packaging of frozen food

Part V

Packaging of Frozen Foods

2006 by Taylor & Francis Group, LLC

29 Introduction to Frozen FoodPackagingJohn M. KrochtaUniversity of California, Davis

CONTENTS

I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616

II. Functions of Packaging for Frozen Foods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617

A. Containment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617

B. Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618

1. Frozen Food Packaging Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618

2. Frozen Food Package Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620

a. Boxes/Cartons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620b. Bags/Pouches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621c. Heat-in-bag Pouches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621

d. Lidded Trays and Pans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622

e. Composite and Plastic Cans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625

C. Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625

1. Laws and Regulations on Food Labeling . . . . . . . . . . . . . . . . . . . . . . . . . 625

2. Marketing Objectives of Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626

D. Convenience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626

E. Production Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627

F. Minimal Environmental Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627

1. Life Cycle Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627

2. Reduction, Reuse, Recycling, and Recovery . . . . . . . . . . . . . . . . . . . . . . 628

a. Source Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628

b. Package Reuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628

c. Package Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628

d. Energy Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629

3. Laws and Regulations on Packaging Waste and Recycling . . . . . . . . . . . 629

G. Food Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630

1. FoodPackage Interaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630

a. Packaging Component Migration . . . . . . . . . . . . . . . . . . . . . . . . . . . 630

b. Laws and Regulations on Packaging Components as

Indirect Food Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631

2. Food-Package Tampering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631

a. Laws and Regulations on Tamper-Evident Packaging . . . . . . . . . . 631

b. Tamper-Evident Packaging for Frozen Foods . . . . . . . . . . . . . . . . . 632

3. GMPs and HACCP Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632

a. Laws and Regulations on GMPs and HACCP Plans . . . . . . . . . . . . 632

b. HACCP for Frozen Food Packaging . . . . . . . . . . . . . . . . . . . . . . . . 632

III. Trends in Frozen Food Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632

A. Flexible Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633

B. Microwavable Trays, Cartons, and Bowls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633

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2006 by Taylor & Francis Group, LLC

C. Nonthermal Food Processing Techniques in Combination with Freezing . . . 633

D. Modified Atmosphere Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634

E. Active Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634

1. Protective Active Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634

2. Convenience Active Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634

F. Intelligent Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634

G. Consumer-Friendly Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635

IV. Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636

I. INTRODUCTION

The first four sections of this book provide information essential to the production, storage, trans-

portation, and marketing of safe, quality frozen foods. However, the time and resources devoted to

selection of the highest-quality raw materials, accurate application of freezing fundamentals, and

use of the most advanced processing and handling facilities are wasted if appropriate packaging

systems are not used for frozen foods.

Although freezing is one of the most satisfactory methods of preserving the quality of foods, the

conditions of frozen storage are such that frozen foods can lose quality over time [15]. Knowledge

of the changes that a specific frozen food can undergo is necessary, because selection of the appro-

priate packaging material and package type options can minimize quality loss [3,6].

Shelf-life of a packaged food is dependent on the nature of the food, the package, and the

environment surrounding the packaged food [710]. The most common problem for frozen

foods is moisture loss through sublimation (freezer burn). Sublimation can occur because of

the temperature difference (and thus water activity difference) between a frozen food and the

colder (and thus frost-accumulating) heat-exchange surfaces of the frozen storage facility. Further-

more, a temperature gradient will also exist within a packaged frozen food, with the resulting for-

mation of ice inside the package (package ice). In addition to aggravating the sublimation

process, temperature fluctuations in frozen storage increase ice crystal size in the frozen food,

due to repeated thawing and refreezing of small amounts of water. Both food desiccation and ice

crystal growth produce undesirable food appearance and texture changes. Thus, the ideal packaging

material and package design will provide an effective barrier against moisture loss from the food to

the environment surrounding the package, minimize moisture movement within the package, and

minimize exposure of the food to temperature fluctuations.

Additional quality changes can occur because the small amount of unfrozen water in frozen

foods provides an environment in which enzymatic and nonenzymatic oxidation of lipids,

colors, flavors, and vitamins can occur, along with both enzymatic and nonenzymatic browning.

Desiccation of the food can increase the rates of these changes. The potential loss in quality due

to these chemical changes will depend on the particular food product involved. Thus, some

frozen foods will have significantly longer storage life when the packaging material and package

design provide for removal of oxygen at time of packaging and protection against the incursion

of oxygen from the surrounding environment into the package.

Although it is impossible to preserve the quality of frozen foods for an indefinite time, proper

packaging can sufficiently delay the rate of quality loss that an acceptable storage life is obtained.

Thus, the last section of this book is devoted to selection of packaging materials and package types

for frozen foods that provide the final link in fulfilling consumer needs and expectations.

616 Introduction to Frozen Food Packaging

2006 by Taylor & Francis Group, LLC

II. FUNCTIONS OF PACKAGING FOR FROZEN FOODS

Generally, packaging is considered to provide four main functions: containment, protection, com-

or production efficiency, involving the ability of the package to perform well in rapid filling,

closing, and handling operations [7,13]. Additional functions have gained increased importance,

including having minimal impact on the environment and maintaining food safety for the consumer

[13,14]. Selection of packaging that is appropriate for specific frozen foods must take into consider-

ation all these functions. Thus, packaging materials and package types will be discussed in the

context of these package functions for frozen foods.

A discussion of the functions of packaging must also consider the package level, which

describes the proximity of the package to the food and the use of the package. The primary

package is in direct contact with the food product (e.g., plastic-coated paperboard carton or

plastic pouch containing frozen food) and usually provides t