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been an important and constantly evolving phenomenon for several
decades. Marketing communications and graphic design are applied to
the surface of the package and (in many cases) the point of sale display.
6. Security - Packaging can play an important role in reducing the security
risks of shipment. Packages can be made with improved tamper
resistance to deter tampering and also can have tamper-evident features to
help indicate tampering. Packages can be engineered to help reduce the
risks of package pilferage: Some package constructions are more resistant
to pilferage and some have pilfer indicating seals. Packages may include
authentication seals to help indicate that the package and contents are not
counterfeit. Packages also can include anti-theft devices, such as dye-
packs, RFID tags, or electronic article surveillance tags, that can be
activated or detected by devices at exit points and require specialized
tools to deactivate. Using packaging in this way is a means of retail loss
prevention.
7. Convenience - Packages can have features which add convenience in
distribution, handling, stacking, display, sale, opening, reclosing, use, and
reuse.
8. Portion control - Single serving packaging has a precise amount of
contents to control usage. Bulk commodities (such as salt) can be divided
into packages that are a more suitable size for individual households. It
also aids the control of inventory: selling sealed one-litre-bottles of milk,
rather than having people bring their own bottles to fill themselves.
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Food packaging types
1. Primary packaging is the material that first envelops the product and
holds it. This usually is the smallest unit of distribution or use and is the
package which is in direct contact with the contents.
2. Secondary packaging is outside the primary packaging, perhaps used to
group primary packages together.
3. Tertiary packaging is used for bulk handling, warehouse storage and
transport shipping. The most common form is a palletized unit load that
packs tightly into containers.
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Type of Packaging Food example
container type
Aseptic Primary Liquid whole eggs
processing
Plastic trays Primary Portion of fish
Packaging machines
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A choice of packaging machinery includes technical capabilities, labour
requirements, worker safety, maintainability, serviceability, reliability, ability to
integrate into the packaging line, capital cost, floor space, flexibility (change-
over, materials, etc.), energy usage, quality of outgoing packages, qualifications
(for food, pharmaceuticals, etc.), throughput, efficiency, productivity,
ergonomics, etc.
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Packaging materials
Some food products are packed in paper bags or carton boxes. Sealed
paper bags protect sugar and flour, because bags allow them to "breathe" as
much as needed. Products packed in carton boxes (like cereal and crackers)
are usually put in a plastic bag prior to the box, for additional protection.
Also, some carton boxes are wrapped in plastic film to prevent them from
getting dirty and wet (like cigarette packs and tea boxes).
Plastic
The food industry uses plastic widely for food protection in the form of
bags, films, containers and boxes. Plastic bags allow for printing and
perforation and hold food like bread, chips, cereal and many others. Cling
films work for meat protection mostly. Plastic containers contain food like
mustard, yogurt, milk and juices and can have different colours.
Manufacturers employ plastic boxes to pack multiple products (ice cream,
sour cream, meat, vegetables), as do people at home to store food.
Foam
Glass
Glass bottles and containers (jars) are mostly used to protect liquids and
sauces. They break easily, but offer good protection and preservation and are
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recyclable. A paper label made of thin film lists the product information and
attaches to the glass packaging. The first attempt at preserving food for an
extended time occurred in France using glass bottles.
Metal
Manufacturers also pack food and beverages in metal cans, usually made
of aluminum and steel. Metal can have an airtight seal, so it is used to pack
food that needs an extra long preservation time (vegetable, fruit, fish, soup).
Bisphenol-A (BPA), sometimes used for inside coating, protects food from
contamination by the metal can during the heating process to kill bacteria.
Adhesives
Some products (like fruit and vegetables) have a label attacked directly
on them. The label offers information about the producer and usually
contains the internal code of the store, to be easily identified and charged.
The adhesive used for these labels comes directly in contact with the food. It
is safe and does not change the nature, substance or quality of the food.
According to the National Center for Home Food Preservation, one of the
oldest and most common methods of food packaging in homes is the use of
home canning. Fruits and vegetables are placed in glass jars and sealed in the
jars by heating the jars and then placing a rubber stopped jar top on the jar.
Historically, home canning was one of the first methods that were used to
store foods in large quantities, particularly in rural areas where farms were
abundant. Some of the concerns with this type of food packaging include the
cleanliness of the jars when food is placed in them and that the fruits and
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vegetables are thoroughly cooked before canning. The seals also need to be
airtight to prevent the growth of botulism.
2. Freezing Food
Canned Foods
Foil Packaging
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One of the innovative methods of commercial food packaging is foil
wrapping. Foil wraps are often pouches that are filled and then the bottom
and top of the pouch is sealed with a heat seal similar to those used with
commercial frozen packaging. According to Free Patents Online, foil
packaging allows the foods to be sealed in the package without losing any
residual moisture that may still be in the food. The best foods to package in
this manner are usually dried fruits, baked goods or grain products.
Vacuum Packed
Nano Technology
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In praise of packaging
• Packaging protects – ten times more energy goes into the production of
the food and goods it contains than into the packaging itself.
• Packaging makes modern lifestyles possible.
• When you buy an undamaged carton or tin in a shop, remember that the
boxes and crates that carried them securely on Lorries and in warehouses
are as vital as the cartons and tins themselves in getting the product to
you.
• The packaging industry continues to rise to the challenge of being
responsible and innovative – glass containers are on average 30% lighter
than in 1980, the weight of cans has fallen by a similar figure in the last
twenty years and carrier bags are 45% lighter than in 1990.
• The industry has driven innovations such as anti-litter retained ring-pulls
and readily open-able / re-sealable cartons.
• Industry continues to make packaging easier to use and more convenient
for consumers, while providing better protection using less material and
so generating less waste.
• As well as protecting and preserving goods, packaging carries vital
information on ingredients, keeps hazardous products away from
children, and ensures goods are safe (where packaging cannot be opened
without showing evidence of tampering).
• Companies that produce and use packaging make a positive contribution
to society both directly and through membership of INCPEN. For nearly
20 years, INCPEN has been running schools programmes. It supports the
Keep Britain Tidy Campaign, and lends its backing to local authority
recycling campaigns.
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• Many packaging innovations are a direct response to consumer demand:
• The growth in single-person households means demand for smaller, more
convenient portions has grown.
• Similarly, as more women now work outside the home than 20 years ago,
demand for food that is easier and quicker to prepare and cook, has risen.
• Convenience culture – half of us now claim to eat ‘on-the go’ with no
prior thought given as to where our next meal is coming from.
• Under the European Packaging Directive, the industry has to meet strict
requirements to prevent the use of excessive packaging.
• The INCPEN Responsible Packaging Code of Practice is widely used.
Trade associations covering over 85% of businesses involved in the
supply chain for packaged goods recommend the Code to their member
companies. Trading Standards Officers up and down the country use the
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Code in their everyday compliance work with small and mid-sized
businesses.
Common Myths
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pigmented red meats, such as venison and wild boar, require higher
concentrations of O2.
Aerobic spoilage bacteria, such as Pseudomonas species, normally
constitute the major flora on red meats. Since these bacteria are inhibited by
CO2, it is possible to achieve both red color stability and microbial inhibition by
using gas mixtures containing 20–30% CO2 and 70–80% O2. These mixtures
can extend the chilled shelf life of red meats from 2–4 days to 5–8 days. A gas/
product ratio of 2:1 is recommended. Red meats provide an ideal medium for
the growth of a wide range of spoilage and food poisoning microorganisms
including E. coli. Because raw red meats are cooked before consumption, the
risk of food poisoning can be greatly reduced by proper cooking. The
maintenance of recommended chilled temperatures and good hygiene and
handling practices throughout the butchery, MAP, distribution and retailing
chain is of critical importance in ensuring both the safety and extended shelf life
of red meat products.
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Raw poultry
Microbial growth, particularly growth of Pseudomonas and Achromobacter
species, is the major factor limiting the shelf life of raw poultry. These
Gramnegative aerobic spoilage bacteria are effectively inhibited by CO2.
Consequently, the inclusion of CO2 in MAP at a concentration in excess of 20%
can significantly extend the shelf life of raw poultry products. CO2
concentrations higher than 35% in the gas mixture of retail packs are not
recommended because of the risks of pack collapse and excessive drip.
Nitrogen is used as an inert filler gas, and a gas/product ratio of 2:1 is
recommended. Since pack collapse is not a problem for bulk MAP master
packs, gas atmospheres of 100% CO2 are frequently used.
Since poultry meat provides a good medium for the growth of
pathogenic microorganisms, including some that are not inhibited by CO2, it is
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critical that recommended chilled temperatures and good hygiene and handling
practices throughout the supply chain are adhered to and that products are
properly cooked prior to consumption.
The principal spoilage mechanisms that limit the shelf life of cooked, cured and
processed meat products are microbial growth, color change and oxidative
rancidity. For cooked meat products, the heating process should kill vegetative
bacterial cells, inactivate degradative enzymes and fix the colour. Consequently,
spoilage of cooked meat products is primarily due to post-process
contamination by microorganisms, as a result of poor hygiene and handling
practices. The colour of cooked meats is susceptible to oxidation, and it is
important to have only low levels of residual O2 in packs. MAP using CO2/N2
mixes (gas compositions of 25–50% CO2 and 50–75% N2) along with a
gas/product ratio of 2:1 is widely used to maximise the shelf life and inhibit the
development of oxidative off-flavours and rancidity. Raw cured meat products,
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e.g. bacon, owe their characteristic pink reddish colour to nitrosylmyoglobin.
This pigment is more stable than oxymyoglobin and is unaffected by high levels
of CO2 but is slowly converted to brown metmyoglobin in air.
During cooking, nitrosylmyoglobin is converted to pink denatured
nitrosohemochrome pigments that are unstable in air. Processed meat products
such as sausages, frankfurters and beef burgers generally contain sodium
metabisulphite, which is an effective preservative against a wide range of
spoilage microorganisms and pathogens. Cooked, cured and processed meat
products containing high levels of unsaturated fat are liable to be spoiled by
oxidative rancidity, but MAP with CO2/N2 mixtures is effective at inhibiting this
undesirable reaction. Potential food poisoning hazards are primarily due to
microbial contamination or growth resulting from post-cooking, curing or
processing contamination.
These can be minimised by using recommended chilled temperatures, good
hygiene and handling practices. The low water activity (aw) and addition of
nitrite in cooked, cured and processed meat products inhibit the growth of
many food poisoning bacteria, particularly C. botulinum. This inhibition may be
compromised in products formulated with lower concentrations of chemical
preservatives than those used in traditional foods.
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some applications only relatively small increases in safe shelf life have been
reported. Spoilage of fish results in the production of low molecular weight
volatile compounds, therefore, packaging technologists need to consider the
odor barrier properties of packaging films and select appropriate high-barrier
materials for packaging strong flavored fresh, smoked and brined fish and fish
products. Spoilage of fish and shellfish results from changes caused by three
major mechanisms: (i) the breakdown of tissue by the fish’s own enzymes
(autolysis of cells), (ii) growth of microorganisms, and (iii) oxidative reactions.
MAP can be used to control mechanisms (ii) and (iii) but has no direct effect on
autolysis. Because autolysis is the major cause of spoilage of fish and shellfish
stored at temperatures close to 0°C compared with the activities of bacteria, this
may explain the reduction in benefits achieved from MAP of fish compared to
other flesh products. MAP, while potentially inhibiting oxidative reactions, may
be more effective at inhibiting microbial growth.
Oxidative reactions are much more important as shelf life limiters in fish
compared with other flesh meat, because seafood has a higher content of
polyunsaturated lipids. Storage temperature has a major effect on fat oxidation
that occurs even at frozen temperatures. Note that salt addition can accelerate
oxidative processes. Generally, the major spoilage bacteria found on processed
fish are aerobes including Pseudomonas, Moraxella, Acinetobacter,
Flavobacterium and Cytophaga species. There are several microorganisms that
are of particular importance when dealing with MAP fish products, these
include C. botulinum.
Use of CO2 can effectively inhibit the growth of some of these species.
The aerobic spoilage organisms tend to be replaced by slower growing, and less
odor producing, bacteria, particularly lactic acid bacteria such as lactobacilli,
during storage. Because fish and shellfish contain much lower concentrations of
myoglobin, the oxidation status of this pigment is less important than that in
other meats. Consequently, there is potential to use higher levels of CO2, e.g.
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40%. Because of the high moisture content and the lipid content of some
species, N2 is used to prevent pack collapse.
One of the concerns about MAP of fish is that removal of O2 and its
replacement by either N2 or N2/CO2 results in anaerobic conditions that are
conducive to the growth of protease-negative strains of C. botulinum. Because
these bacteria can grow at temperatures as low as 3°C and do not significantly
alter the sensory properties of the fish, there is the potential for food poisoning
that can lead to fatalities. While there is no evidence that CO2 promotes the
growth of psychotropic strains of C. botulinum, there are, as discussed
previously, some concerns about CO2 promoting the germination of spores of
this organism. Considerable research has been undertaken to assess, and to
control, the risks associated with the growth of C. botulinum in MAP of fish and
other products.
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Respiration is affected by the intrinsic properties of fresh produce as well as
various extrinsic factors, including ambient temperature. It is accepted that the
potential shelf life of packed produce is inversely proportional to respiration
rate. Respiration rate increases by a factor of 3–4 for every 10°C increase in
temperature. Hence, the goal of MAP for fruits and vegetables is to reduce
respiration to extend shelf life while maintaining quality. Respiration can be
reduced by lowering the temperature, lowering the O2 concentration, increasing
the CO2 concentration and by the combined use of O2 depletion and CO2
enhancement of pack atmospheres. If the O2 concentration is reduced beyond a
critical concentration, which is dependent on the species and cultivar, then
anaerobic respiration will be initiated. The products of anaerobic respiration
include ethanol, acetaldehyde and organic acids. Anaerobic respiration, or
anaerobiosis, is usually associated with undesirable odours and flavours and a
marked deterioration in product quality. While increasing the CO2 concentration
will also inhibit respiration, high concentrations may cause damage in some
species and cultivars.
Dairy products
MAP has the potential to increase the shelf life of a number of dairy products.
These include fat-filled milk powders, cheeses and fat spreads. In general, these
products spoil due to the development of oxidative rancidity in the case of
powders and/or the growth of microorganisms, particularly yeasts and moulds,
in the case of cheese.
Whole milk powder is particularly susceptible to the development of off
flavours due to fat oxidation. Commercially, the air is removed under vacuum
and replaced with 100% N2 or N2/CO2 mixes and the powder is hermetically
sealed in metal cans. Due to the spray drying process, air tends to be absorbed
inside the powder particles and will diffuse into the container over a period of
ten days or so. This typically will raise the residual headspace O2 content to 1–
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5% or higher (Evans, Mullan and Pearce, unpublished results). Because some
markets require product with low levels of residual O2 (<1%), some
manufacturers re-pack the cans after ten days of storage. Obviously, this is both
expensive and inconvenient. We have found that use of N2/CO2 mixes (Evans,
Mullan and Pearce, unpublished results) can be helpful. Use of O2 scavenging
may also be useful. Refer to Chapter 9 for a more detailed discussion of O2
scavengers. English territorial cheeses, e.g. Cheddar, have traditionally been
vacuum packed. Increasingly MAP is being used with high CO2 concentration
gas mixes. This has the advantage of obtaining a low residual O2 content and a
tight pack due to the CO2 going into solution. It is important to balance this
process using the correct N2 level in the gas mix so as to avoid excessive
pressure being put on the pack
RETAIL PACKAGING:
It refers to the containers and packaging for retail goods which are ready to be
displayed instantly or with little set up for retail consumption by consumers.
Retail Ready Packaging is a retail industry term used by both retail stores and
retail goods producers. An example of retail ready packaging is the paperboard
cartons that hold several packs of gum which are placed near cash
registers at supermarkets and retail stores.
Flexible Packaging
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Flexible retail packaging uses a variety of materials, including plastics and
metals, to house products; this is a type of packaging that usually loses its shape
once opened. Food products, especially fruits and vegetables, are placed in
flexible retail packaging such as plastic bags, air-tight sacks and containers and
other enclosures. Flexible packaging also contains a specific way of sealing the
product which, when opened, is often difficult to re-seal or close. Other flexible
types include re-sealable packaging such as that used to package dried fruits and
some frozen foods.
Rigid Packaging
Rigid retail packaging methods consist of a solid body in some form, such as a
cardboard box, and a closing element. Cereal boxes, plastic gallon milk and
juice containers, beverage containers such as soda pop bottles, household
cleaners, and other consumer products like toys and electronics have rigid retail
packaging. Plastic containers and trays, as well as plastic cups, are examples of
rigid packaging.
Custom Packaging
Custom retail packaging is used for irregularly-shaped products that don't fit the
traditional rigid or flexible types of packaging. Manufacturers and retailers
choose custom packaging designs for other reasons, too, such as to create brand
awareness and recognition; a product that has a uniquely-designed and attractive
custom package is easily recognizable to consumers. Custom retail packaging
that includes specific protective materials may also be used if a manufacturer is
trying to extend the shelf life of a product or protect it from breakage.
Recycled Packaging
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Many retailers use recyclable materials to package retail products. Instead of
using mass-produced new cardboard, some companies package retail products
in recycled plastics, glass and paper from discarded consumer product packages.
Leftover raw materials can even be broken down and recycled to create retail
packaging. Recycled materials in many cases can be used to produce a good
portion of the types of packaging that the manufacturer needs.This is also a
money-saving technique that companies use instead of relying on shipments of
new product retail packages and materials.
Easy to Recognise
Easy to Open
Easy to Shelf
Easy to Shop
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Easy to Dispose
UNIT PACKAGING:
Packaging that contains single unit dosages or units.
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How Intelligent Packaging Works
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Figure 1. Colour indicating tags attached as a small adhesive label to the
outside of packaging film can be used to monitor the freshness of perishable
food products such as seafood.
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of a self-chilling beverage can in conjunction with Tempra Technologies and
development is nearing completion. The Crown/Tempra technology uses the
latent heat of evaporating water to produce the cooling effect. The water is
bound in a gel layer coating a separate container within the beverage can, and is
in close thermal contact with the beverage. The consumer twists the base of the
can to open a valve, exposing the water to the desiccant held in a separate,
evacuated external chamber This initiates evaporation of the water at room
temperature. The unit has been designed to meet a target specification set by
major beverage customers cooling 300ml of beverage in a 355ml can by 16.7°C
in three minutes. This performance level has been achieved in laboratory tests
and working samples are currently undergoing focus group trials with
customers.
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