Alternative flexible plastic packaging for instant coffees

Abstract

Instant coffees are consumed worldwide and their packages must protect them mainly from moisture gain. Flexible packaging stand-up pouches made by PET/Al foil/LDPE are currently used but, the look for alternative materials is interesting to replace the aluminum foil with reducing costs and focusing on sustainability. Therefore, the aim of this study was to evaluate the quality loss of freeze-dried and spray-dried (agglomerated and powder) instant coffees during 365 days at 25 °C/75% RH, packaged in five plastic structures: PET (polyethylene terephthalate)/Al (aluminum) foil/LDPE (low density polyethylene), LDPE/HDPE (high density polyethylene)/LDPE, BOPP (biaxially oriented polypropylene)/BOPP met (metallized)/PP, PET/PET met/LDPE and PET/BOPP met/LDPE. The results were compared with the shelf-life estimated by modeling the moisture sorption isotherms of the products by mathematical models. Results indicated that the lower the barrier to water vapor of the packaging material, the greater the gains in moisture and water activity of the instant coffees and in addition to being thermally less stable. After 365 days of storage, the three soluble coffees still had acceptable characteristics in the five packaging structures, indicating that it is possible to replace the currently used laminate, which contains aluminum foil, with recyclable structures. However, the greatest stability for the coffees was obtained using the alternative structures: BOPP/BOPP met/PP and LDPE/HDPE/LDPE, a result that was in concordance with that obtained by mathematical modeling.