Food Packaging Technology docx

Food Packaging Technology Packaging Technology Series Series Editor: Geoff A. Giles, Global Pack Management, GlaxoSmithKline, London. A series which presents the current state of the art in chosen sectors of the packaging industry. Written at professional and reference level, it is directed at packaging technologists, those involved in the design and development of packaging, users of packaging and those who purchase packaging. The series will also be of interest to manufacturers of packaging machinery. Titles in the series: Design and Technology of Packaging Decoration for the Consumer Market Edited by G.A. Giles Materials and Development of Plastics Packaging for the Consumer Market Edited by G.A. Giles and D.R. Bain Technology of Plastics Packaging for the Consumer Market Edited by G.A. Giles and D.R. Bain Canmaking for Can Fillers Edited by T.A. Turner PET Packaging Technology Edited by D.W. Brooks and G.A. Giles Food Packaging Technology Edited by R. Coles, D. McDowell and M.J. Kirwan Packaging Closures and Sealing Systems Edited by N. Theobald FOOD PACKAGING TECHNOLOGY Edited by RICHARD COLES Consultant in Food Packaging, London DEREK M C DOWELL Head of Supply and Packaging Division Loughry College, Northern Ireland and MARK J. KIRWAN Consultant in Packaging Technology London Blackwell Publishing © 2003 by Blackwell Publishing Ltd Editorial Offices: 9600 Garsington Road, Oxford OX4 2DQ Tel: +44 (0) 1865 776868 108 Cowley Road, Oxford OX4 1JF, UK Tel: +44 (0) 1865 791100 Blackwell Munksgaard, 1 Rosenørns Allè, P.O. Box 227, DK-1502 Copenhagen V, Denmark Tel: +45 77 33 33 33 Blackwell Publishing Asia Pty Ltd, 550 Swanston Street, Carlton South, Victoria 3053, Australia Tel: +61 (0)3 9347 0300 Blackwell Publishing, 10 rue Casimir Delavigne, 75006 Paris, France Tel: +33 1 53 10 33 10 Published in the USA and Canada (only) by CRC Press LLC 2000 Corporate Blvd., N.W. Boca Raton, FL 33431, USA Orders from the USA and Canada (only) to CRC Press LLC USA and Canada only: ISBN 0–8493–9788–X The right of the Author to be identified as the Author of this Work has been asserted in accordance with the Copyright, Designs and Patents Act 1988. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, except as permitted by the UK Copyright, Designs and Patents Act 1988, without the prior permission of the publisher. This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. Reasonable efforts have been made to publish reliable data and information, but the author and the publisher cannot assume responsibility for the validity of all materials or for the consequences of their use. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation, without intent to infringe. First published 2003 Library of Congress Cataloging in Publication Data A catalog record for this title is available from the Library of Congress British Library Cataloguing in Publication Data A catalogue record for this title is available from the British Library ISBN 1–84127–221–3 Originated as Sheffield Academic Press Set in 10.5/12pt Times by Integra Software Services Pvt Ltd, Pondicherry, India Printed and bound in Great Britain, using acid-free paper by MPG Books Ltd, Bodmin, Cornwall For further information on Blackwell Publishing, visit our website: www.blackwellpublishing.com Contents Contributors xv Preface xvii 1 Introduction 1 RICHARD COLES 1.1 Introduction 1 1.2 Packaging developments – an historical perspective 2 1.3 Food supply and the protective role of packaging 4 1.4 The value of packaging to society 7 1.5 Definitions and basic functions of packaging 8 1.6 Packaging strategy 9 1.7 Packaging design and development 9 1.7.1 The packaging design and development framework 12 1.7.1.1 Product needs 13 1.7.1.2 Distribution needs and wants of packaging 13 1.7.1.3 Packaging materials, machinery and production processes 16 1.7.1.4 Consumer needs and wants of packaging 18 1.7.1.5 Multiple food retail market needs and wants 22 1.7.1.6 Environmental performance of packaging 26 1.7.2 Packaging specifications and standards 28 1.8 Conclusion 29 Literature reviewed and sources of information 29 2 Food biodeterioration and methods of preservation 32 GARY S. TUCKER 2.1 Introduction 32 2.2 Agents of food biodeterioration 33 2.2.1 Enzymes 33 2.2.2 Microorganisms 34 2.2.2.1 Bacteria 35 2.2.2.2 Fungi 38 2.2.3 Non-enzymic biodeterioration 40 2.3 Food preservation methods 41 2.3.1 High temperature 41 2.3.1.1 Blanching 42 2.3.1.2 Thermal processing 42 2.3.1.3 Continuous thermal processing (aseptic) 47 2.3.1.4 Pasteurisation 51 2.3.2 Low temperature 52 2.3.2.1 Freezing 52 2.3.2.2 Chilling and cooling 53 vi CONTENTS 2.3.3 Drying and water activity control 54 2.3.4 Chemical preservation 56 2.3.4.1 Curing 57 2.3.4.2 Pickling 58 2.3.4.3 Smoking 58 2.3.5 Fermentation 59 2.3.6 Modifying the atmosphere 60 2.3.7 Other techniques and developments 61 2.3.7.1 High pressure processing 61 2.3.7.2 Ohmic heating 62 2.3.7.3 Irradiation 62 2.3.7.4 Membrane processing 62 2.3.7.5 Microwave processing 63 References 63 3 Packaged product quality and shelf life 65 HELEN BROWN and JAMES WILLIAMS 3.1 Introduction 65 3.2 Factors affecting product quality and shelf life 68 3.3 Chemical/biochemical processes 69 3.3.1 Oxidation 70 3.3.2 Enzyme activity 73 3.4 Microbiological processes 74 3.4.1 Examples where packaging is key to maintaining microbiological shelf life 75 3.5 Physical and physico-chemical processes 77 3.5.1 Physical damage 77 3.5.2 Insect damage 78 3.5.3 Moisture changes 78 3.5.4 Barrier to odour pick-up 81 3.5.5 Flavour scalping 81 3.6 Migration from packaging to foods 81 3.6.1 Migration from plastic packaging 83 3.6.2 Migration from other packaging materials 86 3.6.3 Factors affecting migration from food contact materials 88 3.6.4 Packaging selection to avoid migration and packaging taints 89 3.6.5 Methods for monitoring migration 89 3.7 Conclusion 91 References 91 4 Logistical packaging for food marketing systems 95 DIANA TWEDE and BRUCE HARTE 4.1 Introduction 95 4.2 Functions of logistical packaging 96 4.2.1 Protection 97 4.2.2 Utility/productivity 98 4.2.3 Communication 99 CONTENTS vii 4.3 Logistics activity-specific and integration issues 100 4.3.1 Packaging issues in food processing and retailing 100 4.3.2 Transport issues 101 4.3.3 Warehousing issues 104 4.3.4 Retail customer service issues 106 4.3.5 Waste issues 107 4.3.6 Supply chain integration issues 108 4.4 Distribution performance testing 109 4.4.1 Shock and vibration testing 110 4.4.2 Compression testing 111 4.5 Packaging materials and systems 112 4.5.1 Corrugated fiberboard boxes 112 4.5.2 Shrink bundles 115 4.5.3 Reusable totes 115 4.5.4 Unitization 116 4.6 Conclusion 119 References 119 5 Metal cans 120 BEV PAGE, MIKE EDWARDS and NICK MAY 5.1 Overview of market for metal cans 120 5.2 Container performance requirements 120 5.3 Container designs 121 5.4 Raw materials for can-making 123 5.4.1 Steel 123 5.4.2 Aluminium 124 5.4.3 Recycling of packaging metal 124 5.5 Can-making processes 124 5.5.1 Three-piece welded cans 125 5.5.2 Two-piece single drawn and multiple drawn (DRD) cans 126 5.5.3 Two-piece drawn and wall ironed (DWI) cans 127 5.6 End-making processes 129 5.6.1 Plain food can ends and shells for food/drink easy-open ends 130 5.6.2 Conversion of end shells into easy-open ends 130 5.7 Coatings, film laminates and inks 131 5.8 Processing of food and drinks in metal packages 132 5.8.1 Can reception at the packer 132 5.8.2 Filling and exhausting 133 5.8.3 Seaming 135 5.8.4 Heat processing 137 5.8.5 Post-process can cooling, drying and labelling 138 5.8.6 Container handling 139 5.8.7 Storage and distribution 140 5.9 Shelf life of canned foods 141 5.9.1 Interactions between the can and its contents 142 5.9.2 The role of tin 142 5.9.3 The dissolution of tin from the can surface 144 5.9.4 Tin toxicity 145 viii CONTENTS 5.9.5 Iron 146 5.9.6 Lead 147 5.9.7 Aluminium 147 5.9.8 Lacquers 147 5.10 Internal corrosion 148 5.11 Stress corrosion cracking 148 5.12 Environmental stress cracking corrosion of aluminium alloy beverage can ends 149 5.13 Sulphur staining 149 5.14 External corrosion 149 5.15 Conclusion 150 References and further reading 151 6 Packaging of food in glass containers 152 P.J. GIRLING 6.1 Introduction 152 6.1.1 Definition of glass 152 6.1.2 Brief history 152 6.1.3 Glass packaging 152 6.1.4 Glass containers market sectors for foods and drinks 153 6.1.5 Glass composition 153 6.1.5.1 White flint (clear glass) 153 6.1.5.2 Pale green (half white) 154 6.1.5.3 Dark green 154 6.1.5.4 Amber (brown in various colour densities) 154 6.1.5.5 Blue 154 6.2 Attributes of food packaged in glass containers 154 6.2.1 Glass pack integrity and product compatibility 156 6.2.1.1 Safety 156 6.2.1.2 Product compatibility 156 6.2.2 Consumer acceptability 156 6.3 Glass and glass container manufacture 156 6.3.1 Melting 156 6.3.2 Container forming 157 6.3.3 Design parameters 158 6.3.4 Surface treatments 158 6.3.4.1 Hot end treatment 158 6.3.4.2 Cold end treatment 159 6.3.4.3 Low-cost production tooling 160 6.3.4.4 Container inspection and quality 161 6.4 Closure selection 163 6.4.1 Normal seals 164 6.4.2 Vacuum seals 164 6.4.3 Pressure seals 164 6.5 Thermal processing of glass packaged foods 165 6.6 Plastic sleeving and decorating possibilities 165 6.7 Strength in theory and practice 166 6.8 Glass pack design and specification 167 6.8.1 Concept and bottle design 167 6.9 Packing – due diligence in the use of glass containers 169 CONTENTS ix 6.10 Environmental profile 171 6.10.1 Reuse 171 6.10.2 Recycling 171 6.10.3 Reduction – lightweighting 172 6.11 Glass as a marketing tool 172 References 172 Further reading 173 7 Plastics in food packaging 174 MARK J. KIRWAN and JOHN W. STRAWBRIDGE 7.1 Introduction 174 7.1.1 Definition and background 174 7.1.2 Use of plastics in food packaging 175 7.1.3 Types of plastics used in food packaging 177 7.2 Manufacture of plastics packaging 178 7.2.1 Introduction to the manufacture of plastics packaging 178 7.2.2 Plastic film and sheet for packaging 179 7.2.3 Pack types based on use of plastic films, laminates etc. 183 7.2.4 Rigid plastic packaging 186 7.3 Types of plastic used in packaging 189 7.3.1 Polyethylene 189 7.3.2 Polypropylene (PP) 191 7.3.3 Polyethylene terephthalate (PET or PETE) 194 7.3.4 Polyethylene naphthalene dicarboxylate (PEN) 195 7.3.5 Polycarbonate (PC) 196 7.3.6 Ionomers 196 7.3.7 Ethylene vinyl acetate (EVA) 197 7.3.8 Polyamide (PA) 197 7.3.9 Polyvinyl chloride (PVC) 198 7.3.10 Polyvinylidene chloride (PVdC) 199 7.3.11 Polystyrene (PS) 200 7.3.12 Styrene butadiene (SB) 201 7.3.13 Acrylonitrile butadiene styrene (ABS) 201 7.3.14 Ethylene vinyl alcohol (EVOH) 201 7.3.15 Polymethyl pentene (TPX) 202 7.3.16 High nitrile polymers (HNP) 202 7.3.17 Fluoropolymers 203 7.3.18 Cellulose-based materials 203 7.3.19 Polyvinyl acetate (PVA) 204 7.4 Coating of plastic films – types and properties 205 7.4.1 Introduction to coating 205 7.4.2 Acrylic coatings 205 7.4.3 PVdC coatings 206 7.4.4 PVOH coatings 206 7.4.5 Low-temperature sealing coatings (LTSCs) 206 7.4.6 Metallising with aluminium 207 7.4.7 SiO x coatings 207 7.4.8 DLC (Diamond-like coating) 208 7.4.9 Extrusion coating with PE 208 x CONTENTS 7.5 Secondary conversion techniques 208 7.5.1 Film lamination by adhesive 208 7.5.2 Extrusion lamination 210 7.5.3 Thermal lamination 211 7.6 Printing 211 7.6.1 Introduction to the printing of plastic films 211 7.6.2 Gravure printing 211 7.6.3 Flexographic printing 212 7.6.4 Digital printing 212 7.7 Printing and labelling of rigid plastic containers 212 7.7.1 In-mould labelling 212 7.7.2 Labelling 213 7.7.3 Dry offset printing 213 7.7.4 Silk screen printing 213 7.7.5 Heat transfer printing 213 7.8 Food contact and barrier properties 214 7.8.1 The issues 214 7.8.2 Migration 214 7.8.3 Permeation 215 7.8.4 Changes in flavour 216 7.9 Sealability and closure 217 7.9.1 Introduction to sealability and closure 217 7.9.2 Heat sealing 217 7.9.2.1 Flat jaw sealing 218 7.9.2.2 Crimp jaw conditions 219 7.9.2.3 Impulse sealing 220 7.9.2.4 Hot wheel sealing 220 7.9.2.5 Hot air sealers 221 7.9.2.6 Gas flame sealers 221 7.9.2.7 Induction sealing 221 7.9.2.8 Ultrasonic sealing 221 7.9.3 Cold seal 221 7.9.4 Plastic closures for bottles, jars and tubs 221 7.9.5 Adhesive systems used with plastics 222 7.10 How to choose 222 7.11 Retort pouch 224 7.11.1 Packaging innovation 224 7.11.2 Applications 225 7.11.3 Advantages and disadvantages 226 7.11.4 Production of pouches 227 7.11.5 Filling and sealing 228 7.11.6 Processing 229 7.11.7 Process determination 230 7.11.8 Post retort handling 231 7.11.9 Outer packaging 231 7.11.10 Quality assurance 232 7.11.11 Shelf life 232 7.12 Environmental and waste management issues 233 7.12.1 Environmental benefit 233 7.12.2 Sustainable development 233 7.12.3 Resource minimisation – lightweighting 233 [...]... in the packaging chain about key food packaging technologies and processes To achieve this, the following five principal subject areas are covered: 1 2 3 4 5 food packaging strategy, design and development (chapter 1) food bio-deterioration and methods of preservation (chapter 2) packaged product quality and shelf life (chapter 3) logistical packaging for food marketing systems (chapter 4) packaging. .. storage 8 FOOD PACKAGING TECHNOLOGY The food industry is aware of current public concerns related to packaging which include: • • • • • • • • • 1.5 packaging litter and the volume of packaging waste in municipal waste cost of disposal and recovery of discarded packaging in municipal waste pollution associated with methods of disposal, i.e landfill and incineration ease of opening perception of over -packaging. .. roles of packaging are to contain, protect/preserve food and inform the user Thereby, food waste may be minimised and the health of the consumer safeguarded 6 FOOD PACKAGING TECHNOLOGY Packer co-ops Farms Primary processors Secondary processors Regional distribution centres, wholesalers, cash and carry Retail outlets Consumer Figure 1.1 Food distribution systems (adapted from Paine & Paine, 1983) Packaging. .. costs 1.4 The value of packaging to society The value of food packaging to society has never been greater nor, paradoxically, has packaging attracted so much adverse media publicity and political attention In response, stakeholders in the food industries need to fully appreciate and actively promote the positive contributions that their packaging makes to the quality of life Food packaging is governed... packaging design and development to take account of technological, marketing, legal, logistical and environmental requirements that are continually changing Consequently, it is asserted that those involved in packaging need to develop an 2 FOOD PACKAGING TECHNOLOGY integrated view of the effect on packaging of a wide range of influences, including quality, production, engineering, marketing, food technology. .. in food science and technology, packaging materials and machine technology An overview of some developments in packaging during the past 200 years is given below • 1800–1850s In 1809 in France, Nicolas Appert produced the means of thermally preserving food in hermetically sealed glass jars In 1810, Peter Durand designed the soldered tinplate canister and commercialised the use of heat preserved food. .. Helen Brown Biochemistry Section Manager, Campden & Chorleywood Food Research Association, Chipping Campden, Gloucestershire, GL55 6LD, UK Richard Coles Consultant in Food Packaging, Packaging Consultancy and Training, 20 Albert Reed Gardens, Tovil, Maidstone, Kent ME15 6JY, UK Brian P.F Day Research Section Leader, Food Packaging & Coatings, Food Science Australia, 671 Sneydes Road (Private Bag 16), Werribee,... Professor, School of Packaging, Michigan State University; and Susan Campbell Richard Coles Derek McDowell Mark Kirwan 1 Introduction Richard Coles 1.1 Introduction This chapter provides a context for considering the many types of packaging technology available It includes an historical perspective of some packaging developments over the past 200 years and outlines the value of food packaging to society... Campden & Chorleywood Food Research Association, Chipping Campden, Gloucestershire, GL55 6LD, UK Derek McDowell Head of Supply and Packaging Division, Loughry College, The Food Centre, Cookstown, Co Tyrone, BT80 9AA, Northern Ireland Michael Mullan Head of Food Education and Training Division, Loughry College, The Food Centre, Cookstown, Co Tyrone, BT80 9AA and Department of Food Science, The Queen’s... and its operational/financial impacts, for example, regulations regarding food hygiene, labelling, weights and measures, food contact materials, due diligence etc Environmental requirements or pressures and their impacts, for example, light-weighting to reduce impact of taxes or levies on amount of packaging used 10 FOOD PACKAGING TECHNOLOGY innovation is ahead of its time but may be later adopted when . N. Theobald FOOD PACKAGING TECHNOLOGY Edited by RICHARD COLES Consultant in Food Packaging, London DEREK M C DOWELL Head of Supply and Packaging Division. Turner PET Packaging Technology Edited by D.W. Brooks and G.A. Giles Food Packaging Technology Edited by R. Coles, D. McDowell and M.J. Kirwan Packaging Closures