Stretching the limit

23 June 2011



By extending pack functionality, brands are able to deepen the consumer’s trust and loyalty, and gain a host of supply chain advantages. Joanne Hunter reports.


Active packaging has functions beyond the inert passive containment and protection of the product. Technology developers are especially focused on modified and controlled atmosphere applications for perishable products. Intelligent and smart packaging can involve some kind of freshness indicator or a means to measure the internal atmosphere of the pack or the shipping environment. This category is also known as ‘communicative’ packaging because information about the product can be communicated to the supply chain and, perhaps more controversially, the end user; or it can trigger active functions.

The global market for active and smart packaging technology for foods and beverages is expected to grow from US$15.798 billion in 2010 to US$23.474 billion in 2015, at an estimated annual growth of 8.2%, according to market research firm Research & Markets. Technologies have the potential to meet the growing demands of food safety in dairy, meat and poultry, and ready meal segments. After North America, Europe forms the second largest market due to the call for sustainable packaging and stringent regulations.

New product development is driving the introduction of advanced technology in the food and beverage sector, led by the oxygen scavenger segment that offers extended freshness and a higher quality product. Trays with oxygen scavengers were supplied by RPC to French food manufacturer La Belle Chaurienne for premium ready meals, for example (see this month's Ready Meals feature).

Odour scavenging

Sealed Air Cryovac’s integrated odour scavenging system aims to address the presence of off smells in products with a long shelf life that are vacuum packed or packaged with minimal headspace. Costs can be reduced, such as spoilage allowance, end of code date write-downs, and returns, says Cryovac.

The Freshness Plus system contains a mix of additives in a multilayer film that can trap confinement odours in the substrate and take them away from the product. The microbial quality of the product is improved by the use of oxygen absorbers in the film to help preserve the original colour, flavour and nutrition.

Applications include smoked and processed meats, cheeses, baked goods, fresh pasta and dry food products such as coffee, nuts, drink and baking mixes, and snack foods. It is equally effective in dry products because the scavenging action does not require moisture, says the company. Freshness Plus is suitable for use when metal detection is carried out after the packaging operation. It also protects against light-catalyzed oxidation so that products can be displayed in clear packs.

An active packaging system by American company CO2 Technologies uses pads that produce ‘clouds’ of carbon dioxide to extend shelf life, reduce spoilage and improve food safety.

CO2 Fresh-Pads offer meat, poultry and seafood processors an ‘all-natural’ solution, so called because they avoid chemicals, preservatives and high heat processes.

The system contains active ingredients such as citric acid and sodium bicarbonate, the moisture actuated CO2 generating materials in the pads. They are located between layers of absorbent material and bound to fibres of the material. The gradual release of CO2 displaces oxygen and ethylene to retard bacteria growth by up to 50% on perishable items, explains JS Food Brokers, promoting the product on behalf of the patent holder.

Its CEO Steve Josephs tells Packaging Today: “Since our launch this past January into the meat, poultry and seafood processing industry, our business has really taken off with interest from all over the world. The market where the product has been especially well received is with protein processors who supply products to foodservice and retail grocery companies.

“Several companies now using our CO2 Fresh-Pads have conducted scientific tests at independent laboratories as well as internally to validate the significant improvement over time in retarding bacteria growth on ground beef, chicken and seafood, leading to significant improvements in food safety and an increase in shelf life of 20-50%.”

Shamrock Foods, a supplier to food service and meat processing customers in the USA, is a Fresh-Pads convert, as Manufacturing Division Consultant Mike S Brown confirms: “We first tested the CO2 Fresh-Pads in October, 2010 on ground beef and seafood, and got positive results on both. Our processing plants now use them in most of these products. Now, we are also using them with our premium Royal Crest Farms 100% natural chicken. Here in the USA Shamrock Foods is known in the industry for using the highest quality production methods and the CO2 pads help us maintain that quality reputation.”

Mr Josephs adds: “We are in discussions with a food marketing company in Europe to help set up distribution. In fact, we just recently shipped samples for testing in the market.”

Recyclability

An active system should not give cause for concern over the continued recyclability of packaging to which it is introduced. So it was important for PET producers and users that the European PET Bottle Platform (EPBP) has recognised that ColorMatrix’s oxygen scavenging HyGuard and light blocking Ultimate UV technologies do not have a negative impact on current European PET recycling.

HyGuard can help extend shelf life for UV sensitive food, beverage, personal care and home cleaning products. It is a catalytic barrier system, whereas conventional oxygen scavengers are based on an oxidisable polymer. It works with the bottle closure system, leaving the container wall free of any additive material that may adversely affect its clarity and recyclability. Its advantage lies in the ability to offer high level product protection in lighter weight and smaller portion size PET containers.

Healthcare

Biotivia has adopted active packaging technology to protect Resveratrol from oxidation. Resveratrol is an extract of red wine said to have anti-ageing and health properties, but its benefits are compromised if the active isomer is exposed to oxygen. An improved bottle system, developed with Mitsubishi of Japan, uses scavenging technology in the form of a small packet, which is said to prevent product degradation, even when the bottle is opened daily.

“This is a major innovation in supplement packaging which was developed and tested by Biotivia scientists to ensure that our buyers receive a uniquely high potency product,” Michael Zhang, Quality Assurance Officer at Biotivia, tells Packaging Today.

Fresh fruit

Emco Packaging Systems has moved beyond an established range of oxygen and carbon dioxide scavengers and carbon dioxide emitters and is particularly focused on benefits for the fruit industry.

Consultant Technical Director at Emco Dr Nigel Parker explains: “We produce sophisticated pack atmosphere food packaging inclusions, designed to establish and maintain predetermined, optimum pack atmospheres. The main application for this technology is with retail packed whole, fresh fruit, especially soft fruit, where the inclusion is placed in the primary packaging (sometimes well in advance but not always), at the time of packing.

“It is also being considered for prepared produce, although ideally this will require a slightly different delivery format, which we are in the process of perfecting. Another technology we have is an ozone emitting inclusion, again for fresh fruit, which inhibits microbial spoilage.

“With the soft fruit, these inclusions are capable of more than doubling existing shelf lives and halving retail wastage, which has ecological implications, especially as their own eco-footprint is relatively small.”

The overall aim is to deliver still-fresh and safe food at point of sale despite a long chain of distribution.

“At Emco we act in a pilot role, looking at how to produce the packaging at a speed that fits into packing lines. We are seeing in retailers more of a desire for active and intelligent packaging to work. This could be because what we make packaging for - food - is increasing in value and the shelf life and safety for humans are priorities. Fuel costs will continue to drive up overall costs of food. It’s the value of the whole package that counts; but the industry is still focused on the cost of the packaging,” ventures Dr Parker.

Multimedia freshener on the go

Cans produced by Ball Packaging Europe for Coca-Cola have created a mobile link between music and refreshment.

The new 25cl sleek cans printed with a QR code take smart phones straight to a Coke music portal that gives out details of the brand’s ‘exclusive’ music shows in German cities.

Drum and earphone designs on the cans deliver an immediate visual link-up to the musical experience.

The Coca-Cola campaign features the small cans with four different cheeky slogans pitched at younger consumers.


Beer in PET bottle can stand the heat

PET beer bottles around the world have closures by Bericap that are fitted with an oxygen scavenger to maintain the quality of beer during its shelf life.

Bericap’s DoubleSeal SuperShorty Crown O2S closure is designed to absorb the oxygen in the headspace of the bottle. It looks similar to the traditional beer crown cork and was the first 28mm closure fitting to the PCO 1881 neck, says the company.

Since 2003 Germany and countries in Eastern Europe have introduced beer in PET bottles. China followed in 2009, using the Bericap’s oxygen scavenging closure.

The technology has now moved into India in a one-litre PET beer bottle.


CO2 Technologies’ CO2 Fresh-Pads are used in ground beef products from Shamrock Foods. CO2 Biotivia is using oxygen scavenging to increase potency and shelf life of health supplements. Biotivia Cans create link between music and refreshment. Cans Bericap's oxygen scavenger maintains beer quality. Bericap

CO2 CO2
Biotivia Biotivia
Bericap Bericap
Cans Cans


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