packaging agricultural produce 2012
TRANSCRIPT
Packaging Fresh-Cut Agricultural Produce
Dr Alastair Hicks Adjunct Professor of Agroindustry
Mae Fah Luang University Thailand
ProPak Vietnam, Ho Chi Minh
1-3 March 2012
Flow chart for fruits,vegetables, root crops Harvesting and Cooling
Receiving and Storage
Washing and Sorting
Peeling, trimming, de-seeding
Cutting to specific sizes
Sorting for defects
Washing and cooling
Drying
Packaging & labelling Storage and Distribution
Harvesting of fresh produce Selecting raw material
with sound quality avoid produce damage and
contamination workers use gloves, hair
net, sanitary measures Mechanical harvesters
used in large operations
Remove field heat from fresh produce
Ice and water injection Chilled water baths Forced air cooling Vacuum coolers Packing with an ice-water
mixture Vacuum cooling tunnel use a first-in, first out
(FIFO) system
Receive and store fresh produce The receival point for fresh fruit and
vegetables into a fresh-cut processing plant is a key quality check point.
Large processing operations have a list of quality parameters and measurements.
Usually they have an enclosed refrigerated dock facility for receiving product.
Inventory of stocks begins at the receiving stage after deciding whether to process.
Quality Checklist for raw produce received at the pack house
Harvest Area (Number/Field#):
Date/Time:
Harvest Crew: Supervisor:
Vehicle Registration: Bin Label:
Commodity Parameter Result Specifications Corrective Actions
Initials
Size
Brix
Colour
Acidity
Defects
Temperature
Process flow in a fresh-cut processing plant
Washing and sorting of fresh produce cut surfaces removes damaged tissues
These require the use of potable good quality water
Water flume for washing and transporting fruit in a large packing plant
This ensures produce safety and quality
Pre-cutting whole fresh produce to extend the shelf-life
Physical & Chemical pre-cut treatments Physical - mainly air pressure, Modified Atmosphere
(MA), heat and low temperature treatments. Chemical – use of chemical sanitizers, chlorine,
peroxyacetic acid, hydrogen peroxide, acidify sodium chloride or ozone
Firming agents like calcium dip and Methylcyclopropene (1-MCP) plant growth regulator
Peeling, trimming, de-seeding fresh produce
Workers in complete food safety attire,sort & cut fruit
staff use knives to trim and peel fresh produce
plants use abrasive peelers, trimmers
high pressure air and lye and steam for peeling.
Fresh-cut produce cutting, slicing
Product bin dumpers
Product cutting and slicing machine
Washing, cooling of fresh produce Continuous washing of pre-
cut lettuce with sprays Recycle through a filter to
reduce water consumption Check temp (0 – 5C) ,
contact time, pH (4.5 – 5.5) chlorine level (50-100ppm)
Oxido-Reduction potential (650-750 ppm).
Fresh-cut produce washing, drying
Continuous fresh-cut product washing flume
Pre-cut vegetables are dried with centrifugal force of spin dryers
Post- cutting treatments of fresh-cut produce
Post- cutting treatments of fresh-cut produce extend shelf-life
Chemical post-cutting treatments applied
Physical post-cutting treatments applied
Physical post-cutting treatments Modified atmosphere and low temperature storage
reduces respiration rate and deterioration of fresh-cut produce.
Modified Atmosphere (MA) is passive or active Active MA - flushing package with a gas or mixture of gases different from normal air Passive MA- created in package by respiration of
fresh-cut produce and package permeability
Chemical post-cutting treatments
Inhibit enzymatic browning discoloration caused by enzyme polyphenoloxidase (PPO)
Acidification - solutions of acetic, ascorbic, citric, tartaric, fumaric or phosphoric acid
Reducing agents - Such as ascorbic acid, or erythorbate isomer of ascorbic acid
Application of edible coating: using coating such as sodium caseinate-stearic acid
Firming agents- Firmness of fresh-cut fruit products ismaintained by treatment with calcium compounds.
Other post-cutting treatments Low heat treatment to
activate pectinesterase prior to a CaCl2 dip
Drying treatment: water
removed from fresh-cut produce before packaging
Fresh-cut filling, sealing, checking Auto scale with form-
fill-seal packaging unit to pack produce in plastic bags
Metal detectors prevent metal objects being in final product
Packaging to assure quality and safety of fresh-cut produce
When fruit and vegetables are cut, spoilage is faster than with intact or packed product.
Packaging protects physical damage, also chemical and microbiological contamination.
Packaged fresh-cut produce is a key factor to deliver finished product intact to the end user.
Refrigeration maintains package shelf life by keeping product temperature at correct level.
Packaging/labelling treatment Film, rigid plastic used for fresh-cut fruit, vegetables Packs are filled by hand in a small operation Shrink wrap machine removes air, seals bag Plastic pouches in cardboard storage, delivery boxes Automatic operations, bags formed, filled, and sealed Metal detector checks bags passing through the detector
to test for metal contaminants. Finished product has a “Use By” date for optimum product shelf life. Codes are printed on the package.
Types of fresh food packaging film Types of packaging for fresh-cut fruits and vegetables
include: Flexible film, Plastic bags Shrink wrap packaging Rigid plastic containers
Oriented polypropylene (OPP) for MAP Perforated, thin, low density polyethylene (LDPE) Monolayer polyvinylchloride (PVC) Ethylene vinyl acetate (EVA)
Rigid plastic packaging Rigid plastic packaging
used for fresh-cut fruit & vegetable retailing
Finished product has a “Use By” date for optimum shelf life.
Codes are printed on the package.
Rigid plastic packaging cont’d
Flexible plastic packaging Used for fresh-cut salad
vegetables Ready to eat, washed
mixed fresh product Films with permeability,
right area; headspace volume, known product respiration
Labels printed on the plastic film, weight, price, use instructions
Fresh food packaging trends Packaging recyclability, biodegradability: large
buyers are concerned about environment. Packaging variety: more than 1,500 different sizes,
styles of produce packages. Packaging sales appeal: Quality graphics boost sales
appeal. Multi-colour printing, distinct lettering, logos are common.
Packaging shelf life: Fresh produce packaging is engineered to extend shelf life, reduce waste.
Properties of MAP packaging: Modified Atmosphere Packaging (MAP):
MAP reduces respiration rate , slows senescence MAP lowers O2, high CO2 levels reduces ethylene &
extends fresh-cut products shelf life. MAP delays ripening, surface browning, retard enzyme
activity & microbial growth Passive MAP- a hermetically sealed container Active MAP- Flush air from package with filler gas Some limited success cases with MAP, undesirable
sensory changes - colour, flavour, odour, growth of pathogenic organisms
Storage and distribution
Customer demand for convenient, fresh, tasty food led to fresh-cut produce industry
“Cold Chain” is key to delivering fresh wholesome fruit/vegetable products
Fresh-cut plants, cold storage facilities, transport companies, wholesaler, retailer & supermarket all help the fresh product.
Storage times are kept to a minimum.
Quality assurance system Quality assurance is good timely information on
all the quality attributes of a product Physical, chemical, sensory evaluation of raw
materials, processed products Ingredients and packaging supplies, processing
parameters, finished products Microbiological analysis and control of raw
materials and finished products
Quality assurance system cont’d Control of storage and handling conditions Sanitation and waste products control Assurance final products within legal limits and
marketing standards. Quality, food safety used as a marketing tool Quality standards used - EUREPGAP, Good
Agriculture Practices (GAPs) , International Food Standard (IFS), British Retail Consortium (BRC), Good Manufacturing & Hygienic Practices (GMP, GHP) and others.
Thank you !