Barrier Packaging Research Articles

Pioneering high barrier packaging for pressure assisted thermal sterilization of low-acid food products

Pressure-assisted thermal sterilization (PATS) utilizes flexible packaging with low oxygen and water vapor transmission rates (OTRs, WVTRs). In this study, pouches made from metal oxide (MO)-coated (A–D) and ethylene vinyl alcohol (EVOH)-containing (E, F) multilayer films were filled with water and mashed potatoes (MP), preheated at 98 ± 0.5 °C for 10 min, and processed using a pilot-scale high-pressure processing machine (HPP) at 600 ± 5 MPa for 300 s. The initial vessel temperature and the fluid medium were 90 °C, and during processing, the temperature of the fluid medium increased to approximately 120 °C. After processing, the water-filled pouches were emptied, refilled with a novel oxygen indicator, and stored at 40 ± 0.2 °C for 80 days. The MP-filled pouches were stored at 49 ± 1 °C for 60 days. MO-coated film D contained fewer defects, had ultra-low OTRs and WVTRs, showed insignificant (p > 0.05) moisture absorption and changes in crystallinity after PATS processing, and exhibited minimal color change in both the oxygen indicator and the packaged MP during the 60 days of storage. The ultra-high barrier of film D could be attributed to the presence of multiple AlOx-coated PET layers that successfully prevented oxygen ingress, even after exposure to high temperature and pressure conditions during PATS processing. Among the EVOH-based structures, the Film F showed a 22.3 % lower OTR than Film E (p < 0.05), due to a 16.7 % greater EVOH-layer thickness, despite having a lower overall thickness than Film E. Overall, this study can assist packaging manufacturers in designing and developing high-barrier flexible packaging suitable for in-package, shelf-stable food products.

Eco‐Friendly Food Packaging Barrier Coatings Comprised of Ball‐Milled Polysaccharide Polyelectrolyte Complexes

ABSTRACTIncreasing demand for packaging has motivated research into sustainable materials to prevent continued plastic pollution. Materials based on polysaccharide polyelectrolyte complexes (PPCs) are emerging as a viable solution for packaging applications. We employed ball milling, a well‐established technology, for the preparation of PPC materials to create an innovative one‐step process capable of producing highly concentrated and homogeneous PPC particle precursor dispersions. We fabricated carboxymethyl cellulose (CMC) and chitosan (CS)–based PPC solutions exhibiting high‐solid loading and investigated the potential of PPC solutions made from ball milling as alternative barriers for packaging. PPC‐coated paperboard exhibited improved Cobb test performance and outstanding grease resistance as compared to pristine paper. The results certified that a single‐step process via ball milling can produce high‐solid content PPC solutions useful for creating bio‐based coatings with excellent barrier performance.

Biodegradable Copolyesters Derived from 2,5-Thiophenedicarboxylic Acid for High Gas Barrier Packaging Applications: Synthesis, Crystallization Properties, and Biodegradation Mechanisms

Biodegradable Copolyesters Derived from 2,5-Thiophenedicarboxylic Acid for High Gas Barrier Packaging Applications: Synthesis, Crystallization Properties, and Biodegradation Mechanisms

Формирование свойств биодеградируемых пленок на основе рыбного желатина

Nowadays in the food and nutrition industry special attention is paid to the creation of non-toxic, easily recy-clable packaging materials of a new assortment, capable of providing reliable protection of products from harmful factors. The object of the study was biodegradable film compositions based on fish gelatin and agar, with the addition of plasticizing agent - glycerol. Experimental and analytical studies were carried out using standard and original methods. Modeling of the process of thermal treatment of film compositions was carried out, the experimental dependence of moisture absorption of films on temperature (range 120-160 °C) and duration of the thermal modification process (10-30 minutes) was established. The possibility of thermal modification of biodegradable film compositions was determined. The rational mode of thermal treatment of films is the temperature interval of 140 °C for 20 minutes, which allows to keep the moisture absorption index at the maximum level (842%), exceeding the initial index by 8.4 times, during 120 hours. The established parameters of thermal structuring allow to keep organoleptic quality indicators of films at a high level and to obtain a homogeneous, porous and elastic film. Thermally modified films at temperatures of 140 and 160 °C are characterized by increased dissolution time up to 40 and 70 minutes respectively at dissolution temperature of 60 °C and up to 15 and 30 minutes respectively at dissolution temperature of 75 °C. It is shown that thermal modification of biodegradable films will contribute to compliance with safety requirements, environmental friendliness, absence of toxicity. Thermal modification allows to increase functional and technological properties of composite biodegradable films, which can be used to create a wide range of modern packaging barrier materials.

Impact of Packaging Methods Coupled with High Barrier Packaging Loaded with TiO2 on the Preservation of Chilled Pork.

This study investigated the impact of packaging methods coupled with high barrier packaging loaded with titanium dioxide (TiO2) on the quality of chilled pork. The experiment consisted of three treatment groups: air packaging (AP), vacuum packaging (VP), and vacuum antibacterial packaging (VAP). Changes in total viable count (TVC), pH value, total volatile basic nitrogen (TVB-N) value, sensory attributes, and water holding capacity of pork were analyzed at 0, 3, 6, 9, and 12 d. TVC of the VAP group was 5.85 Log CFU/g at 12 d, which was lower than that of AP (6.95 Log CFU/g) and VP (5.93 Log CFU/g). The antibacterial film incorporating TiO2 effectively inhibited microorganism growth. The VAP group exhibited the lowest pH value and TVB-N value among all the treatment groups at this time. The findings demonstrated that the application of VAP effectively preserved the sensory attributes of pork, the hardness, cohesiveness and adhesiveness of pork in VAP group were significantly superior than those in AP group (p<0.05), but not significantly compared with VP group. On the 12 d, the CIE a* value of pork in VAP group was significantly higher (p<0.05). This exhibited that VAP could effectively maintain the freshness of chilled pork and extend the shelf life for 3 d compared to the AP group. These findings provide empirical evidence to support the practical implementation of TiO2-loaded packaging film in the food industry.

Effect of Layered Double Hydroxide and Its Localization on the Structure and Properties of PBAT/PPC Composites

AbstractThe blends of poly(butylene adipate‐co‐terephthalate) (PBAT), poly(propylene carbonate) (PPC), chain extender (ADR) and layered double hydroxides (LDH) are prepared by different extrusion methods. Effects of LDH and its distribution on rheology, phase morphology, mechanical properties, water vapor barrier properties and food preservation properties are investigated. Results show that when PBAT, PPC, and LDH are mixed directly, LDH is preferentially distributed in the PBAT phase. When LDH are mixed with PPC firstly and then further with PBAT, LDH mostly migrates to the interface of PBAT and PPC. The epoxy groups of ADR react with the terminal groups of the polymers to improve the interfacial compatibility. Adding LDH, the mechanical properties and barrier properties of the materials are improved and by premixing of PPC and LDH, properties of composites are further improved. Compared with PBAT/PPC blends, the tensile strength and elongation at break of PBAT/PPC(LDH‐0.5)/ADR increased by 25.2% and 15.3%, respectively. The banana packaged in PBAT/PPC/LDH films maintains good freshness. It illustrates that PBAT/PPC(LDH)/ADR composites have a good application prospect in the field of barrier and food packaging based on their excellent mechanical, barrier, and preservation properties.

Application of Plant Oils as Functional Additives in Edible Films and Coatings for Food Packaging: A Review.

Increasing environmental concerns over using petroleum-based packaging materials in the food industry have encouraged researchers to produce edible food packaging materials from renewable sources. Biopolymer-based edible films and coatings can be implemented as bio-based packaging materials for prolonging the shelf life of food products. However, poor mechanical characteristics and high permeability for water vapor limit their practical applications. In this regard, plant oils (POs) as natural additives have a high potential to overcome certain shortcomings related to the functionality of edible packaging materials. In this paper, a summary of the effects of Pos as natural additives on different properties of edible films and coatings is presented. Moreover, the application of edible films and coatings containing POs for the preservation of different food products is also discussed. It has been found that incorporation of POs could result in improvements in packaging's barrier, antioxidant, and antimicrobial properties. Furthermore, the incorporation of POs could significantly improve the performance of edible packaging materials in preserving the quality attributes of various food products. Overall, the current review highlights the potential of POs as natural additives for application in edible food packaging materials.

Nano boron nitride laminated poly(ethyl methacrylate)/poly(vinyl alcohol) composite films imprinted with silver nanoparticles as gas barrier and bacteria resistant packaging materials

AbstractHerein, nano boron nitride (BN) laminated poly(ethyl methacrylate) (PEMA)/poly(vinyl alcohol) (PVA) nanocomposite films are fabricated by using a simple in situ polymerization technique with incorporation of silver nanoparticles (Ag NPs). Structural investigations of PEMA/PVA/Ag@BN nanocomposite thin films are carried out by Fourier‐transform infrared spectroscopy, dynamic light scattering, X‐ray diffraction analysis, 1H nuclear magnetic resonance, 13C nuclear magnetic resonance, and mass spectrometry. The change in morphology of PEMA/PVA matrix due to the reinforcement of BN platelets are identified by electron microscopic studies. The unique tortuous paths are achieved by the dispersion of BN platelets by which gas penetration is restricted with enhancing the barrier properties of the material by 6.5 folds at 5 wt% BN content as compared with neat PEMA/PVA. Acid and alkali resistant along with biodegradability behavior of as‐synthesized nanocomposites are studied. From limiting oxygen index (LOI) results, it is found that the prepared materials are fire retardant in nature owing to effective reinforcement of BN layers. Antibacterial activities of PEMA/PVA/Ag@BN nanocomposite are studied by Xanthomonas citri or axonopodis pv. Citri, Escherichia coli, and Xanthomonas oryzae pv. Oryzae because of Ag NPs reinforcement. The substantial improvements in gas barrier, fire retardant, and antibacterial properties enable the materials for packaging application.

Circular economy of barrier packaging produced in co-injection molding technology

The paper presents the study of mechanical recycling of three-layer PP/EVOH/PP packaging containers made by the co-injection molding process. It is in alignment with European Circular Economy guidelines. The main objective was to evaluate the recyclability of these packages and their reuse as a secondary material. Thin wall packaging by special cutting and grinding methods were disintegrated, and recorded cutting force allowed the determination of energy per single cut. During these processes, delamination between PP and EVOH layers was observed. The recyclate r(PP/EVOH) was used to produce samples in the standard injection molding process. The similar samples were prepared from recycled virgin PP using the same technology. The paper presents the results of the mechanical properties of samples manufactured from recyclate r(PP/EVOH) and compares them with the properties of samples obtained from recycled polypropylene (rPP). It was observed, that the content EVOH in the PP matrix does not significantly affect the mechanical properties of r(PP/EVOH) samples. It was also found that r(PP/EVOH) blends are characterized by favorable apparent viscosity and MFI and can be a valuable raw material for reuse.

Automatic Inspection of Seal Integrity in Sterile Barrier Packaging: A Deep Learning Approach

Automatic Inspection of Seal Integrity in Sterile Barrier Packaging: A Deep Learning Approach

Stable aqueous dispersions of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) polymer for barrier paper coating

The demand for alternatives to single-use, synthetic, and non-degradable plastic packaging is continuously increasing. Paper products offer an environmentally friendly solution, however, typically do not meet strict barrier and other physical property performance demands unless coated with polymeric films, typically conventional polyolefins. Replacement of the conventional plastic film coating with bio-based and biodegradable polymers, such as poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) could provide competitive packaging properties while meeting sustainability objectives. In this study, PHBV is dispersed and stabilized in water for further environmental and coatability benefits. Four 10 wt% solids waterborne dispersions of PHBV with sodium dodecyl sulfate surfactant and guar gum rheological modifier were prepared and remained stable for several weeks at room temperature when evaluated using rheological study and particle size analysis. Manila paper substrate was coated, evaluated, and compared to uncoated paper. A smooth, transparent film, with great substrate adhesion and flexibility was obtained. Wet mechanical properties, water vapor permeability, oil resistance, and water absorption all displayed excellent results for barrier packaging applications, with substantial improvement over uncoated paper. Overall, the waterborne PHBV dispersion and paper coating exhibited promising results as a sustainable packaging option.

Renewable thermoplastic starch/sugar alcohol blends and their oxygen barrier application

AbstractFully renewable oxygen barrier thermoplastic starch (TPS)/sugar alcohol blown films were innovatively prepared by blending proper loadings of Erythritol (ET), Sorbitol (ST), and Lactitol (LT) and supercritical carbon dioxide (scCO2) assistance. The oxygen transmission rate (OTR) values of the properly prepared scCO2TPSxETy, scCO2TPSxSTy, and scCO2TPSxLTy films reduced to 4.3, 6.6, and 12.5 cm3/m2∙day∙atm, which are about 5–28 times smaller than those of the conventional TPS films reported in the literature. The free‐volume‐cavity characteristics (FVCC) and OTR detected for TPSxETy (or scCO2TPSxETy), TPSxSTy (or scCO2TPSxSTy), and TPSxLTy (or scCO2TPSxLTy) films diminished to a minimum, as their ET, ST and LT loadings came near an optimal value. Slightly smaller OTR and FVCC values were detected for scCO2TPSxETy, scCO2TPSxSTy, and scCO2TPSxLTy films than those of corresponding TPSxETy, TPSxSTy, and TPSxLTy films prepared without scCO2‐assistance. The smallest OTR and FVCC detected for the properly prepared TPSxETy (or scCO2TPSxETy), TPSxSTy (or scCO2TPSxSTy), and TPSxLTy (or scCO2TPSxLTy) films diminished with decreasing sugar alcohol's molecular weight. An essential result is that the OTR of the properly prepared scCO2TPSxETy film was merely 4.3 cm3/m2∙day∙atm, which is small enough to meet the demand of high oxygen barrier packaging application. Dynamic molecular relaxations detected for these films disclosed that ET, ST, and LT were compatible with TPS, as their loads were ≤ the optimum value. The distinctly reduced OTR and FVCC for these properly prepared films are partially attributed to the reinforced molecular interactions between sugar alcohol and TPS's hydroxyl groups when they were prepared with scCO2‐assistance, optimal sugar alcohol loading, and/or smaller sugar alcohol's molecular weight.Highlights High oxygen barrier thermoplastic starch/sugar alcohol blown films were prepared. The lowest oxygen transmission rate of the renewable film was 4.3 cm3/m2∙day∙atm. This oxygen transmission rate is qualified for high oxygen barrier application. Boosted oxygen barrier property was ascribed to the reduced free volume values.

Effect of storage conditions on the physical properties of coffee beans with different qualities

The quality of coffee starts in the field, and goes through the harvesting and post-harvesting processes, and continues to storage and transportation. The storage of coffee beans aims to stock a product for a certain period of time. However, factors such as quality and metabolism of the grain, water content, environmental conditions of the warehouse, type of packaging, and storage time influence the maintenance of these characteristics, and may negatively affect sensory aspects of the beverage. The use of high-barrier packaging or refrigerated storage practices are alternatives that can ensure grain quality during storage. Thus, the objective of the present study was to evaluate the behavior of raw coffee beans, of different processing and quality levels, packed in impermeable packages and stored in a refrigerated environment. The specialty coffees were previously sampled and characterized as to the drink, with two lots (one of natural coffee and the other of pulped natural coffee) evaluated with a score of 82 points, and another lot of natural coffee evaluated with a score of 84 points. They were packed in two types of packaging: moisture and gas permeable, and gas, moisture, and light impermeable. The beans were stored in ambient conditions without temperature control and in refrigerated environments. The CO2 concentration inside the packaging was measured, and the physical analyses – water content, color, and apparent specific mass – were performed. According to the results there is less variation in the water content and coloration of the grains stored in high barrier packages. The storage of the beans in refrigerated condition and in high barrier packing is efficient in the retarding of the loss of quality of the coffees during the nine months of the experiment

Effect of silicon dioxide nanoparticle on microstructure, mechanical and barrier properties of biodegradable PBAT/PBS food packaging

Biodegradable polyester polymers including poly(butylene adipate-co-terephthalate) (PBAT) and poly(butylene succinate) (PBS) are used as sustainable and eco-friendly food packaging but poor water vapor barrier properties limit their applications with moisture-sensitive products. This research blended PBAT/PBS materials at 60/40 and 50/50 with silicon dioxide (SiO2) nanoparticles as master batch pellets via twin-screw extrusion before sheet-casting to improve food packaging barrier properties. PBAT/PBS/SiO2 nanocomposite films were investigated by X-ray diffraction (XRD) and Fourier transform infrared (FTIR) spectroscopy and also for mechanical relaxation, microstructure, surface topography, and barrier properties. Scanning electron microscopy-energy dispersive X-ray analysis (SEM-EDX) indicated dispersed SiO2 nanoparticle aggregation in polymer matrices at higher loading. FTIR spectroscopy results suggested modified CO stretching vibrations in polyesters, concurrent with shifting X-ray diffraction angles depending on nanoparticle content and polymer blend ratios. Adding SiO2 nanoparticles at up to 1% exponentially reduced water vapor permeability by up to 26%, while decreasing oxygen permeability (up to 8%). Mechanical properties reduced when adding SiO2 nanoparticles but film stretching improved polymer orientation at higher loading, thereby increasing tensile strength and elongation. Compounding SiO2 nanoparticles with PBAT/PBS polyester polymer blends enhanced barrier properties for biodegradable food packaging.

Robust Tear-Resistant Blown Nanocomposite Films for Barrier Packaging: Role of Clay Platelet Thickness in Tear Mechanics and Barrier Performances

Robust Tear-Resistant Blown Nanocomposite Films for Barrier Packaging: Role of Clay Platelet Thickness in Tear Mechanics and Barrier Performances

Biocompatible green technology principles for the fabrication of food packaging material with noteworthy mechanical and antimicrobial properties-- A sustainable developmental goal towards the effective, safe food preservation strategy

Biocompatible, eco-friendly, highly economical packaging methods should be needed as conventional packaging is known to cause undesirable effects. As food packaging is the major determining factor of food safety, the selection or methods of packaging materials plays a pioneering role. With this scope, modern food technology seeks unique sustainable approaches for the fabrication of package materials with notable desired properties. The principles, features, and fabrication methodology of modern food packaging are briefly covered in this review. We extensively revealed improved packaging (nanocoating, nanolaminates, and nano clay), active packaging (antimicrobial, oxygen scavenging, and UV barrier packaging), and intelligent/smart packaging (O2 indicator, CO2 indicator, Time Temperature Indicator, freshness indicator, and pH indicator). In particular, we described the role of nanomaterials in the fabrication of packaging material. Methods for the evaluation of mechanical, barrier properties, and anti-microbial assays have been featured. The present studies suggest the possible utilization of materials in the fabrication of food packaging for the production, utilization, and distribution of safe foods without affecting nutritional values.

Potential of polysaccharides for food packaging applications. Part 1/2 : An experimental review of the functional properties of polysaccharide coatings

Environmental issues related to the use of plastic packaging have sparked a growing interest in the development of more sustainable solutions. Biopolymers, used alone or in combination with other materials, have been considered a potential alternative to conventional fossil-based plastics. Hence, this study aimed at unraveling the potentiality offered by polysaccharides for food packaging applications. To that purpose, an extended characterization of the barrier (to oxygen and water vapor), mechanical and optical properties (transparency and UV-blocking ability) of nine different polysaccharide films (hydroxypropyl methylcellulose, methylcellulose, hydroxypropyl cellulose, low-methoxyl pectin, cationic starch, sodium alginate, kappa-carrageenan, chitosan, and pullulan) was performed to provide a broad overview of their main physicochemical properties under standardized conditions. In addition, the properties of the film-forming solutions, such as viscosity and surface tension, were also evaluated. All polysaccharides obviously presented low water vapor barrier performance due to their hydrophilic nature (water vapor permeance from 10−6 to 10−8 mol.m-2.s-1.Pa-1). Among all the polysaccharides studied, chitosan, low-methoxyl pectic, kappa-carrageenan, pullulan, cationic starch and sodium alginate, displayed medium to very high oxygen barrier performance in semi-dry (50% RH) and humid (80% RH) conditions (oxygen permeance from 10−13 to 10−15 mol.m-2.s-1.Pa-1), contrarily to cellulose derivatives which showed the poorest performance (oxygen permeance >10−12 mol.m-2.s-1.Pa-1). This opens on interesting perspectives for the use of polysaccharides as coating materials for high oxygen barrier packaging.

Halloysite Nanotube as a Functional Material for Active Food Packaging Application: A Review.

Halloysite nanotubes (HNTs) are naturally occurring nanomaterials with a tubular shape and high aspect ratio, a promising functional additive for active food packaging applications. HNTs have been shown to possess unique properties such as high surface area, thermal stability, and biocompatibility, making them attractive for active food packaging materials. This review summarizes recent research on the use of HNTs as functional additives in active food packaging applications, including antimicrobial packaging, ethylene scavenging packaging, moisture, and gas barrier packaging. The potential benefits and challenges associated with the incorporation of HNTs into food packaging materials are discussed. The various modification methods, such as the physical, chemical, biological, and electrostatic methods, along with their impact on the properties of HNTs, are discussed. The advantages and challenges associated with each modification approach are also evaluated. Overall, the modification of HNTs has opened new possibilities for the development of advanced packaging materials with improved performance for various functional food packaging materials with enhanced properties and extended shelf life.

Strategic selection tool for thermoplastic materials in a renewable circular economy: Identifying future circular polymers

To progress towards a renewable circular economy for thermoplastic materials it is imperative to decouple from fossil feedstocks, to maximise looping strategies and to manufacture occasionally littered articles from readily biodegradable materials. This transition is complex due to the combination of stringent technical specifications that are required for ordinary plastic products and the demands that all end-of-life scenarios foist on these products. The presented strategic material selection tool for fast moving consumer goods in a renewable circular economy prioritises their suitability for the expected end-of-life fates and the contrived technical performance. This framework is tested for 17 common consumer articles and 21 biobased plastics. The strategic selection tool shows that consumer articles that are made from foamed and fibrous plastics, such as matrasses and textiles, can potentially be produced from biobased alternatives, such as biobased poly(ethylene terephthalate) (PET), poly(trimethylene terephthalate) (PTT), poly(butylene succinate) (PBS), poly(butylene succinate-co-adipate) (PBSA) and poly(butylene adipate-co-terephthalate) (PBAT). On the other hand, the tool also reveals that there are currently no adequate alternatives in barrier (food) packages and in elastomeric products such as tyres, soles of footwear and gloves. Biobased PET is a good polymer for beverage bottles provided that the leakage to the natural environment is minimised with an effective collection, reuse and recycling system. Although there are no viable single-biobased-polymeric alternatives for flexible packages to pack for instance dried foods, solutions could be developed in the form of multi-layered films of various biobased and biodegradable materials. But it would also imply that a dedicated new recycling technology needs to be developed for such multilayer films. The presented tool demonstrates that the technology is ready to start the transition towards a renewable circular economy for consumer articles such as matrasses, cushions, beverage bottles. Simultaneously, new biobased polymeric solutions need to be developed for multiple other applications such as tyres, footwear, gloves and flexible barrier packaging.

Review of coating cracking and barrier integrity on paperboard substrates

Barrier packaging formats are major growth areas for the pulp and paper industry. It is technically challenging to maintain barrier properties during converting and end-use applications. Improved manufacturing capabilities and coating formulation knowledge will help maintain barrier integrity and enable growth of barrier products in challenging applications. These improvements will accelerate product development and commercialization, and allow faster response to product performance issues such as cracking. The literature on coating cracking provides knowledge mostly on the effects of coating formulations and to a lesser extent on substrate effects. Despite a large number of publications dedicated to coating failures, the approach to improve coating cracking remains empirical, and the transferability between studies and to real life applications has not been well established. Model development that successfully predicts commercial performance is in its infancy. However, some of these simplified models do a fairly good job predicting experimental data. The current work reviews the state of understanding as regards coating and barrier cracking and highlights the need for more research on cracking and barrier integrity.