PART III

PRODUCT/PACKAGE INTERACTION

CHAPTER 7
PRODUCT/PACKAGE INTERACTION

(1) INTRODUCTION

A wide variety of materials are currently in used for food packaging. They range
to paper and board products, glass and tin plate to the various types of plastics. The major
function of packaging is to protect the food to a pre-determined degree for the expected
shelf life Food processors expect packaging sensory attributes (color, odor, texture,
flavor) throughout the normal shelf life. The degree of protection necessary will vary
considerably, depending on the food itself and the shelf life required. For example,
although a simple glue sealed craft paper bag will perfectly adequate for, say dried peas,
biscuits will need better moisture and cooked meat almost total exclusion of oxygen, in
the latter case microbiological integrity for the pack is also vital.

The prevention of contamination of food by the packaging intended to protect it,

is the object of constant research, and much official regulation, Any substance which
migrates from the packaging into the food is of particular concern if it harmful to the
consumer Or have an adverse effect of the sensory attributes of the food. However, even
if the migrating substance is neither harmful nor has adverse effect on the sensory
attributes, Its presence in the food as a simple inert contaminant is undesirable.

Examples: Caking of fruit powder

Presence or black spots in canned tuna
Presence of mold in pastilles

(2) MODES OF DETERIORATION

Knowing why a product deteriorates after it 1s manufactured as well as how mush

deterioration occurs, and how one can limit or inhibit this deterioration is the first major
concern in designing/cho0sng a suitable packaging material. The deteriorates are
generally represented as decrease or loss oi some quality factors. Causes of deterioration
are n1ajniy categorized by the three scientific changes, (1) biological, (2) chemical and (3)
physical.

The biological deterioration includes microbial decay, senescence, insect and

animal infestations,
 The chemical deterioration of foods is caused by a series of complex reactions
between components of the foods and the environmental factors such as light, oxygen,
moisture, temperature and catalysts. The resulting effects are oxidation of lipids and
some vitamins, non-enzymatic browning and discoloration.

The physical deterioration of foods is usually water related (i.e. the physical
properties of food is changed by the water involved in the food system). If the water is
absorbed into the food the physical change is caking, while if water is desorbed from the
food, crystallization, casehardening or drying occurs.

(3) THE PRODUCT/PACKAGE PERFORMANCE

There are many actors which determine the suitability of a material for the
packaging of a material for the packaging of foods. These include cost, machine handling
and characteristics, general appearance, printability, resistance to mechanical and climate
hazards, freedom from toxicity and protective properties.

3.1. Protective Properties

3.1.1 Polymer/vapor interaction (permeability)

Permeation is made up of three elements - diffusion, solubility and pore effect.

Pore effect - in which gas flows through microscopic holes or channels in the material.

Diffusion - process of individual molecules (water, oxygen, organism) finding their way
through the amorphous regions of a polymer, by hopping between holes as thermally-
induced polymer chain movements make holes available This process becomes more
difficult as the vapour molecules become larger or bulky to reduced transmission levels.

Solubility - represents the level to which a volatile dissolves in the polymer.

3.1.1.1 Moisture Vapour transfer

The rate of some spoilage reaction in i0ods may be 1ast, such as less of crispiness.
Examples include snack foods, biscuits wherein crispiness/crunchiness is the main
criterion for freshness. Therefore, there is what is known as the Critical moisture content
(CMC) and to protest the product, permissible moisture content is identified.
 However, in many cases the barrier need not and in other cases should not b
perfect, so long as 1ts causes Sufficient delay in sp0ilage and there is an economic
justification for the level of protection

Pressure may also changed and affect the shelf life of the food. For example, if the
food is processed at a place with a high altitude, water will boil a low 100C, and vacuum
will be achieved at lower than 760 mmHg and the temperature is usually lower.

3.1.1.2 Gas Transfer

The gas of major importance in packaged foods is oxygen, Since it plays a rucial
role in many reactions which affect the shelf life of foods. S0me foods (for example: fatty
foods and freeze dried foods) are susceptible to oxidation, and therefore necessary to use
a package with low oxygen permeability. This also reduces losses of Vitamin C in other
foods (fruits and vegetables). In contrast, fresh foods required oxygen for respiration, and
Permeable or perforated package is used.

3.1.1.3 Flavor and Odor transfer

Absorption of flavour by the packaging film is known as “scalping” and is

particularly prone to occur with PE films. Notoriously contaminating substances are
soap, oranges, coffee. In properly retailing Situation, packages Should only be exposed
to very low concentration or odorants.

3.1.2 Permeability to Microorganisms

There some microorganisms that could pass through the film e. g E. Coli,
Leucomostoc mesenteriodes were found to permeate in PE and cellulose acetate films.

3.2 Freedom from Toxicity - Migration of Substances from Packaging Materials.

The toxicological effects of interactions between food and packaging materials and
also the effect of such interactions on the shelf fife and sensory quality of the food are
extremely complex. t he main aspects that are being studied are:
• lacquers and coatings for metal containers to prevent interactions of food acids
sulfur compound an0 other components with steel,, tin or aluminium.
• the migration of plasticers, pigments, metal 1ons and other components of plastic
packaging into foods.
• the migration of oils from foods into plastics
• the interaction of the package and food under different processing conditions
3.3 Climatic Hazards or Environmental Conditions

The deterioration of food IS Cause by attacks from environment. Climatic factor

which vary day to day and place to place are relative humidity and temperature During
the storage and distribution, these factors Will change up and down and attack the food
in terms o1 physical change and chemical reaction rate in the foods.
Effect of light on the product is another important factor to consider

(4) Shelf Life Testing

Ideally, product-package combinations should be tested for shelf life. A successful

assessment should be result from the taking the following Steps.

• Determine the likely mode of deterioration

• Select packaging material of sufficient barrier with an ability to form good integral
seals in the packaging equipment available.
• Test representative packages for seal integrity
• Perform realistic shelf life tests using realistic environmental conditions which
simulate retailing atmosphere

A Cooperation from the packaging supplier could be fruitful, for he will be able to
advise on film performance and the protocols required for successful shelf life testing.

Table 1 shows the degree of protection required by various foods and beverages
(Shelf life = 1 year at 25 C)

Table 1. Degree of Protection Required by Various Foods and Beverages

Food Beverage Maximum Maximum water Requires high Requires good

Oxygen gain gain or loss oil resistance barrier to
(ppm) volatile
compounds
Canned milk 1-5 3 % loss Yes No
Baby foods 1-5 3 % loss Yes Yes
Instant Coffee 1-5 2 % gain Yes Yes
Nuts, Snacks 5-15 5 %gain Yes No
Dried foods 5-15 1 % gain No No
10-40 3 % loss No Yes
Fruit juices &
drinks 50-200 3 % loss No Yes
Jams, jellies,
syrups 50-200 1 % gain No Yes
Pickles, vinegar
condiments 50-200 10 % gain Yes No
Peanut butter

Table 2. Suitable Packaging material Viewed from Quality Preservation of food

Retort sterilization Heat resistance, strength Base PET, ON, PVDC, AI

Sealant CPP

Boiling pasteurization (liquid Heat resistance Base OPP, PET, ON, CN,
food) Strength PVDC, KOP, KPET, KN
Sealant PE, EVA,LLDPE

High and intermediate moisture Oxygen barrier property

food strength

Large bag, medium bag (liquid Strength Base ON

food)
Solid product with edges

Free oxygen absorber enclosing Oxygen barrier property Base KOP, KPET, KON

Carbon dioxide exchange package

Nitrogen exchange package (low Gas barrier Base EVAL, OV
oxygen cone.)

Aroma (flavour) preservation

Volatile substance barrier Base PET, KPET, EVAL, OV,

Moisture prevention property PVDC, AI

Prevention of oxidation Water vapor barrier Base OPP, KOP, AI

property
Fruits and vegetables Oxygen barrier property Base KOP, KPET, KON,
PVDC, EVAL, OV, AI

High oxygen permeability Base PE, EVA, PS, PVC, PP

cellophane

Table 3. Variety and Characteristic of Food Packaging Material

VARIETY OF FOOD COMPOSITION OF FUNCTION REQUIRED

PACKAGING MATERIAL

I. High moisture food

1. Fish cakes ON (CN)/PE (EVA, lonomer) Pinhole-free property
Processed meat products PET/PE (lonomer) Heat resistance, strength
KCN/PE ( EVA, lonomer) Gas barrier property
KPET/PE (lonomer) Vapour barrier property
PP/PVDC/PP
CN/PE-PVDC-PE/CPP (PE) Deep draw aptitude
OPP (PET)/EVOH/PE High gas property
(lonomer)

2. Foods with liquid OPP/PE (EVA, LLDPE) Heat resistance, strength

Pickles, foods boiled in soy ON(PET)/PE(EVA,LLDPE) Gas barrier property
daily dishes, boiled beans KN(KOP,KPET)/PE (EVA, Pinhole-free property
LLDPE)
OPP(ON)/EVOH/PE (EVA, Water-proof, moisture-proof
LLDPE)
OPP/OV/PE (EVA, LLDPE) Impurities sealability

3. Liquid paper container PE/paper/PE Water-proof, moisture-proof

Milk, dairy product, PE/paper/AI/PE Strength
rice wine, fruit juice PE/paper/PE/AI/PE High gas barrier property
PE/paper/PE/AI/PET/PE

4.Soap (liquid) ON(PET)/PE(EVA,LLDPE) Heat resistance

KON(KOP,KPET)/PE (EVA, High gas barrier property
LLDPE)
ON/EVOH/PE(EVA) Pinhole-free property
 ON/PE/AI/PE/(EVA) Impurities sealability
PET/AI/PE/(EVA) Aptitude for high speed
automatic packaging

5.Fresh meat ON/EVOH/PE (EVA) Heat resistance, gas barrier

6.Rice Cake ON/EVOH/PE (EVA) Gas barrier property

KON (KPET)/PE (EVA, CPP) Pinhole-free property

II. Foods with medium water

content

1.Bean paste KP/(KON,K-Cello/PE (EVA) Gas barrier property

K-Cello/ON/PE/EVA Heat resistance, strength
ON/PVDC/PE(LLDPE) Impurities sealability
OPP(ON, Pet)/EVOH/PE High gas barrier property
(EVA)
OPP/OV/PE(EVA)
2.Jam marmalade Gas barrier property
PET(ON/AI/PE) Heat resistance, moisture-
proof
III. Dry Foods

1.Instant noodle
OPP/CPP (PE, EVA) Moisture-proof, light
Cellophane/PE shielding
OPP/PET/PE Gas barrier property
PET(OPP)/PE/paper/PE Oil-proof
KPET/PE/ CPP Aptitude for high speed
2. snack foods packaging
OPP/CPP(VMPE)
CPP/PE/VMPE Transparency, light-
OPP/K-Cello/CPP shielding
KO/PE/CPP Gas barrier property
3. rice cracker Moisture-proof, oil-proof
OPP/CPP(PE, part, coat)
KOP (K-Cello)/PE (part, coat)
4.green tea
 Cellophane/PE/paper/PE Transparency, moisture-
(lonomer) proof
Cellophane(PET)paper/AI/PE Oil-proof
(lonomer)
Cellophane/PE/paper/AI/PE Light-shielding property
(lonomer)
5.powder soup High moisture-proof
Cellophane/PET/AI/lonomer property
Paper/pe/AI/PE (lonomer)
High gas barrier property
6.powder juice
OPP/EVOH/PE
High moisture-proof
7.smoked and dried bonito property
OPP(PET)/EVOH/anti- High gas barrier property
electro-static PE Impurities sealability
PP/PVD/PP
OPP/OV/anti-electrostatic PE Moisture-proof, gas barrier
IV. Others Impurities sealability

restorable pouch food Hgh gas barrier property

ON/CPP Vapour barrier property
PET/ON/CPP Non-electrified,
PET/PVDC(EVOH)/CPP transparency
PET/AI/CPP
PET/ON/AI/CPP
PET/AI/ON/CPP
Frozen food
OPP/PE (EVA) High heat resistance
ON(PET)/PE (EVA, lomoner) Pinhole-free property
ON(PET)/VMPE Strength, water-proof
PET/AI/lomoner Gas barrier property
Bag in box
Fresh cream Corrugated board,
Liquid seasoning, etc. PE/VMPET/PE
Corrugated board, Cold resistance, moisture-
PE/KON/PE proof
Strength
Pinhole-free property
 High impact property

Water-proof,moisture-proof
Gas barrier property

GENERAL CHARACTERISTICS OF PACKAGING FILMS

FILM MATERIAL THICKNESS (In. X CLARITY SPECIFIC

10) ACTIVITY
Cellophane, 0.09 – 0.17 Transparent 1.40 – 1.55
lacquered
– 0.2 Transparent 1.44
Cellophane polymer
coated
and up Transparent to 1.2
Cellophane, translucent
polyethylene coated
0.088 – 25 Transparent 1.25 – 1.31
Cellulose acetate
0.05 – 3 Transparent to 1.13
Nylon -6 translucent

0.012 – 1.4 Transparent 1.38 – 1.41

Polyester
0.003 and up Transparent to 0.91 – 0.925
Polyethylene, low opaque
density
0.04 and up 0.941 – 0.965
Polyethylene, high Transparent to
density opaque
 0.087 – 1.0 0.885 – 0.905
Polypropylene,
unoriented Transparent
0.05 – 0.125 0.902 – 0.907
Polypropylene,
oriented Transparent
0.025 – 2.0 1.05 – 1.06
Polystyrene, oriented
0.05 – 10 Transparent 1.20 – 1.80
Polyvinyl chloride
Transparent to
0.04 – 0.25 opaque 1.11
Rubber
hydrochloride
10.04 – 0.6 Transparent top 1.59 – 1.71
opaque
Vinylidene
Chloride – vinyl Transparent
Chloride - copolymer

GENERAL CHARACTERISTICS OF PACKAGING FILMS

FILM MATERIAL USE LIMITS

MAX. TEMP MIN. TEMP RESISTANCE HEAT
(C) (C) TO SEALING
SUNLIGHT RANGE (C)
Cellophane, About 149 -4 Good 93 -177
lacquered
About 149 About -18 Good 93 -177
Cellophane polymer
coated
82 - Good 110 – 149
Cellophane,
polyethylene coated
66 – 93 -26 Good 177 – 232
Cellulose acetate
93 – 204 -73 Fair to good 183 – 232
Nylon -6
 149 -73 Fair to good 218 – 232
Polyester
82 – 93 -57 Fair to good 121 – 204
Polyethylene, low
density
121 -46 Fair to good 135 – 204
Polyethylene, high
density
132 – 149 -18 Fair 140 -204
Polypropylene,
unoriented
140 – 146 -51 Fair 149 – 160
Polypropylene,
oriented
79 -96 -57 to 70 Fair 121 – 177
Polystyrene, oriented 66 – 93 -29 to -46 Good 149 – 215
Polyvinyl chloride

93 -29 Fair 115 – 149

Rubber
hydrochloride
143 - Fair 115 - 149

Vinylidene
Chloride – vinyl
Chloride - copolymer

MECHANICAL PROPERTIES OF PACKAGING FILMS

BURSTING
TEARING
TENSILE STRENGTH FOLDING
FILM MATERIAL ELONGATION (%) STRENGTH
STENGTH,100 psi Mil Thick, psi ENDURANCE
g/Mil

Cellophane, 70 -180 15 -25 2 -10 55 – 65 Good

lacquered

Cellophane 70 -180 25 – 50 7 – 15 - -
polymer
coated
 70 -180 15 – 25 2– 10 40 -50 Good
Cellophane,
polyethylene
coated
70 -164 15 -70 4-10 30 -60 Fair
Cellulose
acetate 90 – 180 250 – 550 50-90 Elongates Very high

Nylon -6
200 – 350 60 – 165 12-27 55 – 80 Very high

Polyester 15 – 30 100 – 700 50-300 10 -12 Very high

Polyethylene,
low density 24 -61 10 – 650 15-300 - Good

Polyethylene,
high density 45 -70 550 – 1000 - - Very high

Polypropylene,
unoriented 75 – 400 35 – 475 3-10 - Good

Polypropylene,
oriented 80 -120 Mar – 40 5 16 – 35 -

Polystyrene,
oriented 14 – 160 3 – 500 10-1400 20 – 40 -

Polyvinyl
chloride 30 -40 200 – 800 60-1600 Elongates Very high

Rubber
hydrochloride 80 – 60 - 80 10-<100 25 - 35 Very high

Vinylidene
Chloride –
vinyl
Chloride -
copolymer

PERMEABILITY AND CHEMICAL PROPERTIES OF PACKAGING FILMS

RESISTANCE TO
FILM
SRONG STRONG GREASES ORGANIC
MATERIAL WATER
ACIDS ALKALINES AND OIL SOLVENT
Cellophane, Poor Poor Good Poor Fair
lacquered

Cellophane Variable Good Good Good Good

polymer coated

Cellophane, Good Good Variable Good Good

polyethylene
coated
Poor Poor Good Poor Good
Cellulose acetate
Poor Good Good Good Variable
Nylon -6
Good Poor Good Good Good
Polyester
Good Good Poor Good Good
Polyethylene, low
density
Good Good Good Good Good
Polyethylene,
high density
Good Good Good Good Good
Polypropylene,
unoriented
Good Good Variable Variable Good
Polypropylene,
oriented
Good Good Good Variable Good
Polystyrene,
oriented
Polyvinyl chloride Good Good Good Variable Good

Rubber
hydrochloride Good Good Good Variable Good

Vinylidene
Chloride – vinyl
Chloride –
copolymer

WATER VAPOR TRANSMISSION OF ALUMINUM FOIL LAMINATES

THICKNESS, In. WVTR

FOIL LAMINATE FLAT g/100 Sq In./24 hr;
MATERIAL 100 F; 100 % RH
AFTER
CREASING*
Aluminum foil laminated 0.00035 0.0009 0.00
to moisture proof 0.01 0.03
cellophane 0.01 0.01

0.00035 0.0012 0.02 0.07

Aluminum foil laminated
to cellulose acetate
0.00035 0.0008 0.01 0.01
Aluminum foil laminated 0.01
to rubber hydrochloride
0.00035 0.0012 0.01 0.02
Aluminum foil laminated 0.02 0.01
to vinyl polymer
0.00035 ... 0.00 0.04
Aluminum foil laminated
with wax to 30 lb.
Glassine 0.00035 ... 0.07 0.42

Aluminum foil BEIS-O 0.001 0.0009 0.00 0.00

Aluminum foil laminated
to moisture proof 0.001 0.0012 0.00 0.00
cellophane

Aluminum foil laminated 0.001 ... 0.00 0.02

to vinyl polymer

Aluminum foil laminated 0.001 ... 0.00 0.40

with wax to 35 lb.
Glassine

Aluminum foil BEIS-O

CHEMICAL SPECIFICATIONS FOR BASE STEELS

PERCENTAGE PERMITTED
ELEMENT BEER AND
TYPE 1 TYPE MS TYPE MR TYPE MC
STOCK

Manganese .25 - .60 .25 - .60 .25 - .60 .25 - .60 .25 - .60

Carbon .12 max .12 max .12 max .12 max .15 max

Phosphorous .015 max .015 max .02 max .07 - .11 .10 - .15

Sulphur .05 max .05 max .05 max .05 max .05 max

Silicon .01 max .01 max .01 max .01 max .01 max

Copper .06 max .10 - .20 .20 max .20 max .20 max
No limitations specified
Nickel .04 max .04 max
No limitations specified
Chromium .06 max .06 max
No limitations specified
Arsenic .02 max .02 max
No limitations specified
Molybdenum .05 max .05 max
No limitations specified
Phosphorous .015 max .015 max

GENERAL CLASSES OF FOOD PRODUCTS AND TYPES OF STEEL BASED

REQUIRED

STEEL BASE
CLASS OF FOOD CHARACTERISTICS TYPICAL EXAMPLE
REQUIRED

Most strongly Highly or moderately Apple juice Type 1

corrosive acid Berries
Products, including dark Prunes
Colored fruits and pickles Cherries
Pickles

Sauerkraut Type MS
Moderately corrosive Acidified vegetable Apricots Type MR
mildly Figs
Acid fruit products Grapefruit
Peaches

Peas TYPE MR or MC
Mildly corrosive Corn
Low acid products Meats
Fish

Dehydrated soups Type MR OR

Non- corrosive Frozen foods MC
Mostly dry and non- Shortening nuts
processed products

GENERAL TYPES OF CAN COATINGS

COATING TYPICAL USES TYPE

Fruit enamel Dark colored berries, cherries and Oleoresinous
other fruit requiring protection
from metallic salts

C – enamel Corn, peas and other sulphur Oleoresinous with suspended

bearing products including some zinc oxide pigment
sea foods

Citrus enamel Citrus products and concentrate Modified Oleoresinous

Meat enamels Meat and various specially Modified epons with

products aluminium pigment

Milk enamel Epons

Milk, eggs and other dairy
Beverage can enamel products. Two-coat system with
(non carbonated Oleoresinous of
beverage) Vegetable juices, red fruit juices, polybutadiene type base coat
highly corrosive fruits, non- and vinyl top coat
carbonated beverages
Beer can enamel
Beer carbonated beverages