The packaging in food has become an important tool in marketing of a consumer food product. Packaging not only provides shelf life and appearance to the product but also helps us to create pull in the market place. In the present marketing scenario food packaging has become vital tool in promotion and aesthetic quality of the product. To choose a packaging material for a product it is essential to understand the parameters required for designing shelf-life and printability. It is important to note various qualifications of packaging material and their chemical and physical characteristics which are important not only for food laws but also should have the ability to protect the product flavour, taste and should not impart any chemical change. The packaging materials vary in their behaviours and are used accordingly in packaging of various food products.
A food package is a structure design to contain a food product in order -
1. To make it easier and safer to transport 2. To protect the product against contamination 3. To protect product against damage or degradation and 4. To provide a convenient measure of dispersing the product
The addition of printing or other decoration to the exterior of the package serves
1. To identify the contents as to type and quality 2. To identify the manufacturers brand and grade 3. To attract Buyers attention 4. To persuade the buyer to purchase 5. To instruct the purchaser on how to use the product.
The packaging is normally defined by market and the selection is based on cost and requirements. The selection involves many factors:
i) Pack Size ii) Nature of Product iii) Barrier properties iv) Temperature extremes to be encountered v) Regiment of open device or reclosure vi) Shelf life vii) Stackability , in use condition viii) Ease of disposing ix) Competitive Pack x) Dealer Pack, Shipper
Within each package form or category other more specific question need to be answered
1. How many piles should the laminate have? 2. What is the function of the each ply? 3. Which ply should be closest to the product? 4. What thickness should be used? 5. How should the pouch be formed and sealed? 6. What outer protection ( Box shipper) is needed? - 2 - DTKFCPL Dr. Kuchroo June 25, 2003 There have been many packaging materials invented and tried from last two decades for different products. These materials need to qualify for the following characteristics
1. Shelf life 2. Transit 3. Compactness 4. Easy to handle 5. Printability
Shelf life- The shelf life of the product shall depend upon the chemical composition of the product and the packaging material used. There are two broad characteristics of the products: a) Products which have a tendency to absorb moisture b) Products which have a tendency to leave moisture Both these properties need different packaging materials unless the products falling in second category are not modified to achieve the properties similar to group `a. Moisture barrier properties are very important in packaging material. The packaging material also should have the capacity to avoid air ingress in product. Oxygen from air in particular has direct impact on oxidative stability of the product. Fat goes under oxidation in presence of air and form peroxides and other carbonyl compounds which give off odor to the product.
Transit- The packaging material should be able to provide protection to the product and should be able to withstand the transit journey. There are different materials having different properties in this regard.
Compactness - The packaging material should provide compactness to the product to be able to avoid breakage or shape degradation.
Handling-The material should have the capability to have ease in handling and should be able to withstand various packaging techniques.
Printability - The material should have the capability to have ease in printing and should help the product to improve the image. Different packaging materials have different printing quality.
Based on the above physical parameters various packaging materials are in use. Some of them are explained below
RIGID PACKAGING MATERIALS AND PACKAGE FORMS Glass containers Glass containers are one of the stalwart of food packaging. Glass is made from limestone, sand, soda ash and alumina. Colorants are added as per the requirements. It is an excellent protection barrier to solids, liquids and gases. It is the excellent protection against odor and flavor contaminants. The chief disadvantages as a packaging material are weight and fragility and it is not easily disposable. The transparency of the glass provides excellent product visibility and attractive finish. Glass containers include Bottles, jars, tumblers, Jugs, carboys, vials, and ampules. The other important factor in selecting glass container for food is color which can influence the type of light reaching the food and its ability to resist thermal shock. Special glasses have been developed to withstand the temperature shock. - 3 - DTKFCPL Dr. Kuchroo June 25, 2003
Metal containers Metal containers are manufactured from soldered tin plate but more recently aluminium cans have been introduced. Today there are several options available like Standard tinplate, light weight tinplate, double reduced tinplate, tin free steel (coated) vacuum deposited aluminium on steel and aluminium.
Can coatings are now considered as vital components especially for food and beverages. Coatings must be non toxic and free from odors and taste. They must not deteriorate or come loose from the can wall during food storage. Interior coatings made from acrylics, butadiene, epoxy amines, epoxy esters, epoxy phenolics, oleoresins, phenolics and vinyls depending upon the type of food and process
Several type of food products and type of steel base
Class of Food Characteristics Required
Typical example Steel base Most strongly corrosive Highly or moderately acidic Apple juice, berries etc Type L Moderately corrosive Acidified vegetables Apricots, figs, grape fruit Type MS, MC Mildly corrosive Low acid products Peas, Corn, Meat, etc Type MR, or MC Non- corrosive Mostly dry or non processed Dehydrated soups, frozen fruits, shortenings Type MR, or MC
Composite container A composite container is made from two or more constituent materials. It usually consists of paperboard body with metal or plastics ends. Two basic types are available-Spiral wound containers are made in cylindrical shapes where two or more plies of board are glues together around the material. Convolute-wound composites are produced by straight winding. Body materials used are clip board and Kraft paper. Lining used are vegetable parchment, wax laminates, aluminium foil and polyethylene coated paper. Composite cans are closed by a snap or a lid, plug the lid or lever lid.
Aerosol containers Aerosol containers are used to dispense a product by means of pressurized gas or liquid that is held in the same container. The container must be gas tight or may be constructed from steel can, aluminium cans, glass or plastics or combination.
Rigid Plastic packages A wide variety of rigid plastics can be used in the form of thermoformed injection molded and the blow molded containers. Thermo formed containers are formed by exposing the plastic sheet to heat and forming into female around male mold. Vacuum or pressure forming and several other techniques are used. The plastics - 4 - DTKFCPL Dr. Kuchroo June 25, 2003 used for thermoformed trays are poly carbonate, poly ethylene, poly vinyl chloride, poly ester, polystyrene, poly propylene, cellulose acetate and acrylonitrile.
The specific plastic selected depends upon the foods to be packaged and storage requirements. All thermo formed trays are covered with heat sealable or snap-on lids made of plastic film or aluminium foil laminate. Injections molded are used in high volume application for jars, bottle and tubes. Most widely used plastics are polystyrene, poly propylene and acryl nitrite. Blow molding is generally used to produce containers where the neck diameter is small in contrast to overall container diameter. Plastics used are Poly vinyl chloride, polypropylene, PVC, Polystyrene, poly acetyl, cellulose acetate etc.
Solid and corrugated fiberboard containers Solid and corrugated fiberboard containers are used to fabricate shipping cartons and cases used extensively in wholesale and industrial shipping. They are not usually used as direct containers for foods but are extensively employed as outer shippers for packaged foods. Both are made from heavy fibrous Kraft paperboard. Solid fiberboard is made by gluing several piles of paperboard together by using asphalt or special resin adhesive such as urea formaldehyde.
There are five major types of corrugated paperboards; unlined, single-faced, double- faced, double walled and triple walled. Just two are used for wrapping and the others are used where exceptional strengths and rigidity are essential. Double faced corrugated is the most commonly used for boxes liners and partitions.
A B C E(flute) Flutes/fort 35-37 50-52 41-45 90-96 Flute height(in) 0.185 0.105 0.145 0.085 Thickness(in) 3/16-7/32 4/32 5/32 5/64
Each flute has particular properties with respect to load support in each of three possible directions
Aluminum containers Containers fabricated from plain aluminum foil have different degrees of rigidity depending upon thickness, tamper, alloy and container design, some are rigid and are easily deformed and others are more delicate and hence they are included in semi rigid. Aluminium containers provide extreme convenience in preparation and serving of foods they withstand extremes of temperatures. Aluminium protects the food against moisture, gases and light. Folded end cartons have wrinkle free sides and bottoms. Formed containers are made with male and female dies have wrinkled side walls and flanges with smooth flanges flat web materials can be hermetically scaled as closures.
Flexible Packaging Material Flexible packages are made from combination of flexible materials. There are millions of possible combinations.
Paper - 5 - DTKFCPL Dr. Kuchroo June 25, 2003 Paper remains an important factor in flexible packaging because it contributes strength, stiffness, smoothness and low cost. In flexible packaging the basic paper used contains bond, tissue, litho, Kraft, glassine parchment and grease proof.
Bond papers are uncoated sheets made of bleached chemical pulps in weights and ranging from 9.07 to 31.75 Kg. They are supplied with wide variety of finishes and may be purchased with the high weight and tear strength and printing and laminating grades.
Tissues are light weight papers made of semi and fully bleached chemical pulps in basis weight ranging from 3.62 to 9.07 Kg with open or closed fiber formation. Special treatments may be added as such as wet strength and mild resistance.
Litho papers are sheets coated on one or both sides in basic weights ranging from 13.15 through 27.22 kg. They are not strong enough as bonds but have better surface for printing and are preformed for labels etc.
Kraft papers are extremely strong and may be used in bleached or unbleached forms. Basic weight range from 11.34 to 36.28 kgs. Kraft papers are graded according to wood pulps used. The strength of Kraft paper depends upon the quality of wood pulp used provides the strength to the paper accordingly.
Glassine papers are super calendered chemical pulp sheets in basic weights ranging from 6.8 to 20.4 Kgs. They have a high resistance to air and grease. Genuine glassine pulp is beaten much larger than imitation grade and therefore the genuine glassiness have highest resistance to grease.
Parchment papers are made up of bleached chemical pulp which is immersed in a bath of sulphuric acid. The good grease resistance and high wet strength. Both parchment and grease proof papers have a rougher and more opaque appearance than glassiness. They are supplied ranging from 6.8 to 12.3 Kg
Films A film is thin plastic flexible sheeting having a thickness of 0.0254 cm or less. Te first commercial flexible film was cellophane. Cellophane is manufactured from highly purified cellulose derived from bleached sulphite pulp. The cellulose is treated with sodium hydroxide solution and carbon di sulphide to produce "xanthanal which when dispersed with sodium hydroxide, produce viscose. The viscose is extruded through a slot into acid salt baths generate cellulose film. It is then processed and various coatings and modifications are made to develop several grades of cellophane, nitrocellulose coated cellophane after non blocking moisture vapor resistance (MVT) slip and flexibility and heat seal ability. Saran coated offers protection from oxygen and Better MVT.
Polyethylene Polyethylene is the largest volume, simple film used in flexible packaging industry. High pressure polyethylene is obtained by exposing ethylene to temperature between 150 *C and 200 * C at a pressure of about 1200atm in presence of traces of oxygen. This film is known as Low density poly ethylene. Low pressure high density poly ethylene is produced at temperature between 60*c and 160 * C and pressure of 40 Atm with alkyl metal catalysts. Its greatest benefit is its ability to fusion or heat seal ability.
- 6 - DTKFCPL Dr. Kuchroo June 25, 2003 Poly propylene is produced by polymerization of polypropylene. It is more rigid, stronger and lighter than polyethylene. The film has low water vapour permeability, good resistance greases, high temperature stability and poor gas barrier.
Polyesters are condensation products of poly alcohol with a di-acid or its anhydride. They offer excellent tensile strength, tear resistance and good ageing properties.
The polyvinyl chloride films are prepared by polymerizing vinyl chloride in presence of suitable catalysts. By the addition of plasticizers, flexible films are obtained.
Amylose film is made from corn starch. The film is edible and is very soft, slightly hazy, stretchable and water soluble. The film has poor moisture barrier. It is satisfactory as a gas and flavour barrier.
Ionomers based on low density poly ethylene, the ionic bonds in ionomers serve to increase overall bond strengths and yield superior oil, grease and solvent resistance. At normal temperature Surlyn A is tougher and is more sensitive to water absorption. Its high melting strength makes it Surlyn A extremely suitable for extrusion coating, vacuum forming and skin packaging.
Ehtylene- Vinyl Acetate Co polymers (EVA) results from the co-polymerization of high pressure (low density) polyethylene and vinyl acetate. EVA is more flexible; however it is more permeable to water vapor and gases. Impact strength is excellent and the film is clearer than polythene. EVA is thermally unstable at high heat but very stable and versatile at lower temperature and has a wide heat-seal range. The polar nature of side groups present in the co-polymer causes blacking characteristics.
Polypropylene co polymers offers excellent water and gas strength properties, however its cold temperature impact strength is poor. In an effort to overcome this defect, a second monomer usually ethylene is introduced into polypropylene structure. Poly propylene co polymers are used for shrink wrapping.
MECHANICAL PROPERTIES OF PACKAGING FILMS.
Film material Tensile strength Elongation % Tearing strength( G mil) Bursting strength 1 mil thick (P.S.I) Folding endurance Number of foldsx10 3 Heat seal Cellophane plain 104-186 14-36 275-426 ..... .... ..... N C - Coated 70-150 10-50 2-10 55-65 OW 15 93.3- 148.8 Sam Coated 70-130 25-50 2-15 ..... .... 107.2- 176.6 Polyethylene coated 50 and over 15-25 16-50 40-50 good 110- 148.8 Cellulose acetate 50-139 25-45 2-25 50-85 0.25-0.4 176- 232 Polyethylene Low density 13.5-25 200-800 150-350 48 Very high 121.1- - 7 - DTKFCPL Dr. Kuchroo June 25, 2003 176.6 High density 24-61 150-650 15-300 .... .... 135- 176.6 Polyester 170-237 70-130 10-27 45-50 20 135- 204.4 Polypropylene 45-100 400-600 32-1750 Very high .... 162.7- 204.4 Polystyrene (oriented) 80-120 3-20 20-30 23-60 ... 121.1- 162.7 Vinylidene saran 80-200 40-80 10-100 20-40 250 93.3- 176.6 Nylon 138-170 200 50 No burst .... 204- 232
Co extruded films Films called structured films are produced by a process of co extrusion. (Simultaneous extrusion through complex dies) Both flat die and blown structural films are being manufactured. One of the first commercial products was polyethylene- polypropylene. Film designed for broad WMP. Another structure used is a co-polymer-homo polymer-copolymer polypropylene film.
These films are being used for different purposes. The composition of the films depends upon the end use. These are five layer films now available which are personally being used in packing oil and other greasy products and provide an excellent shelf life to the product. The common co-extrusion films are varying from 3 to 5 layer combination
The five layer films have shown superior properties.
a) High tensile strength and improved burst strength b) NO Flex crack c) Light barrier properties for UV stabilization d) Symmetrical film without curl for smooth running in automatic FPS machine. e) Permanent printability f) Very good gas barrier properties g) Leak proof sealing and high seal tack strength h) Aroma retaining properties i) Can withstand hazardous transportation in cardboard boxes j) Easy to handle and low cost material against conventional materials
Co-extrusion technology based on co-extruded films up to 3 layers is now a common usage in our country for many years. The films having 2-3 layers using common polymer link LDPE, HDPE etc. The usage of Nylon 6 has become successful. The available structure of 3 layer film is PA 6/ bonding/surlyn. The typical five layer structure suitable for packing oil, butter oil etc.
LDPE/Bonding/PA6/Bonding/HDPE Or LDPE/Bonding/Pa6/Bonding/Surlyn - 8 - DTKFCPL Dr. Kuchroo June 25, 2003
The heat seal properties of these films are better. To achieve better barrier properties metalizing of film has helped to achieve better shelf life and has provided product a better get-up. Various combinations of film laminate here achieved similar properties. For products which are more solid in nature like snax, powder, biscuits etc.
Various combination of film laminates are in use depending upon the end use. i) Metallized polyester laminated to LDPE or HDPE or LDHD ii) Plain polyester laminated to LDPE or LDHD iii) Plain BOPP laminate to LDPE or LDHD iv) Polyester/ Foil/ Poly v) Paper/Poly vi) Metallized polyester/ paper/poly vii) Metallized BOPP to LDPE or LDHD
The metalized films provide additional characteristics to the films towards the aroma and oxygen barrier properties for packing tea, coffee and sugar. For pharmaceutical packing, aluminium foil laminated to LDPE, glassine etc. is used to laminate to provide better seal ability and barrier properties. The total foil in itself is an excellent barrier. Coating and after substitutes serve only to add strength, decoration and heat seal ability.
The most important laws which govern the packaging is to cognizance of all chemical components of the supply, whether these components enter the food by direct addition or by indirect means. For example, by virtue of migration from a food packaging material.
A food additive is actually any substitute that can become component of food by direct or indirect means unless that is known to be safe or is prior sanctioned. All substances that can become a component of food are presumed to be additives unless declared by law; all other substitutes i.e. non-food additives new prior sanctioning. These substances are listed separately by law in each country.
It is not within the scope of the article to consider legislation relating to various laws required to be followed in manufacture of the packaging material. The laws are different in different countries. It is essential to understand that packing material to follow the regulation enacted by FDA in each country.