Packaging Sector Research Articles

Efficiency and Precision in Printing: Study of the Control System of a Rotogravure Machine

Rotogravure printing is a well-liked and effective printing technique in the packaging sector of a printing cylinder. In making an automatic rotogravure machine, it is necessary to design an appropriate control system. In Indonesia, semi-automatic technology is still used to make rotogravure machines, and printing speeds are often slow. For automation machines, they are still imported. Apart from that, the machine's ability to adjust its precision is also limited. The purpose of this article is to examine the control system for a 6-cylinder automatic rotogravure machine, and discuss the rotogravure machine printing process, important aspects of rotogravure machine operation, differentiation in selecting motor types for torque and speed control, as well as advantages in efficiency and precision control over the environment. The method of using a literature review is qualitative-descriptive. The main findings on rotogravure machines include five main aspects: (1) ink flow management, (2) control of the drying system, (3) register control, (4) tension and speed control, and (5) fault detection, data logging, and analysis.

Sustainable barrier coatings for paperboard packaging: Effect of VeoVa-10 on 2-EHA and MMA containing water-based emulsions

Developing environmentally benign barrier coatings may provide a sustainable alternative to the packaging sector and facilitate minimizing the consumption of single-use plastics in packaging. The synthesis of seven different water-based (W/B) emulsions was achieved via seeded emulsion polymerization using 2-Ethylhexylacrylate (2-EHA), methyl methacrylate (MMA), and a varying amount of vinyl ester of Versatic™ acid 10 (VeoVa-10) to impart the hydrophobic properties. Potassium persulfate (K2S2O8) was used as an initiator. Antifoaming agent and biocide were also added to improve the application and shelf-life of these coatings. The coatings were evaluated by conducting various analytical tests, including pH measurement, viscosity assessment, determination of solid content, measurement of drying time, evaluation of gloss, water absorption testing using Cobb's Test, and assessment of oil and grease resistance via the Kit Test. The coatings were also analyzed using advanced characterization techniques, including Differential Scanning Calorimetry (DSC), Fourier Transform Infrared Spectroscopy (FTIR), Scanning Electron Microscopy (SEM), Zetasizer Nano ZS, and contact angle analysis. The results indicated that as the amount of VeoVa-10 increases in barrier coatings, the coated paperboard demonstrated improved moisture and oil/grease resistance compared to the control paperboard (uncoated). Furthermore, the coatings were also applied on paperboard trays and stored at 0 °C and 90 °C to confirm their practical usefulness, a careful examination after an hour showed no leakage/seepage of hot and cold water through the coated trays, unlike the uncoated ones. Barrier coatings offer sustainable and eco-friendly options that could positively impact the packaging industry, helping reduce environmental footprints while enhancing packaging performance.

Investigation of amyl acetate sorption impact on high‐density polyethylene bottle properties

AbstractThermoplastics based on polyolefins, including polypropylene, high‐density polyethylene and low‐density polyethylene, are extensively utilized across various packaging sectors. The selection of these materials for specific applications is influenced by multiple factors, such as the polymer's absorption characteristics and the impact on its mechanical properties when in contact with the packaged product. This study presents an experimental methodology designed to simulate the effects of absorption on the macroscopic and microscopic properties of high‐density polyethylene bottles in contact with amyl acetate. Macroscopic degradation was evaluated by modeling mechanical damage using unified theory and the energy method. Analytical techniques such as gravimetric analysis, scanning electron microscopy and Fourier transform infrared spectrometry were employed. The findings of this research provide valuable insights for suppliers and industries to experimentally determine the usability and safety intervals of plastic packaging through comprehensive macroscopic and microscopic analyses within relatively short timescales. © 2024 Society of Chemical Industry.

Plant-based chitosan for the development of biodegradable packaging materials

Plant-derived materials and edible films have developed as viable substitutes for standard packaging materials, enabling sustainable and ecologically acceptable alternatives. Chitosan, a cationic carbohydrate polymer derived from animal or marine sources, as well as from agricultural waste such as mushrooms or various fungi possesses excellent properties such as film formation, mechanical strength, non-toxicity, biodegradability, edibility, UV-blocking ability, antioxidant activity, and antibacterial functionality, justifying its potential as packaging/coating material for fresh agricultural products. Chitosan is obtained through the deacetylation of chitin. The quantity of waste generated in a mushroom farm varies from 5–20 % of the total yielding quantity. Filamentous fungi's cellular structure, which is rich in chitin, provides a convenient method for chitin extraction. Fungal-derived chitosan offers the advantage of controllable physicochemical characteristics, including degree of deacetylation and molecular weight, compared to chitosan obtained from crustaceans. This versatility makes fungal chitosan suitable for various utilizations in food, pharmaceutical, and biomedical management. It can be utilised for different purposes in these fields. This review primarily emphasizes the extraction of chitin from mushrooms and various fungal sources, comparing different extraction methods and chitosan-based materials fabrication techniques. Additionally, it discusses the crucial characteristics of chitosan that make it convenient for high value-added functions in the food industry. To sum up, plant-based chitosan films have the potential to completely transform the packaging sector by providing environmentally friendly substitutes for traditional materials. Accepting these advances will help build a more resilient and sustainable earth, encourage the circular economy, and reduce the amount of plastic trash produced.

PlaBacter: Determination of Microbial Diversity on Plastic Polymers in Topçu Pond

Climate change is one of the biggest problems of our world, and one of the biggest measures taken to solve the climate crisis is to reduce the consumption of oil and oil derivatives, which are considered among fossil resources. However, with the globalising world and increasing population, oil companies have turned to the plastic and packaging sector in order to meet the increasing demand for plastic consumption. This situation inevitably increases the environmental damage of plastic waste. In particular, the inability to use water resources correctly and the pollution of water by wastes left in the environment adversely affect the lives of living things on earth. Within the scope of the study, it was aimed to determine the microbial diversity living on polyethylene terephthalate (PET), which is known as the raw material of tools such as plastic bottles, food containers, and fishing line, which are left as waste in the environment, especially in rivers and lake shores. In this context, Topçu Pond, which is an important water source in the field of agricultural irrigation in Yozgat province, was selected as the study area. Genomic DNA (gDNA) was isolated from biofilm layers formed on water, sediment, and PET samples collected from the study area. The bacterial communities living in the samples were identified by analysing the 16S rDNA of the gDNAs with the next-generation sequencing method. Thus, we conducted the first microbial diversity study in Topçu Pond and defined the bacterial composition on PET samples in the pond.

Ready-to-Cook Foods: Technological Developments and Future Trends-A Systematic Review.

Ready-to-cook (RTC) foods can significantly improve the cooking experience of busy or unskillful consumers, based on production involving technical combinations of food processing and packaging. Initialized by a market survey of 172 products in Beijing, this systematic review analyzes RTC foods' development status according to ingredients, packaging, and storage conditions to further clarify the scope of RTC foods. The working principles and efficacy of various food processing techniques, such as washing, cutting, marinating, and frying, and packaging design or innovations such as modified atmosphere packaging (MAP) were both summarized in detail, with attention to their ability to extend shelf life, reduce safety risks, and maximize production efficiency in RTC food production. The cutting-edge technologies that may potentially apply in the RTC food processing or packaging sector were compared with current approaches to visualize the direction of future developments. In conclusion, we have observed the specific pattern of RTC food varieties and packaging formats in the Beijing market and revealed the advancements in RTC food technologies that will continue playing a critical role in shaping this growing market, while challenges in scalability, cost-efficiency, and sustainability remain key areas for future research. The data and perspectives presented will articulate the conceptions and existing challenges of RTC food, foster consumer perception and recognition of similar products, and deliver useful guidance for stakeholders interested in such products.

Applications of bacterial cellulose in the food industry and its health-promoting potential

Bacterial cellulose (BC) is a naturally occurring biomaterial with a wide range of potential applications in the food industry because of its exceptional mechanical qualities, unique nanofiber structure, high purity, and outstanding biocompatibility. Beyond its physical attributes, BC has gained interest recently due to research demonstrating its potential health benefits as a functional food ingredient. This article examines the many uses of BC in the food business, with a focus on how it may enhance food texture, operate as a bioactive carrier, and have promise in the packaging sector. Further research was done on the health-promoting properties of BC in functional foods, particularly with regard to its functions as a blood glucose regulator, and gastrointestinal health. This review seeks to bring fresh ideas for the study of bioactive components in the food industry by providing a summary of the existing research and demonstrating the possible role of BC in food. It also suggests future paths for research.

Global projections of plastic use, end-of-life fate and potential changes in consumption, reduction, recycling and replacement with bioplastics to 2050

Excessive production, indiscriminate consumption, and improper disposal of plastics have led to plastic pollution and its hazardous environmental effects. Various approaches to tackle the challenges of reducing the plastic footprint have been developed and applied, such as the production of alternative materials (design for recycling), the production and use of biodegradable plastic and plastics from power-to-X, and the development of recycling approaches. This study proposes an optimisation strategy based on regression to evaluate and predict plastic use and end-of-life fate in the future based on historical trends. The mathematical model is formulated and correlations based on functions of time are developed and optimised by minimising the sum of squared residuals. The plastic quantities up to the year 2050 are projected based on historical trends analysis, and for improved sustainability, projections are additionally based on intervention analyses. The results show that the global use of plastics is expected to increase from 464 Mt in 2020 up to 884 Mt in 2050, with up to 4725 Mt of plastics accumulated in stock in 2050 (from the year 2000). Compared to other available forecasts, a slightly lower level of plastic use and stock are obtained. The intervention analysis estimates a range of global plastics' consumption between 594 Mt and 1018 Mt in 2050 by taking into account its different increment rates (between −1 % and 2.65 %). In the packaging sector, the implementation of reduction targets (15 % reduction in 2040 compared to 2018) could lead to a 27.3 % decrease in plastic use in 2050 as compared to 2018, while achieving recycling targets (55 % in 2030) would recycle >75 % of plastic packaging in 2050. The partial substitution of fossil-based plastics with bioplastics (polyethylene) will require significant land area, between 0.2 × 106 km2 for obtaining switchgrass and up to around 1.0 × 106 km2 for obtaining forest residue (annual yields of 58.15 t/ha and 3.5 t/ha) in 2050. The intervention analysis shows that proactive policies can mitigate sustainability challenges, however achieving broader sustainability goals also requires reduction of footprints related to energy production and virgin plastic production, the production of bio-based plastics, and the full implementation of recycling initiatives.

Seaweed as a Valuable and Sustainable Resource for Food Packaging Materials.

Plastic food packaging causes massive pollution in the environment via resource extraction, gas emissions, and the enduring plastic waste accumulation. Hence, it is of crucial importance to discover sustainable alternatives in order to protect ecosystems and conserve precious resources. Recently, seaweed has been emerging as a promising sustainable solution to plastic pollution. Seaweed is a fast-growing marine plant that is abundant in tropical coastlines and requires minimal resources to cultivate. In addition, seaweed is rich in valuable polysaccharides such as alginate, fucoidan, carrageenan, agar, and ulva, which can be extracted and processed into biodegradable films, coatings, and wraps. This ability allows the creation of an alternative to plastic food packages that are completely biodegradable, made from renewable resources, and do not linger in landfills or oceans for centuries. In this context, this review discusses the main classification of seaweed, their production and abundance in the world, and provides a summary of seaweed-based materials developed in the last 2-5 years for potential usage in the food packaging sector.

Production of eco composites based on natural rubber and recycled sugarcane bagasse waste to be utilised as a type of food contact

Natural fibres are abundant, renewable, and biodegradable, which has inspired numerous academics worldwide to investigate their possible applications in various industrial fields. The food packaging sector is seeking bio-based and biodegradable substitutes to increase sustainability. In this study, new composites were prepared from natural rubber (NR) and sugarcane bagasse fibres (SCB) with different concentrations of SCB (0, 2.5, 5, 10 &20 phr). The effect of SCB on the properties of natural rubber was studied before and after the alkaline treatment of the fibres. The biocomposites are characterized using Fourier transmission infrared spectroscopy, thermogravimetric analysis, scanning electron microscope, transmission electron microscope, and dielectric measurements in addition to rheological and mechanical analysis. The overall migration test for biocomposites loaded with 20phr SCB was performed to assess the biocomposite’s safety as food contact materials. The study’s results indicated that, adding SCB improved the conductivity, tensile strength, and elongation at break of natural rubber. Alkaline treatment strengthened the bonding between the filler and matrix and improved biocomposites’ thermal dielectric and mechanical properties. The overall migration test indicated that the alkaline treatment increased the overall migration to simulants. Accordingly, alkaline-treated NR-SCB biocomposites are effective eco-friendly food packaging candidates for certain types of food such as aqueous non-acidic products.

Biopolymers as Sustainable and Active Packaging Materials: Fundamentals and Mechanisms of Antifungal Activities.

Developing bio-based and biodegradable materials has become important to meet current market demands, government regulations, and environmental concerns. The packaging industry, particularly for food and beverages, is known to be the world's largest consumer of plastics. Therefore, the demand for sustainable alternatives in this area is needed to meet the industry's requirements. This review presents the most commonly used bio-based and biodegradable packaging materials, bio-polyesters, and polysaccharide-based polymers. At the same time, a major problem in food packaging is presented: fungal growth and, consequently, food spoilage. Different types of antifungal compounds, both natural and synthetic, are explained in terms of structure and mechanism of action. The main uses of these antifungal compounds and their degree of effectiveness are detailed. State-of-the-art studies have shown a clear trend of increasing studies on incorporating antifungals in biodegradable materials since 2000. The bibliometric networks showed studies on active packaging, biodegradable polymers, films, antimicrobial and antifungal activities, essential oils, starch and polysaccharides, nanocomposites, and nanoparticles. The combination of the development of bio-based and biodegradable materials with the ability to control fungal growth promotes both sustainability and the innovative enhancement of the packaging sector.

All-organic transistors printed on a biodegradable and bioderived substrate for sustainable bioelectronics

Biodegradable electronics is an incipient need in order to mitigate the alarming increase of electronic waste worldwide caused by capillary penetration of electronic devices and sensors. Flexibility, solution processability, low capital expenditure, and energy-efficient processes, which are distinctive features of organic printed electronics, have to be complemented by a sustainable sourcing and end-of-life of materials employed. This requirement calls for solutions where materials, especially substrates that typically represent the largest volume, can be biodegraded in the environment with no harm, yet assuring that no precious resources are dispersed. In this work, the bioderived and biodegradable biopolymer polyhydroxybutyrate (PHB) was used as a substrate, cast from an acetic acid solution, for all-organic field effect transistors (OFETs) based on an inkjet printed polymer semiconductor. The OFETs showed small device-to-device variation, a proper current modulation with ION/IOFF of about 1.2·103, mobility values as high as 0.07 cm2/Vs in saturation regime and channel length/width normalized leakage currents in the order of nA, which remained almost unaltered also after intensive mechanical stresses upon bending and rolling. Such mechanical stability and flexibility, together with the biodegradability and bioderivation, make PHB an appealing candidate for the development of sustainable printed bioelectronics, with widespread future applications in the biomedical and food packaging sector.

Scenarios, prospects, and challenges related to supercritical fluid impregnation in the food industry: a scoping review (2018–2023)

AbstractSupercritical fluid impregnation (SFI) is an emerging technique for the incorporation of target compounds into solid matrices. It has attracted attention in the food industry, where it can be applied. As it does not use organic solvents and supercritical CO2 is the most commonly used fluid, SFI is considered to be an ecofriendly and ‘green’ strategy. A review of the literature is essential in order to understand the complex interactions that occur in SFI. This is a scoping review of SFI applied to the food industry from 2018 to 2023. The search used the Web of Science, Scopus, and Science Direct databases. Guiding questions were identified, publications related to the topic were selected, and the information was extracted, organized, and grouped. An overview of the SFI, its operational characteristics, challenges, prospects, and strategies is presented. Initially, 329 records were found; 38 publications were eventually selected for inclusion in this scoping review. The results indicate that the packaging sector has been the focus of publications. However, trends include applications of SFI in micronization, developing of food waste biorefineries, and food protection from direct impregnation. This scoping analysis is therefore a powerful tool for creating new research into the application of SFI to food.

Evaluating The Effectiveness of Wastewater Treatment In the Reusable Packaging Industry: A Case Study of ALNER’S WWTP In Indonesia

The widespread use of single-use plastic packaging has become a significant environmental issue, particularly in the Global South. This study examines the innovative approach of the startup Alner, which employs a combination of electrochemical treatment and Moving Bed Biofilm Reactor (MBBR) technology in its wastewater treatment plant (WWTP) to manage wastewater generated from the cleaning of reusable packaging. Wastewater samples were collected before and after treatment, and analyzed for key parameters such as Chemical Oxygen Demand (COD), Biological Oxygen Demand (BOD5), Total Suspended Solids (TSS), oil and grease, ammonia, surfactants, and phosphates. The results demonstrated a significant reduction in all measured pollutants, with COD reduced by 99.58% and BOD5 by 99.56%. Post-treatment values for all parameters were well within the regulatory limits set by the Ministry of Environment and Forestry Regulation No. P68/MenLHK/Setjen/Kum.1/8/2016. This study underscores the potential of reuse models in reducing single-use plastic waste and highlights the importance of effective wastewater treatment in maintaining environmental sustainability. Alner's approach provides a scalable and environmentally friendly solution, setting a benchmark for similar initiatives in the industry, and supports the feasibility and sustainability of integrating advanced wastewater treatment technologies in the reusable packaging sector, offering a comprehensive solution to plastic pollution.

Nanocomposites of recycled and of virgin polyamide 6.6 with cellulose nanofibers

The inherent properties of cellulose nanofibers (CNFs) make them an interesting and sustainable choice for reinforcing polymeric matrices intended for the automotive, electronic, construction, and packaging sectors. Effective recycling and reuse of polyamide 6.6 significantly reduce the environmental impact of automotive components throughout its entire life cycle. Nanocomposites of recycled polyamide 6.6 and CNF and of virgin polyamide 6.6 and CNF were processed through dissolution in a formic acid/water mixture followed by melt extrusion and injection molding. The results show that pure recycled polyamide exhibited a thermal degradation onset temperature 10 °C lower and a 9 % lower crystallinity compared to pure virgin polyamide. The method used for processing the nanocomposites resulted in homogeneous dispersion and good anchoring of CNF in both polymer matrices. The processing method and the presence of CNF reduce the thermal stability by up to 15 °C for recycled polyamide nanocomposites and up to 26 °C for virgin polyamide nanocomposites. The processing method did not significantly impair the elastic modulus and tensile strength of both recycled and virgin polyamides, showing a 3 % and 1 % reduction in tensile strength for recycled and virgin polyamides, respectively. The incorporation of 1 wt% and 2 wt% of CNF in virgin polyamide showed an increase in the elastic modulus of 16 % and 5 %, respectively, and a reduction in ductility. In summary, this work offers an alternative processing pathway for nanocomposites of recycled or virgin polyamide 6.6 with CNF; however, some improvements are still necessary to achieve the reinforcing effect of CNF on the mechanical strength of the matrices.

Tailoring LLDPE properties with modified palygorskite fillers: A comprehensive study

AbstractLinear low‐density polyethylene (LLDPE) is a polyolefin known for its superior low‐temperature heat seal ability, low‐temperature tolerance, and bag‐tear resistance which are important features for the polymeric packaging sector. In this work, to improve the mechanical properties and expand the range of applications of LLDPE, the microfibrillar clay mineral palygorskite (PAL) was added. However, the use of PAL as a reinforcing agent for polymers depends on its purification process to extract accessory minerals such as calcite, dolomite, and quartz. In addition to this purification process, two surface modifications were used on the purified PAL (PALp) to improve interactions with LLDPE: silanization with aminosilane (PALs) and organophilization by incorporating an organic compound (PALo). The PAL were characterized according to their morphological properties using transmission electron microscopy (TEM), X‐ray diffraction (XRD), and Fourier transform infrared spectroscopy (FT‐IR). The films of LLDPE/PAL, with varying levels (1, 3, and 5 wt%) and types of PAL (raw PAL, PALp, PALs, and PALo), were prepared by an extrusion process, and films were prepared by compression molding, without preferred orientation. The films were characterized by rheological analyses, tensile tests, differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), scanning electron microscopy (SEM), and water vapor permeability. Incorporating modified PAL was significant in enhancing the mechanical properties of the nanocomposites. LLDPE/PALs with the addition of 3 wt% PALs showed a 14% increase in elastic modulus (281.08 ± 8.25 MPa) compared to the nanocomposite with 3 wt% of raw PAL (243.43 ± 15.01 MPa).Highlights The PAL is a clay mineral with a fibrous morphology and has a low cost. The technique to purify PAL is a quick, simple, and inexpensive technique. Comparison between of two technique surface modification of PAL. The effectiveness of modifications of PAL was confirmed in LLDPE films. The surface modification with silanization was more effective.

Assessment of Utilizing Hard-to-Recycle Plastic Waste from the Packaging Sector in Architectural Design—Case Study for Experimental Building Material

Assessment of Utilizing Hard-to-Recycle Plastic Waste from the Packaging Sector in Architectural Design—Case Study for Experimental Building Material

Durability and Functionality of Conventional Polymeric Packaging Materials in Reusable Packaging Systems

Reusable packaging is increasingly recognised as a sustainable solution to address issues related to increasing packaging waste generation and harmful environmental impacts. The packaging sector consumes a significant portion of Europe’s plastic production, which is mostly single-use packaging. There is a sense of urgency to develop sustainable reusable alternatives. Unlike single-use packaging, the longevity of reusable plastic packaging is paramount, necessitating material durability and functionality. This study examines the durability of conventional polymeric packaging materials (polyethylene terephthalate (PET), polypropylene, high-density polyethylene) and investigates the effectiveness of scratch resistance additives. A specialised test set-up was created to evaluate the performance of various polymers in reusable takeaway food packaging scenarios. The research included scratch testing, wear analysis and wash cycles to assess the reuse potential of these materials. Qualitative measures were employed to compare material characteristics. Results indicated that polymer type significantly affects hardness and scratch performance, while additives had minimal impact on hardness and modulus. Although current scratch resistance additives do not effectively mitigate wear in reusable packaging in the experimental scenarios, tailored additives could present potential in increasing the durability and longevity of reusable packaging. PET demonstrated notable recovery post-washing, suggesting that washing conditions could influence material resilience. This study emphasises the need for further research to optimise scratch resistance additives and understand the impact of washing conditions on different polymers, aiming to enhance the design and longevity of reusable packaging systems.

Environmental impacts of food packaging: Is it all a matter of raw materials?

The packaging sector and the environmental impacts stemming from its various materials and applications are currently at the forefront of scientific and political debate. To estimate the environmental impacts associated with raw materials and identify the role of industrial processes, this study presents a cradle-to-grave Life Cycle Assessment applied to two distinct packaging formulations for chocolate bars, namely oriented polypropylene-based and paper-based packaging. The product systems related to the two alternatives were compared by focusing on the contribution of each resource input and emission of the production phase, to identify respective environmental trade-offs and potentials for future improvements throughout the life cycle. Our study also proposes a laboratory-based approach to develop robust assumptions concerning the modeling of end-of-life material treatment and provide support to decision-making toward environmentally sustainable waste management practices. From the outcomes, a relative preference emerges for paper-based packaging, from a minimum of 10 to a maximum of 16 out of 18 environmental categories, depending on the evaluated scenario. The hotspot analysis highlighted a significant influence of the processing phases, with raw materials being generally characterized by lower percentage contributions to the final impact. In conclusion, the findings underscore the importance of considering the entire life cycle when assessing packaging sustainability. Moreover, the proposed laboratory approach offers valuable insights for policymakers and industry stakeholders to optimize end-of-life strategies and minimize the overall environmental footprint of packaging materials.

Improving the overall equipment effectiveness of Sheet-Fed offset printers: A case study

This study investigates a framework for enhancing the Overall Equipment Effectiveness (OEE) of sheet-fed offset printers, focusing on the packaging sector. The research explores the understanding and implementation of OEE valuation within this context. Through a specific case study, the OEE value is 22%, with contributions from Availability, Performance, and Quality rates at 41%, 58%, and 94%, respectively. These findings underscore a substantial deviation from the world-class standard of 85%, indicating significant room for improvement. Based on Six Big Losses (SBL) and Cause and Defect diagram analysis, workers' lack of knowledge and skill and ineffective management methods are critical contributors to low OEE rates. In response, an action plan is proposed to improve OEE, aiming to reduce time losses by approximately 60% and achieve a standard OEE value. This research offers valuable insights into optimizing the efficiency of sheet-fed offset printers, offering practical strategies for enhancing productivity and competitiveness in the printing industry.