The food industry utilizes over hundreds of packaging materials and the four basic packaging materials are Metal, Plant matter( paper and Pulp), glass and Plastic
In some cases these materials are combined to give a suitable package
Food Cans
Cans are made of tinplate (tin-coated steel) but may also be made of aluminium or other metals.
The inside of the can is often sheet coated with lacquers to prevent the cans rusting and reacting with the contents, especially acidic foods.
Seafood, Meats, Vegetables, Fruits, Dry Goods, Beverages etc
Food Cans
PaperboardBoard used for food packaging is often
treated and coated with a wax of polythene to improve water strength, gas impermeability, tear resistance etc
Examples include bags for confectionery, pizza boxes, bread wrap, chocolate interleaving, frozen food containers, vegetable boxes, sugar bags, beverage cartons and food service boards.
Paperboard
Aluminium Foil High grade aluminium foil packaging are
temperature and moisture resistant.
They are excellent for preventing heating and cooling losses.
It completely blocks odour and moisture, thus, preventing the original trait.
Foil trays are suitable for both freezing and heating in conventional ovens
Aluminium Foil
Plastic MaterialFood packaging uses a wide range of both rigid
and flexible plastic materials including:
• Polythene – low density , is used as a film wrapping, resistant to water. High density , is used for packaging such as milk jugs, detergent bottles, margarine tubs, garbage containers
• Polyamide (nylon) – extreme durability, provides a very good barrier to oxygen, so used for vaccum packaging, especially for foods containing fat (which can be susceptible to oxidation).
Polyethene and Polyamide
Plastic Material Polyethlene terephthalate (PET) - rigid plastic
bottles, light-weight, little risk of breakage and keep the fizz in carbonated drinks
Polystyrene – low cost and has insulating properties. Used in foam egg cartons, meat trays, to soup bowls and salad boxes, coffee cups
PET and Polystyrene
Edible FilmsFood materials are protected from loss of
volatiles or reaction with other food ingredients by being encapsulated in protective edible materials
This can be done by spray drying flavoring materials emulsified with gelatin, gum arabic to form a thin coating around the food partucle
Examples: Sausage casings, coating if nuts with monoglyceride derivatives to protect them from oxidative rancidity
Sausage Casing
Cellulose FilmsCellulose films have a range of
characteristics such as different degrees of moisture proofing. Static-free regardless of climatic conditions and some are heat sealable.
It prevents wrapped sweets clinging to one another
In tablet coatings
Cellulose Films
GlassGlass has been used for food packaging for a
long time but tougher, It is chemically inert and non corrosive
It is susceptible to breakage and heavy tooHowever, glass is still very popular and is
used exclusively for many products, e.g. jam.Suitable for house hold canning purposes
Glass
Wood and Cloth materialsWoven cloth such as jute bags and cotton
bags used for bulk shipment of grains and flours.
Wire wound wood strips have been used to make crates for fresh fruits and vegetables.
Solid wooden crates are used for transporting iced fish.
Wood and Cloth materials
Combinations Of Packing Materials A fruit drink box where plastic, paper and
metal are combined in a laminate to give an ideal Package
This concept is also seen in peanut butter jar. The main package containing the food is made of glass(or plastic), the lid is made of metal lined with plastic and the label is made of paper
For a product like milk, which is an essential food, should not be so expensive. Paper is highly economical and also provides good printing surface.
However, since paper absorbs water, it will gain moisture from the milk, and this may spoil the product.
But when a thin layer of a plastic called polyethlene is utilized to line the inside of the milk carton, it serves as barrier to moisture and makes an economical, functional package.
AdvantagesMetal : Good overall barrierPaper : Economical, Good printing propertiesGlass : TransparentPlastic : Versatile, Light weight Therefore combining these basic materials
works well in most cases
DisadvantagesMetal : Prone to corrosionPaper : Not strong, absorbs waterGlass : Breakable, heavy in weightPlastics : Heat labile, environmental issues
MODIFIED ATMOSPHERIC PACKAGING
INTRODUCTIONModified atmospheric packaging (MAP) A preservation technique used to prolong
the shelf life of processed or fresh food by changing the composition of the air surrounding the food in the package .
Was pioneered by MARKS AND SPENCER in 1970’s.
Was use in every major UK supermarket in 1980’s.
REASONS FOR THE GROWTH IN MAP Changing eating habits. Changing lifestyles. The need to ensure the product safety. To extend shelf life. Development of other packaging
technologies. Extend geographic markets.
PRODUCTS INVOLVED IN MAP Raw meats Poultry Cooked and cured
meats Fish and shellfish Dairy products
(particularly cheese.)
Ready meals Fresh pasta Bakery products Fruits and
Vegetables Snacks Dried foods
GASES IN MAPAtmospheric Air composition 21% oxygen 1% Argon 78% Nitrogen 0.03% carbon dioxideGases used in MAP Carbon dioxide- to inhibit the microbial
growth Oxygen- to maintain the colour of red
meat and prevent anaerobic conditions (white fish)
Nitrogen- as an inert filler gas.
Gas Composition within the pack This is unlikely to remain constant
through the shelf life of the product because:
Physical interaction between gas and product
Effects of microbial and product metabolism
Gas permeation through the packaging material
Interaction between gas and productMainly CO2 into the aqueous and fat phases of the food Trapped gases (e.g between slices) can be released into pack Gases dissolved in the food may be released into pack atmosphere
Gas permeation through the packaging
No pack is a perfect barrier! All films are permeable to a greater or
lesser extentPermeability depends on:Nature of gasStructure and thickness of materialTemperatureRelative humidity for some materialsPartial pressures
Machinery types There are 4 distinct methods of producing
modified atmosphere packs Horizontal flow wrapping Vertical form-fill-seal Thermoform-fill-seal Rigid pack fill and sealChoice of pack style/machine depends largelyon the product to be packed
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ADVANTAGES OF MAP Potential shelf-life increase of 50-400% Reduces economic loss Products distributed over larger area Provides higher quality product Easier separation of slices Improved presentation Little or no need for preservatives
DISADVANTAGES OF MAP Visible additional costs Temperature control necessary Different gas formulations required Special equipment and training Food safety concerns Increased pack volume Benefits lost when pack opened or leaks
Fresh and Processed Food Packaging
Packing methods
Shrink - Side Seal
Automatic and manual side seal shrinking machines working with retractable films which allow to obtain a high quality package without folds after passing through a shrinkage oven which adapts film to product shape and dimensions.
Stretch Film
Highly flexible automatic film wrapping machines to pack fresh products in trays using stretched film.
Tray sealing
Automatic traysealing machines for fresh food packaging in trays with facilities for vacuum and/or gas injected packages (MAP)
Vertical (VFFS)
Vertical automatic wrapping machines using a single film coil to obtain a package with three weldings : two cross-weldings and one longitudinal welding. Its main field of application includes loose products, granulated products, doughy products or products difficult to handle.
Flow Pack (HFFS)
Automatic flow wrapping machines for high productions. Horizontal packing using a single film coil with three weldings : two cross-weldings and one longitudinal welding.
Fresh foods
Strawberry packaging in trays with automatic lid
placing machine Cherry tomatoes packaging in vertical machine (vffs) in steady flat bottom pack with 4 edge
seal Tomato clusters packaging in flow pack
wrapper (hffs) Apple and lemons tray packaging in flow pack wrapper (hffs) without tray
Strawberries tray packaging in stretch
film
Onion packaging in flow pack wrapper
(HFFS)
Heads of garlics packaging in flow
pack wrapper (hffs)
Onions (cut in pieces) vacuum
packaging in thermoforming in
flexible film
Cut vegetables
Cut salads packaging in vertical
machine (vffs)
Ready to eat chopped vegetables packaging in vertical machine (vffs)
Spinach leaves packaging in vertical machine (vffs)
Cut vegetables packaging with vertical machine (vffs) in pillow pack
Citrus fruits
Lemon group packaging in flow pack
wrapper
Orange unitary packaging in flow pack
wrapper (hffs) in shrink film
Orange tray packaging in flow pack wrapper (hffs) in shrink film
Dried fruitsMicrowave pop corn bag packaging in
flow pack wrapperDry fruits packaging in vertical machine
(vffs) in steady bottom pillow pack with
zipperDehydrated Apricot, poppy and raisins
vacuum packaging in thermoforming in
flexible filmDried Fruits, dates and dried peaches
packaging in vertical machine (vffs)
Legumes
-Legumes packaging in pillow pack with
polyethylene film.
-Coffee packaging in vertical machine
(vffs) in breathable pack
-Breakfast cereals packaging in vertical
machine (vffs) in gusseted pack
-Mushrooms packaging in traysealing in
modified atmosphere (MAP) in rigid trays
-Mushroom tray packaging in stretch film
Corn cobs packaging in flow pack
wrapper (HFFS)
Corn packaging in thermoforming in
vacuum pack with flexible film
Potatoes, beetroots, corn and carrots
vacuum packaging in thermoforming
with flexible film able to stand the
sanitization process
-Bunch of bananas packaging in flow
pack wrapper (hffs) in shrink film
-Banana cream packaging in
thermoforming with rigid film
-Bouque of aromatic herbs packaging in
Flow pack wrapper
-Herbs packaging in trays in flow
pack wrapper
-Flow pot packaging in vertical machine
(vffs) with handle to carry it
-Infusion dry flowers and herbs packaging
in vertical machine (vffs) in gusseted pillow
pack
-Turnip packaging in flow pack wrapper (hffs)
-Potatoes, beetroots, corn and carrots
vacuum packaging in thermoforming with
flexible film able to stand the sanitization
process
oils Oil, vinegar and salt mini doses packaging in
vertical machine (vffs) in gusseted bottom pack
Oil minidose packaging in thermoformong with rigid film
Meat
-Fresh meat in tray packaging in modified
atmosphere (MAP) using BDF shrink barrier
film in flow pack wrapper (HFFS)
-Fresh meat foam material trays SKIN
packaging in tray sealing
-Fresh meat expanded material trays MAP
packaging in tray sealing
-Mince meat packaging in poliestyren tray and
PVC film.
-Half ham vacuum packaging in
thermoforming in flexible film
-Ham packaging in thermoforming in
vacuum pack in flexible film
EGGS
-Eggs packaging in flow pack wrapper
-Eggs box packaging in flow pack wrapper
(hffs)
-Eggs trays packaging in flow pack
wrapper (hffs) with shrink film
Fish
-Salmon fillets "slice" foam material trays
MAP packaging in tray sealing
-Rigid material trays packaging in tray
sealing
-Fresh fish foam material trays MAP
packaging in tray sealing
-Prawns packaging in thermoforming in
flexible film
-Frozen fish fillets packaging in vertical
machine (vffs) in reclosable pack
Processed Food-Ready meals packaging in traysealingin modified atmosphere (MAP) in rigid trays-Frozen hamburguer packaging in flow packwrapper (hffs)-Vegetable hamburger vacuum packaging in thermoforming in flexible film-Sausage & processed meat packaging in
flow wrapper
-Fresh and cooked sausages packaging
in vertical machine (vffs)
-Sausages packaging in thermoforming
in vacuum pack in flexible film
Processed meat PS expanded barrier
tray packaging in traysealing with
modified atmosphere (MAP)
-Grouping of chocolate biscuit roll packs in
flow pack wrapper (HFFS)
-Biscuits multipack packaging in flow pack
wrapper
-Biscuits in tray packaging in flow pack
wrapper
-Chocolate tablet packaging in flow pack
wrapper (HFFS)
-Chocolate bar packaging in flow pack
wrapper (HFFS)
-Bombons packaging in traysealing in
modified atmosphere (MAP) in rigid
trays
-Chocolate tablets packaging in flow pack
wrapper (hffs)
-Chocolate bars packaging in flow pack
wrapper (hffs)
-Chocolate cream packaging in
thermoforming
-Pineapple flavoured skimmed yoghurt
packaging in thermoforming with sleeve
-Dried, salted and crumbled codfish
packaging in vertical machine (vffs) in
pillow pack
-Codfish packaging in side seal with
shrink film
-Loins and smoked fish filet vacuum
packaging in thermoforming with flexible
film
Bread-Bakery
The bakery sector requires flexible
packaging solutions to offer a quality,
traditional product in an attractive
presentation while conserving the products
natural freshness.
-Slice bread packaging in flow pack wrapper
-Group of cupcake muffins packaging in
flow pack wrapper
-Prepacked muffins packaging in vertical
machine (vffs) in steady flat bottom pack
with clip.
-Wrap and shrink of industrial bakery on
trays with poliolephyne film
-Pasta (Macaroni, noodles, wonders, stars,
letters, spirals, elbows) packaging in
vertical machine (vffs) in 5 kg bags
-Fresh rolled pasta packaging in flow pack
wrapper (hffs)
-Multipack noodels packaging in flow pack
wrapper (hffs)
Snacks
Crisp potatoes packs group packaging
in flow pack wrapper (hffs)
Crisps bags packaging in flow pack
wrapper (hffs)
Dairy products
-Powdered milk packaging in verticalmachine (vffs) in pillow and stable bag-Cheese packaging in flow pack
wrapper-Cheese packaging in flow pack
wrapper(HFFS) in modified atmosphere (MAP)-Soft cheese packaging in flow pack wrapper using shrink film-Sliced cheese MAP packing in thermoforming in rigid film
Cheese dairy dessert packaging in thermoforming
Thermoforming machines specially directed to dairy products (yogur, cream cheese) as well as gelatine and jams
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