PACKAGING AND DAIRY PRODUCTS

Leonardo M. Calixto
FDST 429-150/Term Paper/April 21, 2015

1. INTRODUCTION

Packaging is an essential step in the manufacture of most food products. It plays a

fundamental role in maintaining quality and shelf-life of foods. The package is an integrated part

of the preservation system and functions as a barrier between the food and the external atmosphere.

Besides being developed and designed to hold the food product, the package should also provide

protection and add value to the food, since its design may directly affect the purchase decision of

the consumer. (Cruz et al., 2007; Walstra et al., 2006)

According to Walstra et al. (2006), packaging has four main objectives: (1) Containment;

(2) Protection from outside influences; (3) Convenience for the consumer and (4) Providing

information.

Containment: The package separates the food product from the environment, preventing

contamination and therefore hygienic problems. Consist in the partitioning of the product into units

that can be handled during distribution, storage, transport, and final use.

Protection of the product from outside influences: Protection comprehend the prevention

of contamination, whether with microorganisms and chemical compounds, e.g. oxygen, or dirt

particles, and exclusion of radiation, especially light. Protection also includes the prevention and

minimization of loss of component, e.g. water and flavor compounds, to the environment.

Convenience for the consumer: Factor to be consider here, are: ease to open and close the

package, contamination after removal of a portion of the product from the package, easy stacking

of containers, e.g. package containing milk that can be laid down after it has been opened, and

range of portion sizes.

Providing information: The package includes factual information regarding the quality of

the product and its maintenance, e.g. day before which it should be consumed, its composition,
nutritive value, storage and handling instructions. Moreover, several marketing messages may be

printed on the label, from the brand name, to possible applications of the product and potential

benefits of its consumption.

This paper aims to produce an overview about the importance of packaging; its interaction

with food products; packaging materials generally used in the dairy industry; packages commonly

used for different dairy products; and, finally, new packaging technologies related to dairy

products.

2. FOOD-PACKAGE INTERACTION

Food and packaging interactions can be defined as an interplay between food, packaging,

and the environment, which produces an effect on the food and/or package. Such interactions

include permeability of gases and water vapor into or out of the package, migration of package

components into the food, sorption and/or permeation by organic vapors, and light penetration

through the package. These interactions alter the composition, quality, and physical properties of

the food and the package. Proper selection of a packaging material is essential to provide barrier

properties against the transmission of light, short chain, or organic compounds activated by light,

unfavorable organic compounds, and oxygen from the air into the package. A good barrier will

retain the aroma and flavor of a product to achieve a reasonable shelf life. (Hotchkiss, 1997; Simon

& Hansen, 2001)

Permeability of gases and water vapor into or out of the package: Glass and metal

containers are not permeable to gases and water vapors, on the other hand, gases and water vapors

can permeate packages made from plastics or thin foils. It is important to note that even though all

plastics are permeable to some degree, permeation rates will vary. (Lee et al., 2008)

Migration of package components into the food: Migration can have both quality and

toxicological significance. Very often, the components that migrate from the package are odor

active and can adversely affect the flavor of foods. Migration may also result in the transfer of
potentially toxic substances to foods, e.g. vinyl chloride monomer (VCM) to foods packaged in

polyvinyl chloride (PVC). (Lee et al., 2008)

Sorption and/or permeation by organic vapors: Packaged foods that are exposed to

undesirable volatile odors during storage or shipment might pick up the odor. Besides, the

desirable aroma compounds associated with a particular food are diminished by being sorbed into

or permeated through the package. (Lee et al., 2008)

Light penetration through the package: Light, particularly in the shorter wavelengths, can

catalyze adverse reactions such as oxidation in foods. This may lead to discoloration, los s of

nutrients, or the development of off-odors. (Lee et al., 2008)

3. DISTRIBUTION SYSTEMS AND PACKAGING MATERIALS

Packaging and distribution systems for milk can be classified as returnable containers

(glass bottles, plastic bottles and cans), single service containers (cartons, sachets, plastic bottles

and bag-in-box). (FAO Website)

Packaging in glass bottles (currently also in PET or polycarbonate bottles) has the

advantage that the bottles can be used many times, but the drawback is that their return, and

especially their cleaning and subsequent inspection, is laborious and expensive. The disadvantage

of the great weight of glass bottles may be acceptable in the case of home delivery. Plastic bottles

are normally used as single-service containers. They are usually blow-molded from polyethylene,

which is often a mixture of high and low-density grades. Occasionally polystyrene is used. The

basic advantage of plastic bottles in comparison with glass is the lower weight of the former (about

one-twentieth that of glass). (FAO, ; Walstra et al., 2006)

Most milk is distributed in single-service containers. Containers for durable milk products

are often made of tinplate or various synthetic materials. For less durable products, plastics or

laminates of cardboard and plastic are often shaped into cartons, sachets, or small cups. The

contents may range from about 10 ml (coffee cream) to 3785 ml (beverage milk in some countries).
The bag-in-box system is intended primarily for milk supplies to catering establishments and has

not found application to general milk distribution. (FAO, ; Walstra et al., 2006)

The manufacturer’s selection of a particular packaging system depends on the specific

requirements for the package, the extent to which the process can be fitted into the whole operation,

the reliability, and the costs involved. Among other important aspects are environmental pollution

and restrictions of the use of nonreturnable packages. (Walstra et al., 2006)

Some criteria to be considered regarding packaging materials for dairy products, according

to Walstra et al. (2006), are:

Processability: The packaging material should be adequate to the processing parameters of

the manufacture of the dairy product. Consider characteristics such as flexibility of the material

(brittle, pliable, moldable); thickness; suitability for heat sealing; adhesiveness; ease to cleaning;

resistance to heat.

Resistance: Consider characteristics such as strength of the material (usually, dependent

on its thickness); behavior of the packaging material under fluctuations of pressure and

temperature, and exposition to light; resistance to moist atmosphere; and velocity of aging.

Permeability: Generally, bacteria will not go through the package, since the closure of the

package is perfect. Passage of a substance through the packaging material may be by diffusion

and, consequently, greatly depends on the solubility of the substance in the material. The

permeability also depends on temperature and on the thickness of the packaging material.

Heat Insulation: Often a well-insulating package is not desirable, because after packaging

heating and/or cooling are to be applied. Although most plastics have poor heat conductivity, the

layer often is too thin for satisfactory insulation. If insulation is needed, expanded polystyrene

(polystyrene foam) can be applied.

Light Transmission: A transparent package is desirable so that the user can see the

contents. However, for milk products, light induced flavors (cardboard or sunlight flavor, and

oxidized or tallowy flavor) may develop. Cardboard is not transparent but is certainly not
impermeable to light. Glass can be browned (it is the short-wavelength light that is most harmful),

but brown glass is often considered unattractive. Most plastics are quite transparent. Fillers can be

applied to give color, and TiO2 is often used for a white color.

Often, no single packaging material meets all requirements. In these cases, the solution is

the use of laminates, i.e., the use of different packaging materials in order to combine their desired

characteristics; an example of laminate package is shelf safe carton for aseptically packaged

products.

Below are some properties of different packaging materials. (Walstra et al., 2006)

4. DAIRY PRODUCTS PACKAGING

4.1. Fluid Milk

Traditionally, milk for retail sale was packaged in reliable glass bottles. Nowadays, the

dominant packaging in the market is single-serve paperboard cartons and plastic containers of

various compositions and constructions. The packaging material is critical to the protection of the

flavor and nutritional qualities of the milk. The total amount of light passing through the container

wall depends on the material from which the container is made, and on the pigment either

incorporated into the material or used in printing it. The nature of the pigment also determines the
wavelength of the light reaching the milk. For example, clear PET bottles offer no protection

against light in the critical range for vitamin degradation. There, pigmented PET bottles are

required to protect pasteurized milk against vitamin A and vitamin B2 degradation. (Robertson,

2013)

The packaging process for milk ultra-pasteurized (UHT) is usually different from the

process for HTST milk. For UHT milk, it is common to use aseptic packaging, in which the milk

packaged is formed from a cylinder in a continuous machine. The packaging material is sterilized

inside this machine with hydrogen peroxide and UV radiation. Milk, previously, sterilized is then

packaged in a hermetic and sterile chamber to avoid microbiological contamination. Even though

the packages for HTST milk (refrigerated carton) seems identical to the carton boxes used for UHT

milk (shelf-stable carton), they are made of a completely different material. (Robertson, 2013;

UCP, 2010)

Figure 01 shows the differences between the two boxes.

Figure 01: Comparison between shelf-stable carton and refrigerated carton

4.2. Cheese

The packaging requirements for cheese depend upon its fat and moisture content, degree

of curing and consistency. Fresh cheeses have been using a number of plastics over the years;

however, the standard material is HIPS, which is thermoformed on form-fill-seal machines. It is

also coextruded or extrusion coated with PVdC copolymer to improve its barrier properties, and
pigmented with TiO2 to provide a better barrier to light. Injection molded containers made of

HDPE or PP with slits in the side to allow drainage of whey are also used, with the fresh cheese

being ladled directly into the containers. Outer packaging of PA-LDPE laminates make these

containers gas tight. (Robertson, 2013)

Soft cheeses are still in the maturation process when they in the commercialization phase;

therefore, the package must allow the proper gas exchange to support the maturation process.

Oxygen should be able to enter the package and carbon dioxide and moisture should be allowed

to exit the package. (UCP, 2010)

As for hard and semi-hard cheeses, usually, packaging consists in coating the cheeses with

a layer of wax or paraffin, or packaging in plastic film or cellophane. Pieces and sliced cheese are

often vacuum packaged and, sometimes, in Modified Atmosphere Packaging, in which a mix of

inert gases, rich in CO2, is introduced to the package. The absence of oxygen prevent oxidation

reactions and the high level of carbon dioxide slow the growth of molds. (UCP, 2010)

4.3. Yogurt

The most popular packaging material in current use for spoonable yogurt (either set

or stirred) is thermoformed HIPS in the form of small cups or larger tubs, with either an aluminum

foil/plastic laminate or a paper/plastic laminate heat seal lid or closure. Rectangular paperboard

cartons or cups (with or without an aluminum foil layer), glass containers, PP and blow molded

HDPE containers are also used, and for some specialty products in some markets, ceramic

containers have been used. (Robertson, 2013)

4.4. Butter and Dairy Spreads

Retail packaging of butter is commonly in aluminum foil laminated either to

greaseproof paper or vegetable parchment, or sometimes just the paper or parchment alone. Other

types of packaging for butter and dairy spreads include plastic tubs thermoformed from

white-pigmented HIPS or PVC with a tight-fitting lid of the same material. To fill tubs with butter,
it must be packed directly from the churn or reworked immediately prior to packing so that it will

flow into the package and fill it efficiently. (Robertson, 2013)

4.5. Milk Powders

Milk powders are traditionally packaged in three-piece tinplate cans containing inert

atmosphere such as N2 introduced prior to seaming the base onto the can. Once seamed, the can

should be impermeable to oxygen, water vapor and light. The advantages of this type of package

are the mechanical strength of the cans, which facilitates transport and handling, and the reuse

possibilities of the empty can, which contribute to its popularity in many parts of the developing

world. Usually, the top of the can have a lid, which can be levered off and, in order to provide a

gas-tight seal under the lid; an aluminum foil diaphragm is sealed to the rim of the can. (Robertson,

2013)

In recent years, aluminum foil-plastic laminates have been introduced as a

replacement for the tinplate can. The typical construction of such laminates consists in an inner

layer of LDPE so that the pouch can be sealed and an outer layer of BOPP or PET with alufoil in

the middle. The laminates can be formed, filled, gas flushed and sealed on a single machine from

reel stock. The main advantages associated with laminates are lower material cost and lighter

material weight. The disadvantages are that laminates do not have the mechanical strength and

durability of rigid containers, and there can be difficulty in obtaining a satisfactory heat seal

because of contamination of the heat seal area by powder during filling at high speed. (Robertson,

2013)

5. NEW PACKAGING TECHNOLOGIES

New packaging technologies for dairy products includes modified atmosphere packaging;

active and intelligent packaging; and antimicrobial packaging.

Modified atmosphere packaging is defined as the packaging of a perishable product in an

atmosphere, which has been modified so that its composition is other than that of air. For example,

Cheddar that has been vacuum packed, or the use of mix of N2 and CO2 to improve shelf life of
dairy products susceptible to spoilage by aerobic bacteria. Active and intelligent packaging

systems have been regarded as potential new breakthrough technologies for the future. The

intelligent packaging monitors the condition of packaged foods to give information about the

quality of the packaged food during transport and storage. Anti-microbial packaging is one of the

most researched areas of active packaging. The research activities have been directed at

determining how the surfaces of plastic can be made not only sterile, but also capable of exerting

anti-microbial effect on packaged food or beverage. (Goyal & Goyal, 2012; Arvanitoyannis, 2012)

6. CONCLUSION

Packaging is a vital step in the manufacture of several food products, including dairy,

having a direct influence in the quality, safety and shelf life of the product. Besides, protect

protecting and maintaining the quality attributes of the product, packages are meant to be

convenient for the consumer and inform them. There is a wide range of packaging materials and

packaging requirements for different dairy products. The choice of the material to be used in a

certain product packaging should be made based on the manufacture process parameters and the

material properties. Costs and environmental factors should also be considered. Often, a

combination of materials are required to achieve the level of protection desired. Finally, new

packaging technologies are being developed in order to further improve safety and quality

maintenance by the package.

7. REFERENCES

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Goyal, S.; Goyal, G.K. 2012. Recent Technologies for Dairy Products Packaging. Scientific
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