas
May have antimicrobial effect

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Active, Intelligent & Smart Packaging

MAP OF RED MEAT

Deterioration of Fresh Meat

Vacuum Packaging

Case Ready Meats

High O2 MAP

Low O2 MAP

Oxidative color deterioration & MO deterioration

Meat pigment: Myoglobin, red color and largely determined by oxidative state
Reduced form Deoxymyoglobin Purple color
Oxygenated Myoglobin Bright red color Associated with freshness
Atmp O2 slowly converts myoglobin into metmyoglobin Dull brown Poor quality
Contaminated during slaughtering process
Presence of O2 encourages growth of Pseudomonas putrid & malodorous compounds
Exclusion of atmp O2 prevents :Oxidation og myoglobin to metmyoglobin
Suppress the growth of Pseudomonas
Applied to 2-9 kg of primal & subprimal meat cuts for distribution in stores
Beef of normal pH and kept chill T can be stored for 10 12 weeks
Lamb : more neutral pH exterior adipose tissue than beef, so 6-8 weeks
Packaged at plants and delivered to ready to be placed in the retail case
Combination of MAP: Vacuum packaging , low & high O2 MAP
Poultry, beef, veal, pork, ground meat products
40-80% O2 Extend color stability
20 30% CO2 Delay MO spoilage
Presence of O2 Rancidity and off odor
So not suitable for prolonged storage of red meats
Low O2 + High CO2 : gas flushing of packages
Absence of O2 retard formation of brown metmyoglobin
The CO2 suppresses the growth of spoilage bacteria
CO2 very soluble Package collapse
So need N2 to rescue, in the headspace
Such packages results in shelf life of 3-4 months for lamb & pork

MAP of BAKERY & PASTA PRODUCTS

Subject to moisture loss, oxidative rancidity, MO breakdown due to mainly molds.
MO spoilage
Aw > 0.86 , predominant mold is Penicillum
Aw< 0.86 , predominant mold is Aspergillus (more sensitive to CO2)
Chemical preservatives such as: Calcium & sodium propionate, sorbic acid, potassium sorbate used by the bakery industry
But the trend towards foods free of preservative opens up opportunities for MAP
To prevent deterioration and extend shelf life
Vacuum Packaging : Remove headspace of O2, inhibit oxidative rancidity and growth of aerobic spoilage MO
N2 + CO2 Suppress growth of bacteria and molds due to the presence of CO2
Ethanol emitters
used in JAPAN to extend shelf life of baked goods
Powerful bactericide & effective antifungal agent
Pizza sprayed with 2% ethanol increase in shelf life by 5 fold
Exclusion of O2 is so crucial, packaging material must provide good barrier to O2.
Rigid trays with nylon/LDPE/ PVC/PVDC lid stock
Laminated films made from Nylon/polyethylene, nylon/PVDC/PE or nylon/EVOH/PE have also been used
50-100% CO2 + 0.5% N2 shelf life extension up to several months

Abirami Nadarajan

Active, Intelligent & Smart Packaging

MAP OF FRESH HORTICULTURE PRODUCTS/PRODUCE

Problem
(Summary)

Respiration
(Detail problem)

Ethylene ( Ripening)
Detail problem)

Transpiration
(Detail problem)

Post-Harvest Decay
(Detail problem)

Other preservation
technique
MAP in Vegetable

Examples

As a result of MAP

Factor affecting
MAP

Fresh produce susceptible to diseases because increase in the respiration rate after harvesting
Shelf life at ambient conditions are very limited
Can be extended by retarding physiological , pathological and physical deteriorative processes
Important quality aspect : Freshness
Maintaining freshness during the entire supply chain is a challenge
Involves oxidation of starch & sugars to simples molecules : CO2 & H2O
H20 remains in the tissue, but CO2 escapes
Rate of respiration good index for storage life Higher the rate, shorter the shelf life or VV
Low T give a slow respiration rate
Fruit & Vegetable expels ethylene
A gas which accelerates ripening process in F&V
Even in small quantities
Climateric / Non climacteric
Climateric those in which ripening associated with a distinct increase in respiration and C2H4 production
Results in color changes, softening, increased tissue permeability and development of aroma
Ethylene liberation & sensitivity of ethylene varies from product to product
Low tem low ethylene liberation
Continue to loss water after theyre harvested
Lose their freshness when the water loss is 3-10%
If not retarded, it induces wilting, shrinkage, loss of firmness, crispness and succulence
Respiration generates heat, which is dissipated through direct heat transfer to the environment and evaporation of water
One MO proliferate secrete enzymes deterioration
Fungi : Alternaria, botrytis, Penicilium, Rhizopus
Bacteria : Erwinia & Pseudomonas
Development Favored by high T & high RH condensation spore germination
Respiration of F&V can be reduced by low temperature, canning, dehydration, freeze drying, controlled atmosphere, hypobaric
and modified atmosphere
Preservation technique air surrounding the food in the package is change to another composition
The mixture of gases depends on the type of products, packaging material and storage temperature
Packaging F&V : Lowered level of O2 & Heightened level of CO2
But the suppression of O2 continues until its 2-4%, then fermentative metabolism replaces normal aerobic metabolism & offflavors, off-odors and undesirable volatile are produced
More than 10% CO2, the growth of many bacteria & fungi are retarded
GOAL: To create an equilibrium package atmosphere with low O2 and high CO2 to be beneficial to the produce and not injurious
Ehtylene is halved at O2 levels of around 2.5 %
Active & passive method of creating MA conditions
Passive MA relies on the respiration of the produce and the gas permeability properties of the film to achieve desired MA
The produce is put in a bag, if the permeability of the bag is properly matched with the respiration of the produce, the ideal
atmp will evolve inside the sealed bag
Active MA (Common) gas flushing and gas scavenging technology by adding CO2 and N2 or removing O2 during package
The produce is put inside in a bag and the air in the bag is replaced with air that has the proper mixture of O2 & CO2
Time required to increase CO2 & decrease O2 for active MA shorter than passive MA
Storage of grapes in 80% O2 or 40% O2 + 30% CO2 improved berry hardness, springiness, chewiness, flavors over controlled
stored in air
Avacado, showed potential for long term storage ==> up to 9w weeks under MAP in commercial application
Banana reducing O2 (2.5-5%) & increasing CO2 suppressed respiration rate of banana
Slows down the respiration of the product
Thus increases shelf life, increase freshness
Retards produce ripening by inhibiting both the production & action of ethylene
Temperature control is important as produce are sensitive to temperatures: Biological reaction rises 2-3 fold for every 10C rise in
T.
Film permeability increases as Temperature increases
Low RH increase transpiration damage & lead to desiccation, increased respiration
High in package humidity condensation on the film driven by T