packaging of confectionery and bakery goods

8/8/2019 Packaging of Confectionery and Bakery Goods

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Packaging of Confectionery and Bakery

Goods

Presented By:-Udit Chawla

Mayur Mali

Anup Chalke

Avinash Singh

Nishikant Lautre


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Introduction:-

Baki g is the tech ique f pr l ge

c ki g f f by ry heat acti g

by c vecti , a t by ra iati ,

rmally i a ve , but als i h t

ashes, r h t st es. It is

primarily use f r the preparati f

brea , cakes, pastries a pies,

tarts, quiches, c kies a crackers.

Such items are s metimes referret as "bake g s," a are s l at

a bakery.


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Classificati f Bake s

Bake g s are maj rly ivi e

i t tw br a categ ries:-

Dry Bakery s (s ft biscuits,

har biscuits, c kies, crackers,

wafers)

M ist Bakery s (cakes,

pastries, brea s, bu s, muffi s etc.)


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Cookies

Cookies are ma e i a wi e variety of styles, usi g a array of

i gre ie ts i clu i g sugars, spices, chocolate, butter, pea ut

butter, uts or rie fruits.

Cookies are most commonly bake until crisp or just long

enough that they remain soft, but some kinds of cookies are notbaked at all.

The softness of the cookie may depend on how long it is

baked.

Unlike cakes, cookies do not use water as the medium f or

cohesion.It may use some a type ofoil in the f orm of butter, egg yolk,

vegetable oil etc. as an agent for forming a bond.

These oils are much more viscous than water and evaporate

freely at much higher temperatures.


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ClassificationofCookies

Drop Cookies

Refrigerator Cookies

MoldedCookies

RolledCookies

ressedCookies

Bar Cookies

Sandwich Cookies


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Cakes

Cake i s a f orm of food, typically a sweet, baked dessert.

Cakes normally contain a combination of flour, sugar, eggs, and

butter or oil, with some varieties also requiring liquid (typically milk

or water) and leavening agents (such as yeast or baking powder).Flavorful ingredients like fruit pures, nuts or extracts are often

added, and numerous substitutions for the primary ingredients are

possible.

Cakes are often filled with fruit preserves or dessert sauces (like

pastry cream), iced with butter cream or other icings, anddecorated with marzipan, piped borders or candied fruit.


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ClassificationofCakes

Cakes are broadly divided into several categories, based primarily

on ingredients and cooking techniques:

Yeast cakes are the oldest, and are very similar to yeast breads.

Such cakes are often very traditional in form.

Cheesecakes, despite their name, aren't really cakes at all.Cheesecakes are in fact custard pies, with a filling made mostly of

some form of cheese.

Sponge cakes are thought to be the first of the non-yeast-based

cakes and rely primarily on trapped air in a protein matrix

(generally of beaten eggs) to provide leavening.

Butter cakes, including the pound cake rely on the combination

of butter, eggs, and sometimes baking powder to provide both lift

and a moist texture.


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Cake Flour

Special cake flour with a high starch-to-gluten ratio is made from

fine-textured, soft, low-protein wheat.

It is strongly bleached, and compared to all-purpose flour, cakeflour tends to result in cakes with a lighter, less dense texture.


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Confectionery

Confectionery is the set offood items that are rich in sugar, any

one or type of which is called a confection.

Confections are generally low in nutritional value but rich in

calories.The word candy (U.S.), sweets (UK) or lolly (Australia) is also

used for the extensive variety that compose confectionery.


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ClassificationofCommonConfectionery oods:-

Chocolates

Candies

Fu

dge

Toffee

Mithai

Chewing um

Jellies


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CandyCandy, specifically sugar candy, is a confection made from a

concentrated solution of sugar in water, to which flavorings and

colorants are added.

Candy is made by dissolving sugar in water or milk to form a

syrup, which is bo

iled

un

til it reaches thed

esired

con

cen

tration

or starts to caramelize.

The type of candy depends on the ingredients and how long

the mixture is boiled.

Candy comes in an endless variety of textures from soft and

chewy to hard and brittle.The final texture of candy depends on the sugar

concentration. As the syrup is heated, it boils, water

evaporates, the sugar concentration increases, and the boiling

point rises.


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Sugar Cooking Stages

Stage Temperature in F Temperature in C Sugar concentration

thread 230-233 F 110-111 C 80%

soft ball (e.g., fudge) 234-240 F 112-115 C 85%

firm ball 244-248 F 118-120 C 87%

hard ball 250-266 F 121-130 C 92%

soft crack 270-290 F 132-143 C 95%

hard crack (e.g.,

toffee)

295-310 F 146-154 C 99%

clear liquid 320 F 160 C 100%

brown liquid

(caramel)338 F 170 C 100%

burnt sugar 350 F 177 C 100%


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Shelf Life

The shelf life of a candy can be anywhere between two weeks to

much more than a year depending upon the storage conditions.

This shelf life may be shortened if the product is not stored in a

cool anddry place.


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General Characteristics of

Confectionery and Baked Goods

Fragility

Loss of Crispiness

Loss of Aroma

Rancidity

Water Activity

Prone to Microbial Activity

Temperature Sensitivity

Low Shelf Life


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Packaging Material

Packaging materials can be broadly divided into 3 categories:-

Primary

Secondary

Transport


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Primary Packs Used for Bakery and

Confectionery oods

Laminates:

Plastic Laminates

Paper LaminatesFoil Laminates

Laminated Tubes

Bubble Wraps

Paper andPaperboard:Folding Cartons

Paper Bags

Composite Cans

Paper Cups


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Secondary Packs Used For Bakery and

Confectionery oods

Plastic:

Pet Jars

Laminate Bags andPouches

Paper andPaperboards:

Folding Cartons

Wrap-around

Paper Bags

Metal:

Metal Cans


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Transport Packs For Bakery and

Confectionery oods

Shrink Wraps

Stretch Wraps

Woven Sacks

Paper Sacks

Folding Cartons

Corrugated Fiber BoardBoxes

WoodenCrates andContainers


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Types ofPackaging Materials Used

Laminates:

B.O.P.P.

B.O.P.P./Met. B.O.P.P.

P.E.T./Met. C.P.P.

P.E.T./Met. P.E.T./Poly

P.E.T./Met. B.O.P.P.

P.E.T./Met. C.P.P.

Met. B.O.P.P./Met. P.E.T./Poly

P.E.T./Al./P.E. (Milk Powder)

(Chips and Wafers)

(Biscuits mostly)


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Contd..

P.E.T./Met. P.E.T./Poly

P.E.T./Poly

P.E.T./Met. B.O.P.P.

P.E.T./Met. C.P.P.

P.E.T/Poly

Met. P.E.T.

H.D.P.E. (Cereals)

Al./Food rade Base Paper/Wax (Chewing Gums)

(Miscellaneous)


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Contd..

Paper Products:

Paper Board

CoatedPaper

lassine Paper

Corrugated Fiber Boards

Metal Products:

Foils

Sheets

Containers


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Co

mparison

C

hart


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Moderate Moisture

Barrier

PE

BOPP

High Moisture Barrier AL FOIL

MET PET & MET BOPP

MET CPP & MET PE

Moderate Gas Barrier PET

5-Layer & 7-Layer PA based PE

High Gas Barrier AL Foil

MET PET, MET BOPP


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SUBSTRATE & THEIR

CHARACTIRISTICS


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Advantage Disadvantage

Good Printability

High Moisture Barrier

Softer and Easily Tear able

Low Density leading to High Yield

Available in:

Plain

Heat Sealable

Metalized

White Opaque

Pearlized

Heat sensitive-exhibits

shrinkage whilst printing

and packing operations.

Low corona retention

period.

B.O.P.P. (Bi-axially Oriented Polypropylene)


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Advantages

AdvantagesDisadvantages

Highest Seal Strength and Hot TackLow oxygen barrier

Highest toughness and drop performance

amongst all sealant.

Low heat resistance

Excellent seal ability and preferred sealant

layer.Low modulus

Available in :

Transparent

Metalized

Easy Tear

Retort grade

3 / 5 / 7 Layers Barrier

P.E.(Polyethylene)


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Excellent printability.

Oxygen barrier.

High gloss.

High heat resistant.

Available in metalized, PVDC

coated, SiOx and alumina coated

for enhanced barrier.

Corona & chemically treated for

better anchorage.

Not suitable for moisture

sensitive products in bare form.

Too stiff to be used for softer

and crumple-less packs for feel-

good effect.

High density leading to low

yield.

P.E.T.(Polyethylene Terephthalate)


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Advantages Disadvantages

High Seal Strength High Clarity

Higher Stiffness than PE

Good Hot-Tack and Faster cooling time suitable for high

speed of candies packing. High Heat resistance

Available in:

Transparent

Metalized

White Opaque

Retort grade

Comparatively lowHot-Tack and low Dart

impact than PE

restricting its application

in many packaging

areas.

C.P.P.


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Highest gas, vapor and light

barrier

Poor pin-holes and crack

resistance

Possesses dead fold Chemically reactive withacidic products

Good surface appearance

Moderate printability

Aluminum Foil


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High Bulk

High Stiffness

Dead Fold

Available in

Poster

Map litho

Chromo

Glassine

Kraft

Tissue

Chromo is the best printable paper

Poor Barrier

Poor Inter-Layer

Bonding

Moisture Absorbent causing

curling & de-lamination problemsat times

Paper


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Comparatively high Oxygen

Barrier and Moisture Barrier

than bare film.

Metallic Finish

Poor inter-layer bond

strength than bare substrate

on account of poor metal

adhesion.

Opaque Packaging

MET. P.E.T., MET. B.O.P.P., MET. C.P.P.

MET PE


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Package Material Testing

Testing and Its Significance


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Significance Of:-

Grammage Test:-

Since most of the polymer film is bought and sold in

accordance with its weight, this property hassignificance both to consumer and producer in defining

price.

Most physical properties such as Thickness and Bulk

are evaluated and specified in accordance withparticular grammage involved.


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Significance Of:-

Thickness and Density Test:-

Thickness is very important property as it affects

apparent density, air resistance, rigidity, etc.

Uniformity in thickness is important for most of

requirements. Apparent density influences almost all

physical property as well as printing.


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Significance Of:-

Tensile Strength Test:-

Tensile strength is indicative of the durability and

serviceability of many materials which are subjected

todirect tensile stresses.

It indicates potential resistance to breaking when

subjected to strains during travel from roll through the

press and labeling machine.


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Significance Of:-

Tear strength Test:-It is primarily a property of inner structure of paper. In plastics, it is a

combination of shear and elastic properties. It can influence

processing characteristic.

Unit : gm/micron

Significance : Higher the tear strength value, greater the difficulty to

tear the film. This data is useful in designing the film for laminate /

required application. E.g. - Chocolate packs need lower tear strength

for easy tear.


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Significance Of:-

Haze Test:-

This is an optical property indicating amount of haziness in

film.

Light that is scattered upon passing through a film can

produce hazy field when objects are viewed through material.

This property is affected by surface or internal defect which

can arise while handling or processing.

This property can be useful f or Quality Control and

Specification purposes.


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Contd..

Significance:-

Film clarity is a highly desirable feature for most clear

packaging and label applications.

It tends to symbolize quality and contributes to the positive

visual display of the product.

Compared to other flexible plastic films, clear OPP has one of

the lowest haze values, generally less than 3%.


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Test principles

As represented in the figure , a unidirectional light beam is directed

onto the film specimen. After it enters an integrating sphere, a photo

detector measures the total light transmitted by the film and the

amount of transmitted light that is scattered more than 2.5. Haze is

the percentage of total transmitted light that is scattered by more

than 2.5.

Contd..


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Significance Of:-

Coefficient Of Friction Test:-

Co efficient of Friction, a surface phenomena of

plastic films, is related to slip properties that are of

wide interest in packaging applications.

This test yield empirical data for control purposes in

film prod

uction

.Correlations of test results with actual performance

on machine can be established.


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Contd..

Slip properties are generated by additives which exude to the

surface which makes it slippery.

Manufacturing process and additives used as well as rate of

loading and speed affects the value.


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Significance Of:-

Melt Flow Index:-It is defined as the amount of polymeric mass flow

through narrow orifice when it is extruded at a

specified load at a specific temperature as per

standard.

Heat seal Strength Test:-To understand the heat sealing range to polymers.

This helps in selecting a polymer with optimumsealing temp.


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Significance Of:-

WATER VAPOR TRANSMISSION RATE:

WVTR (water vap

o

r tran

smission

rate) is the stead

y state rate at which

water vapor permeates through a film at specified conditions of

temperature and relative humidity.

Values : g/m2/24 hr in metric (or SI) units.


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Contd..

Significance :

WVTR is the standard measurement by which films are compared

for their ability to resist moisture transmission.

Lower values indicate better moisture protection.

Only values reported at the same temperature and humidity can

be compared, because transmission rates are affected by both of

these parameters.


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WVTR TableMaterial WVTR, g/m2, 24 hr. 38C & 90% RH.

Flat Folded Crumpled Gelboflex

MetP

ET (12) 0.9

1.7

3.4 18

Met PET / LDPE (50) 0.5 0.6 0.7 0.6

2-sides PVDC coated

PET

4.2 3.7 5.9 4.8

2-sides PVDC coated

PET/LDPE

2.9 3.6 3.3 3.1


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Significance Of:-

Oxygen Transmission Rate:-

OTR (oxygen transmission rate) is the steady state rate

at which oxygen gas permeates through a film at

specified conditions oftemperature and relative

humidity.

Value : cc/m2/24 hr in metric (or SI) units.

Standard test conditions are 73F (23C) and 0% RH.


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Contd..

Significance :

The air we breathe is about 21% oxygen and79% nitrogen, with

very small concentrations ofother gases like carbondioxide and

argon.

Essential to human and animal life, oxygen gas is also a reactive

compound that is a key player in food spoilage.

Most of the chemical and biological reactions that create rancid

oils, molds, and flavor changes require oxygen inorder tooccur.


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Contd..

Two methods for reducing product exposure to oxygen via flexiblepackaging:

MAP (modified atmosphere packaging) is a process for replacing

the air in the headspace of a package with another gas before the

final seal is made.

This is also called gas flushing.

The most common replacement gases are nitrogen or

nitrogen/carbon dioxide mixtures.

The shelf lives of potato chips, dried fruits, nuts, and shredded

cheese are commonly extended by this packaging method.


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Contd..

Vacuum packaging is where the atmosphere is drawnout and

eliminated, rather than being replaced by another gas.

This vacuum forces the flexible material toconform to the

product shape.

Juices (fresh and processed) and cheeses are commonly

packaged this way.

Once air has been replacedor eliminated from the package,

there must be anadequate oxygen barrier andseal integrity to

keep a low oxygen concentration inside the pack.


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Significance Of:-Opacity:-

Opacity represents a substrate's light blocking

ability.

It is primarily used as a property of paper and

predicts the relative visibility on one side of the

paper of the images that exist on the other side.

White opaque films are replacing paper in some

applications, therefore one needs to measure

opacity for some white films.


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Significance Of:-

Gloss Test:-Gloss is a measurement ofthe relative luster or shininess of a

film surface.

The incident light beam strikes the film surface at a 20, 60 & 85

degree angle from the perpendicular.

A sensor measures the amount of light reflected by the film at

a mirror image angle.

The gloss value is the ratioof this reflected light to incident

light and is reported ingloss units.

Theoretically, the range of the gloss scale is 0 to 100.


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Contd..

Significance:

It indicates the degree of pleasing sparkle on the product

surface.Higher the gloss higher is the degree of shining of the product.

Shininess, brilliance, and sparkle are properties related to a

film's glo

ss value.They can be valuable appearance attributes for packages,

labels, or graphic arts items.


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What affects film gloss..?

Gloss is primarily determined by material selection and surface

smoothness, which are defined during product and process

development.

Day-to-day process variations will have an insignificant effect on

gloss.

Transparent films have two reflecting surfaces. Although rare, this

can lead to gloss values that exceed 100.

Contd..


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Packaging Laws and

Regulations

The Link Between FoodPackaging and

Consumer Protection


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Overview

The link between food packaging and consumer protection is

of high significance.

A package is a vehicle of safety and achieves the objective of

delivering safe, wholesome, nutritious food to the consumer.

To safeguard the interests of the consumer and the society at

large, Packaging Laws and Regulations have been introduced by

the Government.


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The Packaging Laws and Regulations for food

products are mainly covered under:

The Standards of Weights and Measures Act, 1976 and the

Standards of Weights and Measures (Packaged Commodities)

Rules, 1977 (SWMA).

The Prevention of Food Adulteration Act, 1954 and the

Prevention of Food Adulteration Rules, 1955 and its first

amendment, 2003 (PFA).

The Fruit Products Order, 1955 (FPO)

The Meat Food Products Order, 1973 (MFPO)

The Edible Oil Packaging Order, 1998

The Agmark Rules


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The Standards of Weights and

Measures Act


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The Act also specifies the base units for:

Length Metre

Mass Kilogram

Time Second

Electric Current Ampere

Thermodynamic Temperature Kelvin

Luminous Intensity Candela

Base Unit of Numeration International form of Indian

numerals.


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DeclarationonPackagedCommodities for

Interstate Trade or Commerce:

Identity of the commodity in the package.

Net quantity, in terms of the standard unit of weight or

measure, of the commodity in the package.

Where the commodity is packagedor sold by number, the

accurate number of commodity containedin the package.

The unit sale price of the commodity in the package.

The sale price of the package.


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Label Declarations:

Then

ame and

add

resso

f the man

ufacturero

r where themanufacturer is not the packer, the name and address of the

manufacturer andpacker.

The commonor generic names of the commodity containedin

the package.

The net quantity in terms of the standard unit of weight or

measure, of the commodity contained in the package or where the

commodity is packedor sold by number, the number of commodity

contained in the package.


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The month and year in which the commodity is manufactured

or pre-packed. (Provided that for packages containing food

articles, the provisions of the Preventionof Food Adulteration

Act (PFA), 1954 (37of 1954) and the rules made there under

shall apply).

The retail price of the package.

The retail sale price of the package.


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Commodities to be Packed in Specified

Quantities (StandardPackages)

as per The Third Schedule of SWMA Rules

Commodities Quantities In which to be


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Commodities Quantities In which to be

packed

Biscuits 25g, 50g, 75g, 100g, 150g, 200g,250g, 300g and thereafter in

multiples of 100g up to 1 kg

Bread including brown bread but

excluding bun

100g and thereafter in multiples of

100g

Cereals 100g, 200g, 500g, 1 kg, 2 kg, 5 kg

and thereafter in multiples of 5 kg

Aerated soft drinks and

non- alcoholic drinks

100ml, 150ml, 200ml, 250ml,

300ml, 330ml (in cans only),

beverages 500ml, 750ml, 1 litre,

1.5 litre, 2 litre, 3 litre, 4 litre, and 5

litre


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Maximum Permissible Error in Relation to

Quantity Contained in Individual Package

as per the First Schedule of SWMA Rules

Description of Commodity Quantity Declared Maximum


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Permissible

Error

B

iscuits i. Up to

and

equal to

500gii. Above 500g

7

.0%6.0%

Bread i. Up to and equal to 400g

ii. Above 400g up to and

equal to800g

iii. Above 800g up to andequal to 1200g

8.0%

6.0%

4.0%

Provisions sold in poly bags

or plastic bags and

powdered commodities(such as, dry fruits, seeds and

other

commodities (such as, sugar gur,

khandsari and the like)

i. Up to and equal to 100g

ii. Above 100g up to and

equal to 500giii. Above 500g up to and

equal to 1kg

iv. Above 1kg

3.0%

2.0%

1.5%

0.75%


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Symbols for Unit

Kilogram Kg

Gram g

Milligram mg

Litre l

Millilitre ml

Metre mCentimetre cm

Millimetre mm

Square metre m2

Square centimetre cm2

Cubic metre m3

Cubic centimetre cm3


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As per the Act a food is deemed to be adulterated:


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As per the Act, a food is deemed to be adulterated:

(a) If the article sold by a vendor is not of the nature, substance or

quality demanded by the purchaser and is to his prejudice, or is not ofthe nature, substance or quality which it purports or is represented to

be.

(b) If the article contains any other substance, which affects, or if the

article is so processed as to affect, injuriously the nature, substance or

quality thereof.

(c) If any inferior or cheaper substance has been substituted wholly or in

part for the article so as to affect injuriously the nature, substance orquality thereof.

Contd


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Contd

d) If any constituent of the article has beenwholly or in part abstracted

so as toaffect injuriously the nature, substance or quality thereof.

(e) If the article had been prepared, packedor kept under insanitary

conditions whereby it has become contaminatedor injurious to health.

(f) If the article consists wholly or in part of any filthy, putrid, rotten,

decomposedor diseased animal or vegetable substance or is insect-

infestedor is otherwise unfit for human consumption.

(g) If the article contains any poisonous or other ingredient which

renders it injurious to health.

(h) If the container of the article is composed, whether wholly or in part,

of any poisonous or deleterious substance which renders its contents

injurious to health.


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A utensil or container made of the following materials or metals,

when used in the preparation, packaging and storing of food shall

be deemed to render it unfit for human consumption:

Contai

ners which are rusty Enamelled containers which have become chipped and rusty

Copper or brass containers which are not properly tinned

Containers made of aluminium not conforming in chemical

composition to IS:20 Specification for cast aluminium and

aluminium alloy for utensils or IS:21 specification for wroughtaluminium and aluminium alloy for utensils

container made of plastic materials not conforming to the

Indian Standards specifications.

Packaging and Storage Requirements


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Fruit Products Order (FPO)


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Fruit Products Order is concerned with fruit and vegetable

products including synthetic beverages, syrups, sharbats and vinegar.

Objective of this law is mainly to regulate the quality and hygiene of

these products.

All labels should have the approval of the authorities concerned, and

carry the license number allotted.

FPO also prohibits use of any statement, designor device, which is

false or misleading concerning the fruit product.

Synthetic products associated with fruits and vegetables should clearly

be markedSYNTHETIC.

packaging of confectionery and bakery goods

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