INTRODUCTION TO FOOD PACKAGING 3114

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INTRODUCTION TO INTRODUCTION TO FOOD PACKAGINGFOOD PACKAGING

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Steven C SeidemanSteven C Seideman

Extension Food Processing SpecialistExtension Food Processing Specialist

Cooperative Extension ServiceCooperative Extension Service

University of ArkansasUniversity of Arkansas

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INTRODUCTIONINTRODUCTION

This module is a brief overview of the area This module is a brief overview of the area of food packaging. It is intended to give of food packaging. It is intended to give the reader an understanding of a broad, the reader an understanding of a broad, highly technical area.highly technical area.

Food packaging is an extremely broad Food packaging is an extremely broad area. Just go to a food store and look at all area. Just go to a food store and look at all the types of packaging used for food the types of packaging used for food items.items.

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Functions of Food PackagingFunctions of Food Packaging

Major role is preservation.Major role is preservation.

Aid the customer in the use of the productAid the customer in the use of the product

Used to unitize or group product togetherUsed to unitize or group product together

Used to communicate and educate the Used to communicate and educate the consumerconsumer

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Packaging’s Role in Packaging’s Role in PreservationPreservation

Protect the product from physical damage.Protect the product from physical damage. (e.g. inject nitrogen in potato chip bags)(e.g. inject nitrogen in potato chip bags)

Protect the product from the environmental Protect the product from the environmental contamination from dirt, insects and air.contamination from dirt, insects and air.Limit the oxygen around the product.Limit the oxygen around the product.

(This prevents the growth of bacteria and (This prevents the growth of bacteria and oxidation rancidity on food in vacuum packaged oxidation rancidity on food in vacuum packaged products)products)Limit the loss of moisture in the product.Limit the loss of moisture in the product.

(Prevents the surface dehydration of foods)(Prevents the surface dehydration of foods)

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Aid The Customer in the Use of Aid The Customer in the Use of the Productthe Product

Food packaging should have features Food packaging should have features which make the product easier to use and which make the product easier to use and add convenience.add convenience.

This includes zip-lock / recloseable This includes zip-lock / recloseable features, microwaveable products like features, microwaveable products like popcorn, screw caps like on milk popcorn, screw caps like on milk containers, dual ovenable trays, presliced containers, dual ovenable trays, presliced cheeses etc.cheeses etc.

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Used to Unitize or Group Used to Unitize or Group Product TogetherProduct Together

Most food products are shipped to stores Most food products are shipped to stores in master cartons that contain a number of in master cartons that contain a number of retail units.retail units.

Some retail foods are sold in individually Some retail foods are sold in individually packaged units such a soft drinks, small packaged units such a soft drinks, small bags of chips and puddings for school bags of chips and puddings for school children. children.

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Used to Communicate and Used to Communicate and Educate the ConsumerEducate the Consumer

It is the package that identifies the product to the It is the package that identifies the product to the consumer.consumer.

In addition to convincing customers to buy the In addition to convincing customers to buy the product, the package must inform consumers product, the package must inform consumers about how to prepare or use the product, about how to prepare or use the product, contents or amount of product contained, contents or amount of product contained, ingredients, nutritional content, and other ingredients, nutritional content, and other pertinent information found on a label on the pertinent information found on a label on the package.package.

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The Cost of PackagingThe Cost of Packaging

The packaging industry, as a whole, is one of The packaging industry, as a whole, is one of the largest industries in the United States and the largest industries in the United States and food packaging represents about half of the food packaging represents about half of the overall packaging industry.overall packaging industry.

Food packaging is not cheap. It does pay for Food packaging is not cheap. It does pay for itself in preventing food from spoilage.itself in preventing food from spoilage.

The cost of packaging in many cases is greater The cost of packaging in many cases is greater than the cost of the raw ingredients used to than the cost of the raw ingredients used to make the food.make the food.

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Requirements for Food Requirements for Food PackagingPackaging

1) Be non-toxic1) Be non-toxic

2) Protect against contamination and growth of 2) Protect against contamination and growth of

microorganisms.microorganisms.

3) Act as a barrier to moisture and oxygen.3) Act as a barrier to moisture and oxygen.

4) Filter out harmful UV light4) Filter out harmful UV light

5) Provide resistance to physical damage5) Provide resistance to physical damage

6) Protect against the ingress of odors and 6) Protect against the ingress of odors and

environmental toxicants.environmental toxicants.

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Requirements for Food Requirements for Food PackagingPackaging

7) Be tamper-resistant or tamper evident.7) Be tamper-resistant or tamper evident.

8) Be easy to open8) Be easy to open

9) Have dispensing and resealing 9) Have dispensing and resealing

features, if useful.features, if useful.

10) Be readily disposable10) Be readily disposable

11) Meet size, shape and weight 11) Meet size, shape and weight

requirements.requirements.

12) Have appearance, printability features12) Have appearance, printability features

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Requirements for Food Requirements for Food PackagingPackaging

12) Be low cost12) Be low cost

13) Be compatible with the food13) Be compatible with the food

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Types of Food ContainersTypes of Food Containers

Food packaging can be divided into Food packaging can be divided into primary, secondary and tertiary types.primary, secondary and tertiary types.

Let’s go through each one of theseLet’s go through each one of these

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Primary ContainersPrimary Containers

A A primary containerprimary container is one that comes in is one that comes in direct contact with the food, for example, a direct contact with the food, for example, a jar or a can.jar or a can.

It is the retail unit that you normally buy.It is the retail unit that you normally buy.

The packaging must be nontoxic, and The packaging must be nontoxic, and compatible with the food and cause no compatible with the food and cause no odor, flavor or other foreign chemical odor, flavor or other foreign chemical reactions. reactions.

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Secondary ContainersSecondary ContainersA A secondary containersecondary container is an outer box, case or is an outer box, case or wrapper that holds or unitizes several cans, wrapper that holds or unitizes several cans, jars, or other retail units together but does not jars, or other retail units together but does not contact the food directly.contact the food directly.It is often referred to as the master container.It is often referred to as the master container.It would not be possible to distribute products in It would not be possible to distribute products in glass jars, for example, without the corrugated glass jars, for example, without the corrugated secondary carton to protect against breakage. secondary carton to protect against breakage. The function of the secondary container is to The function of the secondary container is to protect the primary from physical damage protect the primary from physical damage during shipment and storage.during shipment and storage.Corrugated fiberboard (cardboard) is the most Corrugated fiberboard (cardboard) is the most commonly used to make secondary containers.commonly used to make secondary containers.

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Tertiary ContainersTertiary Containers

Tertiary containersTertiary containers group several group several secondary cartons together into pallet secondary cartons together into pallet loads or shipping units.loads or shipping units.The objective of tertiary packaging is to aid The objective of tertiary packaging is to aid in the automated handling of larger in the automated handling of larger amounts of products.amounts of products.Typically, a forklift or pallet jack is used to Typically, a forklift or pallet jack is used to move and transport tertiary containers.move and transport tertiary containers.

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FOOD PACKAGING FOOD PACKAGING MATERIALSMATERIALS

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Food Packaging MaterialsFood Packaging Materials

There are relatively few materials used in food There are relatively few materials used in food packaging ( metal, glass, paper and paperboard, packaging ( metal, glass, paper and paperboard, plastics ) but within each of these categories, plastics ) but within each of these categories, many types of packaging materials or many types of packaging materials or combinations of materials are available.combinations of materials are available.For example, within the category of plastics, For example, within the category of plastics, there are literally hundreds of types of films and there are literally hundreds of types of films and laminates varying in moisture permeability, gas laminates varying in moisture permeability, gas permeability, flexibility, bursting strength and so permeability, flexibility, bursting strength and so on.on.

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MetalMetal

Most cans are made of either steel or aluminum.Most cans are made of either steel or aluminum.The majority of canned products are in steel. Up The majority of canned products are in steel. Up until a few years ago, most steel cans were until a few years ago, most steel cans were coated with tin, hence the term “tin can”. The tin coated with tin, hence the term “tin can”. The tin has been replaced with thin coatings of has been replaced with thin coatings of chromium and chromium oxide and some food chromium and chromium oxide and some food compatible organic coatings.compatible organic coatings.The strength of the can is very important with the The strength of the can is very important with the canning of fruits and vegetables since it must be canning of fruits and vegetables since it must be able to withstand the pressure of retorting.able to withstand the pressure of retorting.

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MetalMetal

Steel cans are common for retorted fruits and Steel cans are common for retorted fruits and vegetables because of the strength needed to vegetables because of the strength needed to withstand the external pressure exerted from withstand the external pressure exerted from retorting.retorting.

Aluminum is used primarily in the beverage Aluminum is used primarily in the beverage industry (soft drinks and beer) since aluminum is industry (soft drinks and beer) since aluminum is structurally weak and the internal pressure from structurally weak and the internal pressure from the carbon dioxide in the drink adds the the carbon dioxide in the drink adds the necessary strength to the container.necessary strength to the container.

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GlassGlass

Glass is chemically inert and an absolute barrier Glass is chemically inert and an absolute barrier to the permeation of oxygen and water vapor.to the permeation of oxygen and water vapor.The principle limitations to glass are its The principle limitations to glass are its susceptibility to breakage, which may come from susceptibility to breakage, which may come from internal pressure, impact and thermal shock, its internal pressure, impact and thermal shock, its weight which increases shipping costs and the weight which increases shipping costs and the large amounts of energy required for forming large amounts of energy required for forming into containers.into containers.Glass is primarily formed from oxides of metals, Glass is primarily formed from oxides of metals, with the most common being silicon dioxide with the most common being silicon dioxide which is common sand.which is common sand.

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GlassGlass

Many glass containers are being phased Many glass containers are being phased out of use to plastics. For example, milk out of use to plastics. For example, milk and coffee used to be sold in glass jars but and coffee used to be sold in glass jars but now come in plastic containers.now come in plastic containers.

Breakage, liability issues, shipping weight Breakage, liability issues, shipping weight are all reasons that glass is slowly being are all reasons that glass is slowly being replaced by plastic.replaced by plastic.

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Paper, Paperboard and Paper, Paperboard and FiberboardFiberboard

The principle differences between these three The principle differences between these three are thickness and ultimate use.are thickness and ultimate use.Papers are thin, flexible and used for bags and Papers are thin, flexible and used for bags and wraps.wraps.Paperboard is thicker, more rigid and used to Paperboard is thicker, more rigid and used to construct single-layer cartons.construct single-layer cartons.Fiberboard is made by combining layers of Fiberboard is made by combining layers of strong papers and used to construct secondary strong papers and used to construct secondary shipping containers and is often referred to as shipping containers and is often referred to as “corrugated paperboard”.“corrugated paperboard”.

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Paper, Paperboard and Paper, Paperboard and FiberboardFiberboard

When used in primary containers, most paper When used in primary containers, most paper products are treated, coated or laminated to products are treated, coated or laminated to improve their protective properties.improve their protective properties.Paper from wood pulp and reprocessed waste Paper from wood pulp and reprocessed waste paper is bleached and coated or impregnated paper is bleached and coated or impregnated with waxes, resins, lacquers, plastics and with waxes, resins, lacquers, plastics and laminations of aluminum to improve its strength. laminations of aluminum to improve its strength. Other additives can be used to increase Other additives can be used to increase flexibility, tear resistance, burst strength, wet flexibility, tear resistance, burst strength, wet strength, grease resistance, sealability, strength, grease resistance, sealability, appearance, printability and barrier propertiesappearance, printability and barrier properties

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PlasticsPlastics

The term “plastics” refers to a broad range of The term “plastics” refers to a broad range of materials that have the common property of materials that have the common property of being composed of very large long-chain being composed of very large long-chain molecules and are made by connecting small molecules and are made by connecting small repeating molecules called “monomers” together repeating molecules called “monomers” together in a head-to-tail fashion, hence their name in a head-to-tail fashion, hence their name “polymers”.“polymers”.

Scientists came up with the concept of polymers Scientists came up with the concept of polymers from studying some natural occurring polymers from studying some natural occurring polymers such as starches, proteins and natural rubber.such as starches, proteins and natural rubber.

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PlasticsPlastics

The are only about 20 polymers that are The are only about 20 polymers that are used in food packaging but when they are used in food packaging but when they are combined in a variety of ways, they give combined in a variety of ways, they give rise to hundreds of different plastic-rise to hundreds of different plastic-containing structures. These polymers containing structures. These polymers vary widely in strength, oxygen and vary widely in strength, oxygen and moisture permeability, sealability etcmoisture permeability, sealability etc

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Polymers used in Food Polymers used in Food PackagingPackaging

Cellulose AcetateCellulose Acetate

PolyamidePolyamide

PolyestersPolyesters

PolyethylenePolyethylene

PolypropylenePolypropylene

PolystyrenePolystyrene

Polyvinylidene chloridePolyvinylidene chloride

Polyvinyl chloridePolyvinyl chloride

--CellophaneCellophane

--NylonNylon

-PET, Mylar-PET, Mylar

-Saran-oxygen impermeable-Saran-oxygen impermeable

-PVC – meat overwrap-PVC – meat overwrap

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CopolymersCopolymers

One can use a combination of the One can use a combination of the previous mentioned polymers to make previous mentioned polymers to make what is called copolymers that combine what is called copolymers that combine the strengths of various polymers. the strengths of various polymers.

For example, we can combine ethylene For example, we can combine ethylene with vinyl acetate, we get the plastic with vinyl acetate, we get the plastic polyethylene-vinyl acetate copolymer polyethylene-vinyl acetate copolymer known as ethylene-vinyl acetateknown as ethylene-vinyl acetate

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LaminatesLaminates

One can fuse together various types of One can fuse together various types of paper, plastics and aluminum foil to create paper, plastics and aluminum foil to create a class of films called laminates.a class of films called laminates.The advantage of laminates is that they The advantage of laminates is that they combine the advantages of certain combine the advantages of certain materials to improve the resulting film.materials to improve the resulting film.Some commercial laminates may contain Some commercial laminates may contain up to 8 layers.up to 8 layers.

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CoextrusionCoextrusion

Coextrusion is the process whereby two or Coextrusion is the process whereby two or more molten plastics are layered upon more molten plastics are layered upon each other in a flat manner and ultimately each other in a flat manner and ultimately produces a multilayer film on cooling.produces a multilayer film on cooling.

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Edible FilmsEdible Films

Edible films have been around for centuries. Edible films have been around for centuries. Sausage casings are one example.Sausage casings are one example.Food materials can be protected from loss of Food materials can be protected from loss of volatiles or reaction from other food ingredients by volatiles or reaction from other food ingredients by being encapsulated in protective edible materials.being encapsulated in protective edible materials.This can be accomplished by spraying a thin film This can be accomplished by spraying a thin film of gelatin, gum arabic or other edible material of gelatin, gum arabic or other edible material onto a food product. onto a food product. The coating of raisins with starches to prevent The coating of raisins with starches to prevent them from moistening the packaged breakfast them from moistening the packaged breakfast cereal is one example. cereal is one example.

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Edible FilmsEdible Films

Edible films are also used to coat fresh fruits and Edible films are also used to coat fresh fruits and vegetables to reduce moisture loss and provide vegetables to reduce moisture loss and provide increased resistance to the growth of surface increased resistance to the growth of surface molds.molds.

The most common and oldest edible film is wax.The most common and oldest edible film is wax.

A wide range of products such as apples are A wide range of products such as apples are waxed for appearance and improved keeping waxed for appearance and improved keeping qualityquality

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HOW DIFFERENT FOODS HOW DIFFERENT FOODS ARE PACKAGEDARE PACKAGED

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How Different Foods are How Different Foods are PackagedPackaged

Since different foods spoil or deteriorate Since different foods spoil or deteriorate differently than others, there are certain differently than others, there are certain ways that foods are packaged to give ways that foods are packaged to give them the longest shelf life possible.them the longest shelf life possible.

We will now go through some of the major We will now go through some of the major categories of foods and discuss their categories of foods and discuss their packaging.packaging.

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Meat PackagingMeat Packaging

Red meats such as beef and pork have Red meats such as beef and pork have traditionally been overwrapped in a traditionally been overwrapped in a styrofoam tray with PVC film- oxygen styrofoam tray with PVC film- oxygen permeability for red color. More recently, permeability for red color. More recently, meats are being packaged in gas meats are being packaged in gas atmospheres such as a mixture of oxygen, atmospheres such as a mixture of oxygen, carbon dioxide and nitrogen.carbon dioxide and nitrogen.

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Meat PackagingMeat Packaging

Red MeatRed Meat

SausagesSausages

PoultryPoultry

SeafoodSeafood

PVC overwrap (Oxygen)PVC overwrap (Oxygen)Gas flushed in a trayGas flushed in a tray

Vacuum packaged Vacuum packaged Frozen turkeysFrozen turkeys

In a OIn a O22 impermiable bag impermiable bag

Gas atmosphere in a trayGas atmosphere in a trayFrozen as precooked chickenFrozen as precooked chickenFrozenFrozenGas flushedGas flushed

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Fruits and VegetablesFruits and Vegetables

Canned- shelf stableCanned- shelf stable

Jars- especially baby foodJars- especially baby food

Frozen -in bags in a boxFrozen -in bags in a box

Netted fruitsNetted fruits

Edible coatedEdible coated

Gas flushed plastic bags, especially Gas flushed plastic bags, especially saladssalads

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Cereals and Cereal ProductsCereals and Cereal Products

Oat Meal in paperboardOat Meal in paperboard

Most breakfast cereals in waxed or plastic Most breakfast cereals in waxed or plastic bags inside a paperboard box.bags inside a paperboard box.

Bread and bakery items are packaged in a Bread and bakery items are packaged in a plastic bag.plastic bag.

Crackers are packaged in waxed or plastic Crackers are packaged in waxed or plastic bags within a paperboard box.bags within a paperboard box.

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ChipsChipsMost chips in a gas filled bagMost chips in a gas filled bag

Some chips in paper bagsSome chips in paper bags

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Dairy ProductsDairy Products

Originally in glass jugsOriginally in glass jugsLater came wax coated paperboardLater came wax coated paperboardNow, still some wax paperboard but Now, still some wax paperboard but changing over to plastic jugschanging over to plastic jugsCheese, yogurt, cottage cheese etc in Cheese, yogurt, cottage cheese etc in plastic containers.plastic containers.Ice cream, butter come in wax coated Ice cream, butter come in wax coated paperboard or plastic containers.paperboard or plastic containers.

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BeveragesBeverages

Most soft drinks in aluminum cansMost soft drinks in aluminum cans

Some juices sold in plastic jugsSome juices sold in plastic jugs

Coffee sold in glass jars, plastic jars and Coffee sold in glass jars, plastic jars and metal or plastic cansmetal or plastic cans

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EggsEggs

The egg shell is mother natures most The egg shell is mother natures most perfect package. Enzymes under surface perfect package. Enzymes under surface prevent microbial invasionprevent microbial invasion

Usually sold in paperboard container that Usually sold in paperboard container that protects the eggs against shockprotects the eggs against shock

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Popcorn in Microwavable PackagesPopcorn in Microwavable Packages

Packaged with outer plastic wrap to Packaged with outer plastic wrap to prevent moisture migration.prevent moisture migration.

Inner paper package may contain a Inner paper package may contain a susceptor than focuses the microwaves susceptor than focuses the microwaves energy to pop the popcorn.energy to pop the popcorn.

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SUMMARYSUMMARY

This module has covered the role of This module has covered the role of packaging in food preservation, the packaging in food preservation, the requirements of food packaging, type of requirements of food packaging, type of containers and packaging materials used containers and packaging materials used in food packaging and how various types in food packaging and how various types of packages are used to package foods of of packages are used to package foods of different types.different types.

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