Food packaging by JASNA. Food packaging methods

Food packaging methods and techniques

1. FOOD - PACKAGING
PRESENTED BY JASNA S
I MSC MICROBIOLOGY

2. Fermented food products are important for human diet, and their
protection through packaging is crucial.
Effective packaging requires a blend of packaging art, materials
science, and technology, tailored to the product's nature and
characteristics, as well as market needs and potential hazards.
The need for packaging dates back to ancient times when people
stored food for survival, initially using plant leaves and other natural
materials. Over time, as human needs evolved, so did the
requirements for more effective and durable packaging solutions.
INTRODUCTION

3. Packaging is often described as a silent salesman and is defined as a
device to contain what it sells or a device which sells what it contains
Today we find packages which provide all the information about its
contents and also educate the consumer about its use and its shelf-
life
Many product manufacturers today use packaging as a marketing
tool, as they realise that packaging is no more an element of cost
which can be discarded after the product reaches the consumer
By using appropriate packaging, losses and damages in storage,
transportation and distribution of the products are prevented and
thus, with little investment by using appropriate packaging, one is
able to save product losses

4. Today with the substantially increased needs of human beings, a
variety of products are made and used which not only help the
survival but also provide for beauty, decoration, aesthetics, comforts
and many other virtues for better life. Packaging for different
products today has to cater to many important requirements, such
as:
To contain, preserve and to protect the food product.
To dispense the food product.
To communicate about the product to the consumer.
To provide aesthetic appeal.
To withstand storage and transport hazards
NEED FOR PACKAGING

5. Some of the basic packaging materials used today
Cellulosic materials like paper and cellulosic films
Glass.
Metals like aluminium, steel and tin plate.
Plastics with a host of polymers.

6. PACKING MATERIAL

7. CONSIDERATIONS AND REQUIRMENTS FOR PACKAGING OF
FERMENTED PRODUCTS
Fermentation is also used to produce new flavours 16 desired by
consumers which also changes its physical characteristics, thus, creating
different food products.
It also helps in inhibiting spoilage by producing alcohol or acids, and
when associated with other preservation techniques like low
temperature, heating, vacuum packaging or in combination with salt and
sugar, extends its shelf life.
If fermentation process is not properly carried out or preservation is not
adequate, fermented food can still spoil due to oxidation, growth of
micro-organisms or migration, contamination or other similar reasons

8. Some of the important factors in selection of packaging
materials
Shelf-life desired
Packaging process adopted
Volume of business
Unit quantity packed
Type of market
Cost of packaging, besides other factors

9. Gass bottles
Plastic containers
Rexible laminates
based on pastic films,
aluminium foil and
paper
Metal containers
Wines, therapeutic products & other
fermented products based on fruits
and vegetables.
Wines, therapeutic products and
Indian sweets like Shrikhand, Rasgullas
etc.
Paneer, cheese and other milk
products.
Cheese and Indian sweets based on
milk products.

10. GLASS
CONTAINERS

12. GLASS CONTAINERS FOR PACKAGING
Glass containers of different shapes and sizes have been used
for packaging of variety products for many years.
Owing to its inertness, glass seems to be one of the most
favoured packaging media, particularly for beverages,
bottles have been employed for this purpose.
The glass of type I, commonly known as neutral glass or
borosilicate glass is used for packaging of very sensitive
products.

13. Glass containers of type II have their inner surface alkalanity
neutralised by a treatment
Glass of type III with limited alkalinity is used for packaging of
many product including pharmaceuticals which are not very
sensitive to changes in their pH value of the dry products are
packed in glass containers of type III.
Glass is very transparent and, therefore, its contents can be
clearly seen for any rities or suspended particles, but this
transparency of the glass containers times becomes detrimental
to its content as some of the products tend to morate on
exposure to sunlight. In such cases, amber coloured glass or
green glass is used. These colours filter the detrimental wave
length of sunlight

14. One of the most important characteristics of the glass containers is
its top bottom compression resistance. Packaging of products like
beer in glass bottles is a example where the use of good
compression resistance of glass bottles is made
DIMENSION
This refers to height, body diameter, neck diameter, etc. These are critical
as they affect productivity on the high speed machines)
VOLUME
This parameter is important as an oversize bottle would give an impression
of less volume to the consumed On the other hand an undersize bottle
would overflow with the correct fill-volume.

15. This becomes critical particularly on high speed machines for application of
ciasures, and therefore, their tolerances and finish become very important.
Many a times the formulation of ingredients if not uniform, produces the
glass containers without proper homogenity. For testing the homogenity of
the glass, ring section analysis is done. In this test, a small ring is cutout from
a glass body and seen against polarized light i polariscope. On movement of
the ring, a play of colours is indicative of non-homogenity of glass which
should be avoided.
HOMOGENEITY
NECK DIMENSIONS AND FINISH

16. ANNEALING
Glass containers are produced at a very high temperature. Subsequent to
their production, they are exposed to room temperature and due to a
sudden change in the temperature (exposure to room temperature) of the
outer surface stresses build into the glass containers, weaken them.
THERMAL SHOCK
Glass containers during their use often receive thermal shock due to
sudden exposure to very high or low temperature. For example,
during hot-filling, container may receive the product at 70 to 80°C. To
evaluate whether the glass container has adequate strength to
withstand such thermal shock, thermal shock test is conducted

17. List of some Indian standards used for glass bottles.
IS 75-11 (Part 1 to 8) Dimensions for neck finishes
IS 10133 Glass Bottles Dimensional relationship and tolerances
IS 10497 Method of test for brimfull capacity
IS 11984 Glass bottles for free-flowing liquids

18. METAL
CONTAINERS

19. The metal containers for packaging are considered here with reference to
their use as unit or retail pack. The two major types of containers are tin
plate and aluminium containers
TIN CONTAINERS
In food packaging, tin containers are accepted as ideal because of their excellent
properties (Plate 3) Tin containers are made from tin plate. Tin plate is light gauge
cold reduced, low carbon steel strip or sheet which is coated on both sides by pure tin
It has thus, strength and formability of steel coupled with corrosion resistance,
Tin coating has low melting point, possesses lubricant quality and imparts a good
appearance. It also provides an excellent printing surlace
Tin plate is sold in the thickness from 0.13 mm to 0.5 mm. At present,
base plate is coated by differentially coated tin by electrolytic process

20. (The steel plate production is the first step in the tin plate production.
(a) The Steel Plate: The steel base plate is low carbon mild steel typically containing 0.03
to 0.13% carbon and is generally obtained by basic oxygen process (BOP).
(b) Chemical Composition: When molten steel is cooled, the solubility of gases
dissolved in the metal decreases and due to the reaction of carbon with oxygen, carbon
monoxide is formed.
Gases sometimes are trapped in semi-solid żone as molten steel does not solidify at
precise temperature. The unavoidable carboxygen reaction, can be controlled, to check
the gas evolution and allowing the reaction to proceed upto the desired level)
TIN PLATE PRODUCTION

21. Aluminium or silicon compounds are deoxidisers that are used? The
killed or stabilised steel is used for deep drawing application. Sufficient
deoxidiser is added to stop evolution of gases
TINNING METHODS
Electrolytic Method: In this method, electrolytically tin is deposited on
steel plate. The steel plate is cleaned by electrolytic pickling. The
electrolyte is a diluted acidic or alkaline solution. The tin deposited in this
method is uniformly spread over the surface. The tin flow is brightened by
melting the tin momentarily and chilling quickly. It is finally chrome
plated and given a thin coating of oil. The tin can be differentially coated
by electrolytic method)

22. Hot Dipping Method: In the hot dipping method, the sheets are dipped in
breaking the surface after passing through roller which strips-off tin. The tin
surface is cleaned by soda bath, dryed and polished by branner The tin
coating is not uniform in this method and below a certain coating thickness, it
is difficult to go. Differential in coating is not possible by hot dipping
method)

23. PLASTICS FOR FOOD
PACKAGING

25. PLASTICS FOR FOOD PACKAGING
The conventional packaging materials for food are metal and
glass containers. Today these are faced with a stiff competition
from plastics. The plastics being les expensive are finding more
and more use in food packaging . The plastic packaging due to
their light weight, convenience for use and rise of flexible
packaging for food are contributing to its popularity
Various types of plastics are used for food packaging but these
should be of food grade

26. TYPES OF PLASTICS
(a) Low density Polyethylene (LDPE): This is the most widely used polymer in food
packaging. It is a low cost and an easily processable polymer, exhibiting chemical and
water resistance. It has moderate resistance for gases and water vapours. It cannot be
used for products needing sterilization under steam. It can be blow-moulded or
injection moulded or extruded on substrates.
(b) Linear Low Density Polyethylene (LLDPE): LLDPE has a linear structure without
branching. It has higher density than LDPE. It melts at higher temperature than
LDPE. It has higher strength properties and stress-crack resistance)
(c)High Density Polyethylene (HDPE): HDPE is hard, tough and opaque when
compared to LDPE. Its melting point is high, hence can be used for process requiring
steam sterilization. It has good barrier properties

27. (d) Polypropylene (PP): PP is hard and exhibits shining and glossy surface. It has better
barrier properties and hence finds good applications in food packaging. Its strength
properties are higher when compared with LDPE. It can be used in retort pouches, where
processing temperature of 130°C can be reached.)
(e) Bioxically Oriented Polypropylene (BOPP): The polypropylene is oriented to
give binxically oriented polypropylene with excellent strength, barrier and clarity. In the
case of films, a heat seal coating is required for sealing purposes.
(f)Polyvinylidine Chloride (PVDC): PVDC is a Vinyl co-polymer having combi-
nation of vinylidine chloride and acrylonitrile or PVC with excellent barrier properties. It
has also excellent oil resistance and aroma retention, does not need coating for heat
sealing and can be used as heat sealent for films like BOPP, polyester and paper.

28. (g) Nylon: Nylon is a polymer exhibiting high mechanical strength with better gas barrier
properties and high chemical and oil resistance. It has poor water resistance.
(h) Polyester (PET): PET has excellent gloss and clarity with high mechanical properties. and
good resistance to gases, water vapour and chemicals. PET has dimensional stability over a
wide range of temperature. If metallised, it gives additional advantages.
(1)Ionomer: These are co-polymers produced by reaction between ethylene and acrylic acid
derivatives and possess excellent hot-tack strength. They have good clarity, oil resistance and
sealing characteristics.
(j) Ethylene-Vinyl Alcohol (EVAL): The co-polymer is obtained by reaction between ethylene
and vinyl acetate, process good strength properties and has good heat sealability. It withstands
low temperature. It has high impact and puncture resistance with excellent gas barrier
properties,

29. ALUMINIUM FOIL AND
LAMINATES

31. Aluminium foil is a post war development in the country. Rise of the flexible
packaging is due to its light weightness, low cost and convenience. Its easy
disposal adds to its credit. Aluminium foil alone has above requisites and many
more to give it a highest place in the barrier flexible packaging systems.
Aluminium foil is a light gauge material ranging from 0.009 mm, to 0.06 mm
thickness. It is produced from commercially available aluminium, with
aluminium content of more than 98%. It is available in two grades or temper ie
hard or soft. It may also have bright finish on both the sides or matt finish on
one side. When used as plain, it can be coloured, printed, coated, lubricated
and embossed. It can be laminated to several flexible substrates

32. PROPERTIES
Aluminium foil is non-toxic.
odourless and tasteless and is a good conductor of
heat, which is useful in freezing or baking of packeted
food products.
With laminates it can be used in several ways in food
packaging field,

33. Aluminium Foil/Polyethylene
These laminates are used in pharmaceutical industries for strip packaging of tablets and
capsules.
Aluminium foil/heat seal coating
Heat sealing characteristics of aluminium foil is contributed by coating of a lacquer on to the
inner surface of the aluminium foil. This type of laminate is also useful in pharmaceutical and
allied industries.
Paper/Aluminium foil/polyethylene
Paper laminates of this type have excellent barrier properties and are used for packaging of
electrolytes, fruit concentrates, coffee and similar products which are highly moisture sensitive.
Polyester/aluminium foil/polyethylene
This tripple laminate is a popular laminate as it offers highest barrier properties for protection
of sensitive food products. Aluminium foil also finds application in multi-layered structure of
5/6/7 layered laminates which are used for manufacture of laminated tubes or sterile packaging
of food products, like milk, fr inuit juices etc.)

34. MOULDED PULP
CONTAINERS

36. These containers are produced from paper pulp normally
used for production of paper and paperboard .The
containers are formed by injecting pulp in the mould and
then compressed air at high temperature. The containers can
have Shape of different designs depending upon the shape of
the product. Generally, these containers are used for product
protection against shock and impact during handling and
transportation. For example, the packages such as egg trays,
moulded pulp Sleeves for fragile bottles are commonly used

37. CLOSURES

38. There are variety of closures used for closing different type of
containers The se of a closure can be one or more of the following:
To hermetically seal the container and protect the contents from
exposure to atmosphere and from contamination.
To provide a pilferproof seal and the built-in pilfer evidence feature
for the benefit of package buyer.
• To provide a means of decoration.
• To act as a dispensing device or measuring cup
• To provide any other specific features needed for product use/
application

39. The closures are manufactured from a variety of materials though
primarily als and plastics are predominantly used. Metal closures are
fabricated from plate, mild steel plate or aluminium. These closures take
different forms rending upon the need of application. For example, in
metal closures there are nety of designs used such as:
Roll-on pilferproof (ROPP).
Roll-on non-pilferproof (RONP) and others
There are also crown caps used for beverage bottles and other process
products. closures used for cans have a special feature for easy opening
and these are described as easy opening ends (EOE)

40. BOXES

41. When designing boxes, there are several important factors to consider:
Customer related factors, design of graphics, convenience for carrying
and storing.
Dimensions to allow easy handling and to efficiently cover a pallet when
stacked with no overlap at the edge.
Board quality and direction of flute, to give maximum stacking strength.
Type of finish on the board if the surface is sealed efficiently, glue will not
adhere correctly and
Bag to box ratio, e.g. for four-litre casks, a head space of about 10% is
recommended. This can be estimated by calculating the volume of the
box from inside measurements and taking the actual volume of wine in
the bag plus the volume of inert gas as the bag volume.

42. The cask has to be:
Free of bulge and warp.
Yet resist bulge on the filling line.
Fold crisply along score lines.
Fit within the outer box on high speed palletizing lines and
The perforations around the spiggot hole must open cleanly
but not burst open when travelling along the filling line.
These and many other factors require consideration in
production of bag-in-boxes.

43. Reference
Food fermentation - Joshey and
Pandey

44. THANKYOU