FDFTEC4008A

Apply Principles of Food Packaging

Contents

Introduction and Unit Details ………….…………………………....4

Element 1: Identify characteristics of packaging suitable for use with food products………………………………………………..………... 8

Packaging of Food - History ………………………………….………..9

Food Grade …….………………………………………………….….…10

Legislation …………………………………………………….…………12

Basic Functions of Packaging …………………………………………15

The Packaging Mix ……………………………………………….…….18

Hurdle Technology and Packaging ……………………………………21
Active Packaging ……………………………………………………….24
Food Packaging Materials …………………………………………….27

Metal containers………………………………………………….27

Glass containers …………………………………………………32

Paper and Cardboard ………………………………………….36

Plastic packaging ……………………………………………….40

Combinations ……………………………………………………43

Element 2:

Apply packaging knowledge in a production environment……47

Packaging Machines……………………………………………………48

Combinations………….………………………………………...48

Food Packaging Categories …………………………………….….….55

Environmental Considerations …………………………………………..57

Packaging Specifications ………………………………………………62

Activity Answers………………………………………………………….65

Appendix A: Standard1.4.3 Articles and Materials in Contact with Food…….. 66

Appendix B: Example of a Packaging Specification ………………………….67

Packaging of Food - History

The first packages used the natural materials available at the time, nature provided shells, gourds, animal skins etc. In time, containers or packaging were made from natural materials such as reeds and grasses (to form baskets and woven bags), clays (to form pottery vases and ceramic amphorae), logs and timber (wooden barrels and crates), bark and animal parts. Processed materials were used to form packages as they were developed: for example, early glass and bronze vessels. An approximate chronology is as follows:

  • > 20,000 years ago – modified natural materials – grass, reeds, skins
  • 8,000 years ago – ceramics, amphorae, - developed in the Middle East
  • 5,000 years ago – wood, barrels, boxes, crates – wooden boxes found in Egyptian tombs
  • 3,500 years ago – mass produced ceramics, pottery – invention of the pottery wheel
  • 2,500 years ago – glass containers, - glass blowing developed by the Phoenicians and Syrians
  • 2,000 years ago – paper and cellulose fibres - not true paper. [1]

The last 1000 years has seen many changes and advances in packaging as a result of social change. The expansion of trade has played a part. The study of old packages is also an important aspect of archaeology.

Packaging advancements in the 19th and 20thcenturies include: iron and tin plated steel used to make cans, paperboardcartons and corrugated fiberboardboxes, ‘Bakelite’ closures on bottles, transparent cellophane overwraps and panels on cartons, increased processing efficiency and improved food safety. As additional materials such as aluminum and several types of plastic were developed, they were incorporated into packages to improve performance and functionality.

Active Packaging

The terms active packaging , intelligent packaging, and smart packaging refer to packaging systems used with foods, pharmaceuticals, and several other types of products. They help extend shelf life, monitor freshness, display information on quality, improve safety, and improve convenience.[2]

The terms are closely related. Active packaging usually means having active functions beyond the inert passive containment and protection of the product.[3] Intelligent and smart packaging usually involve the ability to sense or measure an attribute of the product, the inner atmosphere of the package, or the shipping environment. This information can be communicated to users or can trigger active packaging functions.[4]

Depending on the working definitions, some traditional types of packaging might be considered as ‘’active’’ or ‘’intelligent’’. More often, the terms are used with new technologically [5]

Active packaging is often designed to actively interact with the contents of the package. Thus extra care is often needed for active or smart packaging that are food contact materials.[6]

Food packagers must take extra care with some types of active packaging. For example when the oxygen atmosphere in a package is reduced for extending shelf life, controls for anaerobic bacteria need to be considered. Also when a controlled atmosphere reduces the appearance of food degradation, consumers need to retain a means of determining whether actual degradation is present.

Types of active packaging have been outlined in the following pages:

  • Dispensing systems

Some packages have closures or dispensing systems that actively change the contents from a liquid to an aerosol or foam. Food applications include ‘whipped cream’ in a can (aerating at the time of dispensing) and spray-on vegetable oils.

  • Moisture control

For many years, desiccants have been used to actively control the moisture in a closed package. A desiccant is a hygroscopic substance usually in a porous pouch, is placed inside of a package. They have been used to reduce corrosion of machinery and to extend the shelf life of moisture sensitive foods and drugs.[7]

Second operation seam

the second operation roller then moves inwards and presses the interlocking metal of the body and end of the can together to form the hermetic seal. [8]The five layers in the final seam are then called;

a) End,

b) Body Hook,

c) Cover Hook,

d) Body,

e) Countersink.

All cans require a filling medium within the seam because otherwise the metal-to-metal contact will not maintain a hermetic seal. In most cases, a rubberized compound is placed inside the end curl radius, forming the critical seal between the end and the body.

Seamer setup and quality assurance

Many different parts during the seaming process are critical in ensuring that a can is airtight and vacuum sealed. The dangers of a can that is not hermetically sealed are contamination by foreign objects (including bacteria), or that the can could leak or spoil.

One important part is the seamer setup. This process is usually performed by an experienced technician. Incorrect setups can be non-intuitive. For example, due to the spring-back effect, a seam can appear loose, when in reality it was closed too tight and has opened up like a spring.

Quality control usually involves taking full cans from the line and performing a teardown operation (wrinkle/tightness), mechanical tests (external thickness, seamer length/height and countersink) as well as cutting the seam open with a twin blade saw and measuring with a double seam inspection system. The combination of these measurements will determine the seam's quality.[9]

Packaging Machines

A choice of packaging machinery includes technical capabilities, labor 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 etc.[10]

Packaging machines may be of the following general types:[11]

  • Blister, Skin and Vacuum Packaging Machines
  • Capping, Over-Capping, Lidding, Closing, Seaming and Sealing Machines
  • Cartoning Machines
  • Case and Tray Forming, Packing, Unpacking, Closing and Sealing Machines
  • Check weighing machines
  • Cleaning, Sterilizing, Cooling and Drying Machines
  • Conveying, Accumulating and Related Machines
  • Dispensing, Feeding, Orienting, Placing and Related Machines
  • Filling Machines: handling liquid and powdered products
  • Package Filling and Closing Machines
  • Form, fill and seal machines
  • Inspecting, detecting and check weighing machines
  • Palletizing, De-palletizing, Pallet Unitizing and Related Machines
  • Product Identification: labeling, marking, ink jet etc.
  • Wrapping Machines
  • Converting Machines

Combinations of packaging materials and machines can often be used to improve the shelf-life of foods.

These include:

  1. Vacuum packaging
  2. Modified atmosphere packaging (MAP)
  3. Aseptic packaging

Which are discussed in the next fewpages.

Aseptic processing is commonly used for the packaging of milks, fruit juices, liquid whole eggs, gravies, and tomatoes.

Aseptic containers may range in size from a millilitres to a nearly 30000m3 aseptic tank on an ocean-going ship. Aseptic processing makes worldwide export and import of new, economical and safe food products possible. Bag-In-Box technology is commonly used because it provides strong containers that are light weight and easy to handle prior to being filled. Other common package types are drink boxes and pouches.

The typical aseptic retail packages (example in diagram on right) are a mix of paper (70%), polyethylene (LDPE) (24%), and aluminium (6%), with a tight polyethylene inside layer. Together these materials form a tight seal against microbiological organisms, contaminants, and degradation, eliminating the need for refrigeration.[12]

ACTIVITY ANSWERS

Activity 1
AS 1157.1 - 1998 Describes requirements and general information on the methods of testing materials for resistance to fungal growth which are specified in other Parts of this series.
AS 1048 - 2005 Specifies a numerical system for the designation of types of fibreboard boxes based on groups of category, supplemented by letters and symbols related to dimensions and elements of construction.
AS 2354 -1991 Defines open-top cans and can types, cross-sections, constructions, shapes, special features and capacities. Specifies methods for determining cross-sections and gross lidded capacities and provides tolerances on capacity. This edition, which contains substantial changes in content and presentation from the previous edition, is identical with and has been reproduced from ISO 90-1:1986; additional Australian appendices provide an alternative designation system and a method for determining the height of cans.
Activity 2
Bag in box better shelf presence. Probably most expensive packaging of the three (as 2 packs). More packaging machinery required ie one to put product into bag the other to put bag in box. Protects product well because of two packaging layers. Box is recyclable.
Plastic bag, more easily punctured. Protects product from moisture. Probably not recyclable. Only one filling and sealing machine required. Less packaging into in land-fill.
Paper bag. Cheapest. Won’t protect product if it gets wet. Not recyclable but biodegradable. / Activity 3
Packaging type / Category / Food examples
Plastic trays / Primary / Portion of fish or meat, Chocolates
Plastic Jars / Bottles / Primary / Fruit juices, soft drinks, jam, mayonnaise
Paper Bags / Primary / Flour, sugar
Boxes / Secondary / Box of coca-cola, breakfast cereal
Cans / Primary / Soup, baked beans
Cartons / Primary / Carton of eggs, breakfast cereal (secondary)
Flexible Packaging / Primary / Potato chips, bagged salad
Glass jars / Primary / Jam.
Pallets / Tertiary / A series of boxes on a single pallet used to transport from the manufacturing plant to a distribution centre.
Wrappers / Tertiary / Used to wrap / secure the boxes on the pallet for transport.

Appendix A

STANDARD 1.4.3

ARTICLES AND MATERIALS IN CONTACT WITH FOOD

Purpose

This Standard provides permission for articles and materials to be in contact with food inaccordance with the conditions set out in this Standard. Standard 1.4.1 sets out the maximumlevels for a number of metal and non-metal contaminants and natural toxicants that may bepresent in food as a result of contact with the articles and materials regulated in this Standard.

Table of Provisions

1 Interpretation

2 Permission for articles and materials

Clauses

1Interpretation

In this Standard –

articles and materials means any materials in contact with food, including

packaging material, which may enclose materials such as moisture

absorbers, mould inhibitors, oxygen absorbers, promotional materials,

writing or other graphics.

2 Permission for articles and materials

Articles and materials may be placed in contact with food, provided such articles or materials,

if taken into the mouth, are not –

(a)capable of being swallowed or of obstructing any alimentary or

respiratory passage; and

(b) otherwise likely to cause bodily harm, distress or discomfort.

Editorial note:

This Code does not specify details of materials to be added to or used to produce food

packaging materials or articles in contact with food. It is the responsibility of food

manufacturers and retailers to ensure that their products are safe and that they comply with all relevant legislation.

Standards Australia has developed an Australian Standard for Plastics Materials for Food Contact use, Australian Standard AS2070-1999.\

© Food-Wise Training Solutions

Version 1.1 Page of 70

[1](reducepackaging.com, na)

[2](Wikipedia, 2013)

[3](Wikipedia, 2013) cites (Soroka, 2008)

[4](Wikipedia, 2013)

[5](Wikipedia, 2013)

[6](Wikipedia, 2013)

[7](Wikipedia, 2013)

[8](Board, 1985)

[9](Board, 1985)

[10](Wikipedia, 2012)

[11](Wikipedia, 2012)

[12](Wikipedia Foundation Inc, 2012)