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Packaging/Brody, Inc.
STATE OF THE ART OFACTIVE/INTELLIGENT FOOD PACKAGING
Aaron L. BrodyPackaging/Brody, Inc.P O Box 956187Duluth, Georgia 30095 USA
Institute of Food Technologists Food Packaging Summit7-9 May 2006
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Packaging/Brody, Inc.
OVERVIEWDefinitionsActive packaging
Moisture OxygenEthyleneMicrobiological
Intelligent packagingTemperatureLocationMicrobiological status
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Packaging/Brody, Inc.
CONCLUSIONSDevelopmental
Many good laboratory resultsRelatively little commercial application
CostAccuracyAdverse secondary effects
Commercialization has been relatively slowPurge, moisture controlOxygen removalTime temperature integratorsLocation/identification
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Packaging/Brody, Inc.
CONCLUSIONS
Potential for futureCombine moisture control with antimicrobialsInventory monitoringInteraction of package with home and food service appliancesTemperature dataReduced oxygen to prolong biochemical shelf lifeStimulates enhanced barrier packaging
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Packaging/Brody, Inc.
NEEDS FOR FUTURE
Improved communication among academic, industry and others involvedA single independent objective resource to objectively evaluate developing technologiesCloser targeting of longer term commercial needs
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Packaging/Brody, Inc.
ACTIVE PACKAGING
Active packaging is sensing followed by the overt manipulation of the environment in the package to better retain food content microbiological or biochmemical quality
Purge absorbersMicrowave susceptorsOxygen scavengersOxygen additionsMoisture absorbers or emittersOdor absorbers or emittersAnti or counter microbialsAnd other controllers of active variables
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Packaging/Brody, Inc.
INTELLIGENT PACKAGING
An intelligent package senses change and communicates that information to can provide benefits (such as more convenience, better safety, or higher quality) if used.Examples
Time-temperature, etc. indicators can imply/signal user the quality of the packaged productBiosensor in theory can inform the user of the presence or growth of microorganisms, spoilage and even pathogenicityin the packageBar or PDF code can help to provide better reheating and/or cookingRipenessNutritional attributesGas concentrations in modified atmosphere packages
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Packaging/Brody, Inc.
ACTIVE PACKAGING
Moisture controlDesiccants for dry food
Internal Multiphase plastic for both pre and post opening activity
Humidity controllersFor high moisture foods, e.g. cut fruit, vegetablesTo retard moisture lossTo retard excess moisture in headspace and interstices where microorganisms can grow
Integrate moisture control with other active packaging functionalities
e.g., antimicrobials, pH controllers, oxygen removers
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Packaging/Brody, Inc.
Active PackagingPurge absorption
To remove liquid squeezed or leaking from fresh products such as meat, poultry and fruit
UnsightlyMedium for microbiological growthOdor generatingLeaks into consumer environment: source of major consumer complaints
Controlled by pulp or polymers
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Packaging/Brody, Inc.
Active Packaging
Purge absorption Can be enhanced by active additives
AntimicrobialspH reducers Carbon dioxide generators
The largest commercial application of active packaging although not always classified as active packaging
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Packaging/Brody, Inc.
Purge Absorbers- Pulp
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Packaging/Brody, Inc.
Maxwell-Chase Polymeric Purge Absorbers
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Packaging/Brody, Inc.
CONTROLLED PURGE FRUIT PACKAGE
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Packaging/Brody, Inc.
ACTIVE PACKAGING
Moisture controlDesiccants for dry food
Internal adjunctsPorous sachets or perforated plastic cartridgesMostly for pharmaceuticals for long term preservation
Incorporate into plastic packagePlastic is partial moisture barrierMultiphase plastic for both pre and post opening activity
Largely for multi-use drugs/testing devices
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Packaging/Brody, Inc.
MINIPAX® SORBENT PACKETS
MiniPax® Sorbent silica gel packets are formed of heat sealed Tyvek®spunbonded polyolefin.
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Packaging/Brody, Inc.
Active PackagingHumidity controllers
For high moisture foods, e.g. cut fruit, vegetables To control in-package relative humidity To retard moisture lossTo retard excess moisture in headspace and interstices where microorganisms can growInfrequently used
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Packaging/Brody, Inc.
ACTIVE PACKAGING: OXYGEN REMOVERS
Oxygen scavengersTo remove oxygen and retard oxidative reactionsAs sachets in headspace
JerkyPepperoniPastaBakery goods
As labels – with less quantity of active componentIncorporated into package materials
Plastic beer bottlesPastaRetortable pouches and trays
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Packaging/Brody, Inc.
OXYGEN SCAVENGERS
Mitsubishi Gas Chemical Ageless; MultisorbTechnologies, etc., oxygen absorbers
Ferrous oxide in Tyvek spun bonded polyolefin sachetsWater vapor activated“Rusted” to ferric oxide by reacting with environmental oxygenIn excellent oxygen barrier primary packages, removes residual and entering oxygenUsed widely in Japan for dry meats, bakery goods, nutsNot overly successful in North America or Europe
Ascorbic acid, sulfites, photosensitive dyes, unsaturated hydrocarbons and ligandsOxbar™ cobalt catalyzed nylon MXD6 imbedded in the plastic structure
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Packaging/Brody, Inc.
Mitsubishi Ageless® Oxygen Absorber
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Packaging/Brody, Inc.
MULTISORB OXYGEN ABSORBERS
FreshPax™ Packets and Strips are designed to absorb oxygen inside sealed packaging to less than 0.01%
FreshMax™ Label is designed for adhesion with high value foods where oxygen absorption requirements are at levels below 50 cc.
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Packaging/Brody, Inc.
Oxygen Scavenger Label
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Packaging/Brody, Inc.
OXYGEN SCAVENGERSChevron Phillips OSP oxygen scavenging polymer
EMCM:BenzoacrylatesNo resulting odor from oxidation reactionBasis for current Cryovac OS2000
Incorporated in filmLidding on Barilla moist pasta, processed meat trays
Ultraviolet energy triggeredClaimed capable of reducing oxygen to 4-10 ppmDeparting the business
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Packaging/Brody, Inc.
Oxygen ScavengersStarshield
Crown Cork and SealConstarPET bottles
Multilayer preformsPET/5 % Oxbar/PETOxbar=MXD6 nylon + Cobalt catalystFor beer and juice
Continental PET TechnologiesMXD6 nylon + Cobalt catalyst
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Packaging/Brody, Inc.
PET BEER BOTTLE WITH OXYGEN SCAVENGERS
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Packaging/Brody, Inc.
Oxygen Scavengers
Amcor PETBind-OxAmguard multilayer preformsPET bottlesBeer and juices
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Packaging/Brody, Inc.
Oxygen Scavengers
BP ChemicalsAmosorb ferrous iron Licensed by Color MatrixPET bottles
Monolayer or multilayer
BericapOne piece bottle closure with multilayer oxygen sulfite scavenger
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Packaging/Brody, Inc.
Oxygen Scavengers
O-OxSnappy AppleClaims 5X oxygen removal rateFerrous iron based concentrateFor plastic beer bottles
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Packaging/Brody, Inc.
Oxygen Scavengers
HoneywellBlend scavenger with nanocomposite to enhance barrierAegis Ox – OXCERemoves oxygenRestricts oxygen AND carbon dioxidePlastic beer bottle
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Packaging/Brody, Inc.
Oxygen ScavengersActituf
Monolayer PETLiquid activated+passive barrierPlastic beer bottles
Unsaturated hydrocarbon butadiene: produces off odorsGlucose oxidase
NutraceptsCan simultaneously produce carbon dioxide as an antimicrobial
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Packaging/Brody, Inc.
Oxygen Scavengers
HuhtamakiCombine scavenger with EVOHGrey color
Hsaio Sung – TaiwanO-buster ferrous ironFor consumer useSachets
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Packaging/Brody, Inc.
Oxygen Scavengers
CibaShelfplusFerrous iron basedNow combining with EVAL’s EVOH
Bebo Plastik
For polypropylene and even polyethyleneSemi-rigid containersRetort trays
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Packaging/Brody, Inc.
Oxygen Scavengers
Mitsui – JapanWonderkeepIntegrate with RFID
WipakCombithermMultilayer of scavenger and EVOH
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Packaging/Brody, Inc.
ADD OXYGEN
To retard respiratory anaerobiosis Responsive to temperatureIntellipack™ increases/controls package gas permeability to permit entry of air as a function of temperature
To retard respiratory anaerobic pathogenic microbiological growthTo retard respiration in cut lettuce: > 70 % oxygen
Oxygen generating chemicals in package structureFrom Atco, France
To “control” oxymyoglobin red color in fresh meatBut does the oxygen reach into pockets and interstices?
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Packaging/Brody, Inc.
CARBON DIOXIDE CONTROL
Add carbon dioxide from package structure to carbonated beverages to compensate for losses due to insufficient gas barrierAdd carbon dioxide to increase internal environmental gas to suppress microbiological growth
A sub-set of modified atmosphere packagingFrom plastic package structureFrom moisture-activated chemicals in sachets, absorbent pads, etc.
Remove excess carbon dioxide from fast respiring produce using very high gas permeability plastic
Asparagus
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Packaging/Brody, Inc.
OTHER ACTIVE PACKAGING CONCEPTS
Odor scavengersRemove trivial amounts of odor such as from initial lipid or plastic oxidation from package headspaceActivated carbon
Most effectiveBest when on interior surface
Multiphase plastic CyclodextrinsMolecular sievesAlpha tocopherol (vitamin E)Polyethylene imide aldehyde scavengers
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Packaging/Brody, Inc.
ODOR CONTROLAroma additions
Enhance the product sensory attributesMay be incorporated into plastic
Continuous emissionActivated by physical activity
May be on plastic surfaceMay be independent device such as an impregnated straw or closure Activate on opening
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Packaging/Brody, Inc.
ETHYLENE ABSORBERSEthylene is respiratory gas from fresh produce – also from engine exhaust fumesExcess ethylene accelerates respirationRemove ethylene extend shelf life
Physical absorptionOn active surfaces
Activated carbonZeolite
Chemical removal with permanganateEffective and commercial – in bulk distribution
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Packaging/Brody, Inc.
ACTIVE PACKAGING: ANTI-MICROBIAL
Antimicrobial or countermicrobialObjective is to reduce the rate of growth of spoilage and/or pathogenic microorganisms in the contained food and thus extend the shelf lifeTechnologies under study
Silver ionAllyl isothiocyanateChlorine dioxideAntibioticsOrganic acidsEthyl alcoholNatural spices and essential oils
None commercial for food packaging in United States
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Packaging/Brody, Inc.
ANTI-MICROBIALS
Silver saltsDirect contactSlow migrationReact with organics preferentiallyBroad spectrum effectivenessSurface effects primarilyFew, if any, secondary effects
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Packaging/Brody, Inc.
ANTI-MICROBIALS
Ethyl alcoholAdsorbed on silica or zeoliteEmitted by evaporationSomewhat effectiveSecondary odorRegulatory restrictionsConsumer concernUsed in past for soft bakery goods
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Packaging/Brody, Inc.
ANTI-MICROBIALSChlorine dioxide
Widely publicizedPrecursor in package structure
Reacts with water to produce ClO2
ClO2 is vapor and can permeate productBroadly effective against microorganisms, but weakAdverse secondary effects
Meat color darkeningGreen vegetable bleaching
Principal advocate no longer in business
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Packaging/Brody, Inc.
ANTI-MICROBIALSAllyl Isothiocyanate (AIT)
Active component in wasabi, horseradish, mustardBroad spectrum anti-microbial, antimycoticStrong secondary odor effects
Possible amelioration by vanillinOther essential oils
Clove, carvacrol, thymol, cinnamon, etc.Diacetyl
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Packaging/Brody, Inc.
AND MORE ACTIVITY FOR THE FUTURE
Heat the contents on demand: self heatingChill the contents on demand: self chillingBoth of the above have been commercial
At a costMoneySpace
Sense the temperature and control the content temperature
To compensate for the deficient distribution system (cold chain)
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Packaging/Brody, Inc.
Self Heating Packaging
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Packaging/Brody, Inc.
Self Heating PackagingCalcium oxide + water exothermic reaction
Magnesium oxide + water exothermic reaction
For coffee) cansPolypropylene barrierWolfgang PuckRetorted6-8 minute heating time after activation
Military rationsOn the go mealsHeating device occupies large space volume
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Packaging/Brody, Inc.
Self Heating Coffee Can
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Packaging/Brody, Inc.
Self-Cooling Packaging
Evaporation of external compound removes heat from contents
Freon – not environmentally soundCarbon dioxide – pressurizedWater evaporated and adsorbed on surfaces –
Functional and commercial for beer kegsReversible
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Packaging/Brody, Inc.
ACTIVE PACKAGING: MICROWAVE BROWNING
Packaging devices to achieve surface browning and crusting in rapid heating microwave oven environmentLimited technical abilityLimited market success
Bakery goodsFinger foodsPopcorn popping adjunct
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Packaging/Brody, Inc.
Susceptors
Susceptor materials consisting of a metallized coating at optical density of around 0.25.
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Packaging/Brody, Inc.
SHIELDING WITH REFLECTORS
Without Shielding(Over-exposure of the
edges)
With Shielding(Reflector shields the edges
and redirect the power to the center)
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Packaging/Brody, Inc.
MICROWAVEABLE PIZZA WITH
SUSCEPTOR, SHIELDING AND FOCUSING
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Packaging/Brody, Inc.
INTELLIGENT PACKAGING
If you can measure a variable, you can probably control it Location Indicators
The current classical application for Radio Frequency Indentification (RFID)For distribution inventory control
SiteTimeQuantity
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Packaging/Brody, Inc.
Intelligent Packaging
TechnologiesOxygen scavenging with integrated monitoringEthylene scavenging with integrated monitoringMicrowave readyThermochromic inksBarrier plus integrated monitoringSelf-heating/cooling plus monitoring
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Packaging/Brody, Inc.
INTELLIGENT PACKAGING: TEMPERATURE EXPERIENCE
Temperature indicatorsTime temperature integrators
Commercial and in useSignificance of TTI data re: shelf life, quality, etc.Required for military rations and some pharmaceuticalsCost
Maximum temperature, i.e., threshhold, indicatorsCommercial and in useMostly for heatingSome for refrigerated, frozen foods, ice cream
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Packaging/Brody, Inc.
CURRENT COMMERCIAL TTI PRODUCTS
LifeLines Fresh-CheckBased on polymerization reaction
3M Monitor MarkBased on dye diffusion
Vitsab® TTI (Cox Technologies)Based on enzymatic lipase color change
.
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Packaging/Brody, Inc.
Lifelines' Fresh Check Indicators
Fresh Check indicator is printed in a bull's-eye configuration
Lifelines’ Fresh Check indicators are color-changing, self-adhesive labels which respond to cumulative exposure to temperature. The indicator center irreversibly darkens, faster at higher temperatures. Price ranges from US $0.025 – 0.035 each.
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Packaging/Brody, Inc.
3M MONITOR MARK TEMPERATURE LIMIT INDICATORS
Activation strip
Upon exposure to temperatures above the threshold, the activatedindicator's window irreversibly turns blue.
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Packaging/Brody, Inc.
3M MONITORMARK TTI
The MonitorMark time temperature indicator contains a porous wick indicator track strip, one end of which is positioned over a reservoir pad containing a blue dyed chemical with a desired melt point.
The diffusion of a dye is the indicator
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Packaging/Brody, Inc.
Vitsab Single Dot Label (TTI)
Single dot Vitsab’s CheckPoint™ brand labels: (1) distribution temperature monitoring of cartons or pallets of product, and (2) distribution or consumer package unit.
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Packaging/Brody, Inc.
INTELLIGENT PACKAGING
Food preservationSenses the age, quality level of the food and signalsSignals on exterior of food storage areaHas been demonstrated in laboratoryUsually a secondary measurement
Measures time/temperatureSignals based on history
Publicized as mechanism to incorporate tighter temperature controls into distribution channels
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Packaging/Brody, Inc.
SHELF LIFE SENSING
DevelopmentalRFID remote sensorChipless with internal paper batterySmart active label – SAL – with chipCan be added to logistic sensorSense time temperatureSend signal to readerDisplay time temperature record or integral
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Packaging/Brody, Inc.
Food: Microbiological Growth/Spoilage Indicators
Rapid microbiological indicators do not exist in real commercial world Rapid microbiological spoilage sensors do not exist in commerceRapid microbiological pathogen indicators do not exist in commercial worldConsumer smell, observations and judgment are today the best signals of food spoilage or hazard.
Do instrumental, etc. sensors truly reflect spoilage?
Alternative is tedious laboratory analysis
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Packaging/Brody, Inc.
BIOSENSORS
Biomolecular recognitionAntigen-antibodyPhage capture
SporesBacteriaHigher capture rate than antibodies
Both highly specific
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Packaging/Brody, Inc.
BIOSENSORS
Sensor platformsAcoustic wave
Thickness shear quartz resonatorMicrocantilevers
Laser measuredFlexure plate wave devices
Piezoelectric actuatedPiezoelectric polymer devicesMicroelectric-mechanical-magnetostrictive devices
All require on-board power and connection to RFID
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Packaging/Brody, Inc.
BIOSENSORS
Sensor platformsSurface plasmonMagnetostrictive
Integrated with antibody/phage layerOscillationProduces magnetic field signal
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Packaging/Brody, Inc.
Food: Microbiological Growth/Spoilage Indicators
The former Cox TechnologiesRespond to amine and sulfide volatiles from spoilageUsed to colorimetrically signal seafood microbiological spoilageCommercial
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Packaging/Brody, Inc.
Ripeness Sensors
ripeSense LabelReportedly senses aromatics emitted from ripening fruitSignals ripeness by label visual cue/color change – for fruit that does not change color during ripening
PearsMelonsAvocados
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Packaging/Brody, Inc.
UPC (Universal Product Code) Bar Codes
Manufacturer ID(6 digits)
Item Number(5 digits)
UPC of 12 oz can of Coke
Check Digit(1 digits)
The first digit of the manufacturer is called
the number system character: 0 for standard UPC
number, 2 for random weight items (fruits,
vegetables, meat), 3 for pharmaceuticals,
etc.
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Packaging/Brody, Inc.
PDF 417 Symbol (2-Dimensional)
PDF417 is a two-dimensional symbolIt can carry up to 1.1 kilobytes of machine-readable data in a space no larger than a standard bar code. A PDF scanner is required to require PDF symbols. Ordinary bar code scanners would not work. PDF stands for “Portable Data File”
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Packaging/Brody, Inc.
INVENTORY “CONTROL”
Determine the presence. absence or impending decrease in quantity of a packaged food in pantry/refrigerator inventorySignal consumer that the pantry is empty or near empty
Alert consumer to restockSignal retail grocer that Mr./Mrs./Ms. X is low on product and to remind her/him by telephone, e-mail or by sending replenishment stockSignal distribution center that the stock is low or outIndicator on package as empty package is discardedActive signaller – or messenger to grocer - on package as empty package is discarded
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Packaging/Brody, Inc.
INTELLIGENT PACKAGING FOR THE HOME/FOOD SERVICE OPERATOR
Inventory controlTracks inventory of food in homeSenses when empty package is discardedPlaces tentative order with retailer /delivery service
Confirm by consumerComplemented by interaction with retailer
Special requestsChange order schedule
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Packaging/Brody, Inc.
INTELLIGENT PACKAGING FOR THE HOME/FOOD SERVICE OPERATOR
Provides product informationRecipe specific to consumer’s “kitchen” equipment Nutritional characteristics
Beyond reading the labelIntegrates individual consumer’s nutritional needsTakes into account the age and time/temperature experienceOvertly signals the individual consumer as to dietary value
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Packaging/Brody, Inc.
INTELLIGENT PACKAGING FOR THE RETAILER
Automatic self-check outNo direct reading by scannerRDID or equivalent
Printed on packageRead remotely as consumer moves out of retail establishmentTotals all items acquiredDebits consumer accountNo movement of product from “shopping cart”
Automatic shelf price change
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Packaging/Brody, Inc.
INTEGRATE PACKAGING WITH APPLIANCES
Many attempts to integrate food packaging and food heating appliances
Generally few successful marriagesMicrowave reheating for home meal replacements
But not appliance specificDo not accommodate to the wide variety of microwave ovens
Other appliancesToaster ovensRefrigeratorsCoffee brewers
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Packaging/Brody, Inc.
FOOD PREPARATION: MICROWAVE
Microwave ovensMajor differences in ovens
Power levelsDistribution of energyAge of oven
Major differences in energy absorptionMicrowave heating now judged by operatorAutomatic control integrates food, package and oven
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Packaging/Brody, Inc.
COOKING/HARDWARE
TrendsMulti-modal heating
Single mode too limitingMulti-modal cooking
Consumer educationCost higher than conventionalFood processor/packager involvement
Not all foods can be prepared in multi-modal ovens
High speed ovenSmart ovens
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Packaging/Brody, Inc.
SMART OVENS
Because new energy source ovens cook differently, automatic operating controls are requiredConvert from conventional recipes and cooking instructionsDownload recipes from internet since consumers will need directions
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Packaging/Brody, Inc.
HEALTH MONITORING
Records the food intake by the consumer. Display a summary of food intake, nutritional and other information.Connecte to an electronic scale for monitoring the weight of the consumer. Provide the consumer useful suggestions based on the above information. The information may also be transmitted to the doctor’s office.
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Packaging/Brody, Inc.
THE FUTURE
Food shelf life will be shorterTime in home will be shorterFood preservation and preparation will integrate with packaging
Packaging will be integrated with processing and distributionPackage will be a preparation and serving aid
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Packaging/Brody, Inc.
NEEDS FOR THE FUTURE
Visible inventory communication for refrigerated and frozen foods
AgeTime temperature integral
Possible quality signal
Overt signal to consumer
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Packaging/Brody, Inc.
NEEDS FOR THE FUTURE
Cooperation among food processors, retailers which offer prepared foods
Product packaging to fit home processingInstructionLinkage by computer sensor read and responseLong term program
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Packaging/Brody, Inc.
THE FUTURE
Long termAccurate information
Target each household member individuallyQuality
Flavor, mouth feelNutrient valueOther value
“Spoilage”Preparation directions based on food, consumer and in-home equipment/interface
Communication channel/message
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Packaging/Brody, Inc.
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Packaging/Brody, Inc.
STATE OF THE ART OFACTIVE/INTELLIGENT FOOD PACKAGING
Aaron L. BrodyPackaging/Brody, Inc.P O Box 956187Duluth, Georgia 30095 USA
Institute of Food Technologists Food Packaging Summit7-9 May 2006