03 Active Packaging

2/6/2020
ITP632 Teknologi Pengemasan Pangan Lanjut
Smart Packaging Systems:
Dr. Nugraha Edhi Suyatma, STP, DEA

Food Science and Technology Department
Faculty of Agricultural Engineering and Technology
IPB University
What is Smart Packaging?
• Smart packaging refers to packaging

systems that help extend shelf life,
monitor freshness, display
Definition information on quality, improve
safety and improve convenience.
Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut
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What is Smart Packaging?

Smart
Packaging
ACTIVE INTELLIGENT
• Absorber/Scavenger: • Indikator: Freshness,
⁻ Senyawa yang spoilage, TTI,
tidak dikehendaki/ Leakage, gas
merugikan concentration, etc.
• Releaser/Emitter: • Sensor: Pathogen
⁻ Senyawa yang contamination
menguntungkan
untuk pangan dan • RFID and others.
obat.
Smart Packaging References
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Passive vs Smart Packaging

Passive Packaging Smart Packaging
Basic functions:  Active Packaging: actively
1. Containment changes the condition of
2. Protection the packaged food to
3. Communication extend shelf-life or to
improve safety and sensory
4. Convenience
properties
 Intelligent packaging:
monitors the condition of
packaged foods to give
information about the
quality and safety of the
packaged food.
Active and Smart Packaging Market

 In Japan, USA, Europe and Australia, Smart (active or
intelligent) packaging are already being successfully applied
and easily found in the market.
 Smart packaging demand in US to hit $3.5 bn in 2017
(www.bakeryandsnacks.com)
 The global smart packaging market is expected to reach
USD 46.74 Billion by 2022
(https://industrytoday.co.uk/packaging/smart-packaging-market-2018).
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TREND PENELITIAN ACTIVE PACKAGING

Antioxidant active packaging
Antimicrobial active packaging (natural
preservative)
Oxygen scavenger
Double/multi functional active system
7
TUGAS KAJIAN PENELITIAN ACTIVE PACKAGING

Setiap kelompok memilih 1 artikel dari Jurnal
International berupa hasil penelitian
pengembangan kemasan aktif.
Presentasikan artikel tersebut:
 Judul,
 Tujuan,
 Metode (Preparasi, prinsip, analisis yang
dilakukan),
 Hasil penting dari system active yang
dikembangkan.
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Active Packaging
Scavenging/absorbing systems:
remove undesired compounds such
as oxygen, excessive water, ethylene,
carbon dioxide, odor, and other
specific food compounds.
Releasing systems: actively add

compounds to the packaged food
such as preservatives, carbon
dioxide, heat, antioxidants etc.
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Selected examples of active packaging systems

Active packaging System mechanisms Food Applications
Oxygen scavengers Iron based, Metal/acid Bread, cakes, cooked rice,
Nylon MXD6, Metal (e.g. platinum biscuits, pizza, pasta,
catalyst) cheese, cured meats and
Ascorbate/metallic salts fish, coffee, snack foods,
Enzyme based dried foods and beverages
Carbon dioxide Iron oxide/calcium hydroxide Coffee, fresh meats and fish,
scavengers/emitters Ferrous carbonate/metal halide (e.g. nuts and other snack food
NaCl) products and sponge cakes
Calcium oxide/activated charcoal
Ascorbate/sodium bicarbonate
Ethylene scavengers Potassium permanganate Fruit, vegetables and other
Activated carbon horticultural products
Activated clays/zeolites
Preservative Organic acids Cereals, meats, fish, bread,
releasers Silver zeolite cheese, snack foods, fruit
Spice and herb extracts and vegetables
BHA/BHT antioxidants
Vitamin E antioxidant
Chlorine dioxide/sulphur dioxide
Cont..
Active System mechanisms Food Applications

packaging
Ethanol Encapsulated ethanol Pizza crusts, cakes, bread,
emitters biscuits, fish and bakery
products
Moisture PVA blanket Fish, meats, poultry, snack
absorbers Activated clays and minerals foods, cereals, dried foods,
Silica gel sandwiches, fruit and
vegetables
Flavour/odour Cellulose triacetate, Acetylated paper Fruit juices, fried snack
absorbers Citric acid, Ferrous salt/ascorbate foods, fish, cereals, poultry,
Activated carbon/clays/zeolites dairy products and fruit
Temperature Non-woven plastics, Double-walled Ready meals, meats, fish,
control containers, Hydrofluorocarbon gas poultry and beverages
packaging Quicklime/water, Ammonium
nitrate/water, Calcium chloride/water
Super corroding alloys/salt water
Potassium permanganate/glycerine
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Active Packaging
Why Oxygen scavengers ?
oxygen plays a major

role in many spoilages
and quality losses of
foods
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Active Packaging
Why Oxygen scavengers ? •off-flavours: e.g. rancidity

as a result of lipid oxidation
Oxydation •colour changes
•nutrient losses
Development of accelerates spoilage and

deterioration of many
Aerobic foods.
Microorganism accelerates the growth of
and Insect insects and insect damage
Respiration rate accelerates senescence.

and ethylene reduce shelf-life of fresh
fruits and vegetables
production
The expected effects of oxygen scavengers (OS)
Effect Typical application

Fresh taste and aroma Various food items, coffee, tea
Preventing mold growth Bakery product, cheese,
processed seafood
Preventing rancidity Nuts, fried foods, processed
meat, whole milk
Preventing Discoloration Processed meat, herbs, tea, dried
vegetable
Preventing Insect damage Beans, grain, herbs, spices
Maintaining nutritional All kind of foods
value
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SELECTING OXYGEN SCAVENGER TYPES

Selection Factor affecting the choice
Harmless Oxygen level in headspace
Absorption rate Nature of food
Compact size and capacity Water activity
Desired shelf-life of
Economic Price
product
OS may be self-
Not produce toxic
reaction type or
substance and odor
moisture dependent
Oxygen Scavenger Type

How to scavenge oxygen?
Iron oxidation (moisture dependent)
Ascorbic acid oxidation
Enzyme activity (moisture dependent)
Immobilised yeast on a solid material
PUFA (e.g. olec and linoleic acids)
Combination
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Active Packaging
OS with iron oxidation
 1 gram Fe reacts with 300 ml O2 (Vermeiren et al, 1999)

 cannot be effectively used with low-water content foods
OS with Ascorbic acid

 Action principle based on ascorbate oxidation to
dehydroascorbic acid (developed by W.R. Grace and Co., US).
 OS can be used for Dry food (low Aw)
2AA + O2 → DHAA + H2O

where: AA = ascorbic acid
DHAA = dehydroascorbic acid.
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Enzyme-based oxygen scavengers

• Mixed enzymes (glucose oxidase and catalase) are commonly
used.
 Glucose oxidase catalyses the following reaction
2Glucose + 2O2 + 2H2O → 2Glucono-lactone + H2O2
 The produced hydrogen peroxide is eleminated by
peroxidase/catalase
2H2O2 + catalase → O2 + 2H2O
• Two molecules of glucose are needed to reduce one molecule of

oxygen, systems require water for their action  cannot be
effectively used with low-water content foods
OS WITH PUFA
 The oxidation of polyunsaturated fatty acids (PUFAs) is another
technique to scavenge oxygen.
 It is an excellent oxygen scavenger for dry foods because most
known oxygen scavengers have a serious disadvantage: when
water is absent, their oxygen scavenging reaction does not
progress.
 Mitsubishi Gas Chemical Co. (Japan) holds a patent that uses
PUFAs as a reactive agent, i.e., oleic, linoleic or linolenic acid.
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COMMERCIAL OS AVAILABLE IN INDONESIA
Ageless (Mitsubishi Gas Chemical Co.
FreshPax (Multisorb Technologies Inc)
Rp. 65000
O-Buster (Dessicare Inc) per 250
sachet
Atco (Emco Packaging Systems)
Ageless formats available: sachet, pressure-sensitive label and card
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FreshPax Oxygen Scavenger

Four main types: type B, D, R and M
Type B: for moist or semi-moist foods (aw > 0.7).
Type D: for dehydrated and dried foods.
Type R: for refrigerated or frozen storage
temperatures.
Type M: for moist or semi-moist foods, which are
packaged under MAP with CO2.
Oxygen Scavenger Application

OS application:
Sachette
Sealing compound
Embedded in packaging material
Label
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Fig . AgelessTM formats available: sachet, pressure-sensitive label and card.
Oxygen scavenger Label FreshPaxTM and FreshMaxTM

Figure. Crown oxygen scavenger from Darex (W.R.Grace).

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Effect of different treatments on bread slices at the 14th

day of storage
a. EVOH film + O2 scavenger b. PA/PE film + O2 scavenger
c. EVOH film + 30% CO2/70% N2 d. PA/PE film + 30% CO2/70% N2 e. LDPE film
Effect of Using OS
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APLIKASI KOMERSIAL DI INDONESIA
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Condition for OS application:
Packaging material with high

oxygen barrier PVDC, PP/Alu/PE,
PET/Alu/CPP
Complete Heat Sealing Packaging

integrity
Redox Indicator (e.g. Ageless eye)

No leaks
Appropriate Size and Type Calculate moisture

(Aw) and oxygen
in the head space
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Ulasan Soal UTS
Contoh kasus: estimasi kebutuhan OS

Produk keripik kentang rasa BBQ, dikemas dalam
kemasan pouch aluminium foil berukuran: panjang
x lebar x tebal = 20 cm x 10 cm x 3 cm. Berapa
kebutuhan penyerap oksigen minimal, jika isi
produk = 60% dari volume kemasan dan
diasumsikan kadar O2 dalam produk negligible ?
Tebal kemasan = 3 cm.

Isi produk = 60%
20 cm
maka head space (ruang kosong

dalam kemasan) = 100 - 60 =
40%
10 cm Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut
Contoh kasus: estimasi kebutuhan OS

Solusi:
 Volume kemasan = 20 x 10 x 3 = 600 cm3. Head space (ruang
kosong) = 40% x 600 = 240 cc. (Asumsi: tidak ada oksigen
terlarut di produk solid)
 Volume oksigen = 20% x 240 cc = 48 cc.
 Jadi kapasitas minimal penyerap oksigen = 48 cc.
 Untuk aplikasinya sebaiknya 2-3x kapasitas minimal
penyerapan OS (disesuaikan target umur simpan dan
permeabilitas O2 dari kemasan).
 Jenis OS yang dipilih harus dari jenis yang Non moisture
dependent (contoh: Ageless dari Mitsubishi Gas Chemical
Co.) karena keripik kentang memiliki kadar air yang sangat
rendah (Ka < 4%).
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Active Packaging
Etilen berperan sebagai hormon pada tanaman yang

mempunyai efek fisiologis pada buah dan sayuran segar:
Memicu pematangan
Mempercepat penuaan (senescence)
Menginduksi pembungaan
Mempercepat pelunakan tekstur
Meningkatkan degradasi klorofil
Memperpendek umur simpan buah dan sayuran segar dan
yang diolah minimal (minimally processed)
Akumulasi etilen pada kemasan buah dan sayuran

segar harus dihindari
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The Ethylene Gas Impact
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The Ethylene Gas Impact
Active Packaging
Acetaldehyde
Acetaldehyde acetic acid
Violet Brown
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ACTIVATED CARBON ETHYLENE REMOVERS

Principle:
 Metal catalysts on activated carbon remove ethylene from air
passing over the bed of activated carbon.
 Activated charcoal impregnated with a palladium catalyst and
placed in paper sachets effectively removes ethylene by
oxidation from packages of minimally processed kiwi, banana,
broccoli, and spinach (Abe and Watada, 1991).
COMMERCIAL ETHYLENE SCAVENGER
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Comercial exemple of ethylene-scavengers:
Active bag developed by P.B.I. Ltd

Biofresh developed by Biofresh Ltd
Ethylene Removing plastic bag
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Packaging
material that has
been coated with
AM
Ehicap Sachet
ANTIMICROBIAL AGENT
The mechanism of action for antimicrobial

substances are usually based on:
1) destruction of cell wall or cell membrane,
2) inhibition of various enzymes in the microbial
cell,
3) destruction of the genetic structure of the
protoplasm.
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ANTIMICROBIAL AGENT
ORGANIC ACIDS NATURAL EXTRACTS
o Benzoic acid (benzoates) o Cinnamaldehyde
o Sorbic acid (Sorbates) o Eugenol
o Acetic acid o Allyl isothiocyanate
o Propionic acid o Green tea extract
(Propionates) o Various extract
o Lysozyme
POLYMERS
BACTERIOCINS o Chitosan
o Nisin
o Pediocin SOME OTHERS
o Sulphure dioxide, chlorine
dioxide, Triclosan, silver zeolite,
nitrate, etc.
Spoilage Microorganisms (are mostly aerobic)
Food Food
Antimicrobial film Food additive
 Antimicrobial film (AF) is more effective as a barrier of spoilage

microorganisms.
 AF needs less preservatives than food additive application.
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3 Ways to convey Antimicrobial activity from the package

1. Within a structure
2. Through headspace
3. As a coating
Packaging
material that has
been coated with
AM
Ehicap Sachet
ANTIMICROBIAL AGENT SELECTION
 Antimicrobial substances for food packaging

should be selected on the basis of
 spectrum of activity,
 mode of action,
 chemical composition, and
 the rate of growth.
 MIC of antimicrobial agent has to be concerned.
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ANTIMICROBIAL AGENT SELECTION
Radusin et al, 2013. Actual and Future Trends in Antimicrobial Food Packaging. Agro
Food Industry, Vol. 24 (4) 44-49.
Type of AP
1. Addition of packet/pads containing volatile antimicrobial
agents into packages.
2. Incorporation of volatile and non-volatile antimicrobial
agents directly in the polymers
3. Coating antimicrobials on surface of polymers
4. Immobilization of antimicrobials onto polymers by
various linkages
5. Use of polymers that are having inherent antimicrobial
properties. Packaging
material that has
been coated with
AM
Ehicap Sachet Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut
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1. ADDITION OF SACHETS-PADS
• Ethyl alcohol has been known
for a century to act as
preservatives
• Ethanol vapor has been shown
to be effective in controlling:
• molds: Aspergillus and
Penicillium sp;
• bacteria: Staphiylococcus,
Salmonella, E. coli
ETHANOL EMITTER
• yeast: e.g. Saccharomyces
Commercial Ethanol Emitter

Trade Name Manufacturer
Ethicap® Freund Industrial Co. (Japan)
Negamold®2 Freund Industrial Co. (Japan)
OitechTM Nippon Kayaku Co. (Japan)
Ageless® SE1 Mitsubishi Gas Chemical Co. (Japan)
Fretek® Techno Intl Inc. (USA)
ET Pack Ueno Seiyaku Co. (Japan)
1Combined actions between ethanol-generating and O2 scavenging
2Under license from Freund Industrial Co. (Japan)
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2. INCORPORATING DIRECTLY INTO POLYMERS

Antimicrobial
agent
EXTRUDER
Antimicrobial
(Source: Dzrby, PKGSC 430)
packaging
57
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Incorporation of Organic acids
• Propionic, benzoic, sorbic acid were incorporated directly

into LDPE (Hotchkiss and his group).
 Result: It was not successful, Why ????
• What is an alternative way ?
• 1% Benzoic anhydride incorporated in LDPE, was

hydrolyzed within 5 hours as benzoic acid in PDA
(Potato dextrose agar) and completely inhibited R.
stolonifer, Penicillium sp. and Asp. Toxicarius.
3. COATING OR ADSORPTION ON POLYMER SURFACE
Fig. Gravure coater
(Source: Darby, PKGSC 430)

60
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4. IMMOBILIZATION OF ANTIMICROBIALS BY COVALENT LINKAGES
(Source: Darby, PKGSC 430)

61
5. ANTIMICROBIAL POLYMER
Chitosan polymer
Chitosan polymer
Poly-L-lysine
62
Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut (Source: Darby, PKGSC
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Control Chitosan Coating Chitosan Coating

without CEO + CEO
Microbiological quality - Total plate count

test during storage at room temperature
Application of Total plate count (log CFU/g) Shelf-lif

Chitosan in Tofu day-0 day-1 day-2 day-3 (day)
Control 3.83 TNTC TNTC TNTC <1
Incorporation 4.52 TNTC TNTC TNTC <1
Incorporation + CEO 4.09 9.77 TNTC TNTC 2
Coating 3.94 5.80 8.29 9.37 4
Coating + CEO 4.94 8.08 9.17 9.34 4
Note:
• TNTC = too numerous to count
• At the end of storage, tofu samples were lost the pleasant fresh
flavor, emitted a strong sour odor and their color turned darker.
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Organoleptic Test
Panel data on color of product:
Application Score
Method Chitosan Chitosan+CEO
Incorporation 5.24a 3.76b
Coating 5.60a 3.96b
• There was no significant difference at α = 5%

between incorporation and coating method.
• The use of CEO decreased preferrence of
judge significantly.
Texture analysis by SMS-Texture Analyzer

 Tofu control
 Tofu+Chitosan(I)+CEO
 Tofu+chitosan(I)
 Tofu+chitosan(C)+CEO
 Tofu+chitosan(C)
• The use of chitosan increased gel strength of Tofu significantly.

• CEO tends to decrease gel strength of tofu+chitosan
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Texture analysis
Gel strength (N)
A=Control
B=Incorporation
C= Incorporation + CEO
A B C D E D= Coating + CEO
E= Coating
Chitosan Application
• There are significant differences in Tofu gel strengh.
• Tofu coated by chitosan without CEO has the highest gel strength.
• The gel strength of tofu: control < Chit (I)+CEO < Chit (I) < Chit (C) +CEO <
Chit (C).
(a) (b)
SEM Micrograph of the surface of Tofu: a) control, b) coated
Chitosan + CEO
The microstructure of Tofu coated by chitosan is more
smooth and strengthNugraha
than that without coating.
E. Suyatma - Teknologi Pengemasan Pangan Lanjut
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2/6/2020
Odour scavengers
To scavenge the malodorous constituents of both
oxidative and non-oxidative biochemical
deterioration:
 sulphurous compounds and amines from
protein/amino acid breakdown
 aldehydes and ketons from lipid oxidation or
anaerobic glycolysis.
care must be taken as in some cases these odours
may be a signal indicating that the products are
exceeding the microbial or chemical limits.
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Exemple of Odour scavengers
To reduce malodorous amines (e.g. TMA), resulting

from protein breakdown in fish muscle:
Using acidic compounds, e.g., citric acid,
incorporated in polymers.
Some commercialised odour-absorbing sachets,

e.g., MINIPAX and STRIPPAX (Multisorb
technologies, USA) absorb the odours mercaptanes
and H2S developing in certain packaged foods
during distribution.
Exemple of Odour scavengers
To reduce bitterness in grapefruit juices:

oCaused by glycosidic flavanone naringin and
triterpenoid lactone limonin
Using enzyme naringinase immobilized in Cellulose
Acetate (CA) film, consisting of α-rhamnosidase
and β-glucosidase, which hydrolyses naringin to
naringenin and prunin, both non-bitter compounds.
a reduction in the limonin content due to adsorption
on the CA film
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Aroma Emissions from PACKAGING
Flavour incorporation in packaging material might be

used to minimise flavour scalping.
to mask off-odours coming from the food or the
packaging.
EXEMPLE:
Polyvel Inc., (Hammonton, NJ), USA: made by
incorporating liquid additives, such as fragrance oil,
during plastic PE extrusion.
SMART PACKAGING FOR DAIRY PRODUCTS
• 70% penduduk didunia mempunyai kandungan enzim

laktase yang rendah pada usus halus menyebabkan
gangguan pencernaan (diare) setelah meminum susu
atau produk susu lainnya (Lactose intolerance)
• Kadar kolesterol pada susu juga cukup tinggi
Smart packaging dengan menggunakan enzim dapat

menjadi suatu alternatif
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SMART PACKAGING FOR DAIRY PRODUCTS
Kemasan aktif dengan

Enzim laktase yang telah
dicangkokan atau
diimmobilisasi pada bagian
dalam kemasan akan dapat
memecah laktosa menjadi
glukosa dan galaktosa.
Dengan cara yg sama,
enzim kolesterol
reductase dapat memecah
kolesterol menjadi
coprostanol dan
coprosterol
For Convenience
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Self-Heating Can
Self-Heating Can
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Self-Chilling Can
Self-Chilling Can
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Contact:
Dr. Nugraha Edhi Suyatma, STP, DEA
HP/WA : 0813 86 035 135
Email: nugrahaedhi@yahoo.com ; nugrahaedhis@gmail.com
41

03 Active Packaging

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2/6/2020

ITP632 Teknologi Pengemasan Pangan Lanjut

Smart Packaging Systems:

Dr. Nugraha Edhi Suyatma, STP, DEA

What is Smart Packaging?

• Smart packaging refers to packaging

Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut

What is Smart Packaging?

Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut

Smart Packaging References

Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut

Passive vs Smart Packaging

Active and Smart Packaging Market

Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut

TREND PENELITIAN ACTIVE PACKAGING

Double/multi functional active system

TUGAS KAJIAN PENELITIAN ACTIVE PACKAGING

Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut

Releasing systems: actively add

Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut

Selected examples of active packaging systems

Active System mechanisms Food Applications

Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut

Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut

Why Oxygen scavengers ?

oxygen plays a major

Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut

Why Oxygen scavengers ? •off-flavours: e.g. rancidity

Development of accelerates spoilage and

Respiration rate accelerates senescence.

The expected effects of oxygen scavengers (OS)

Effect Typical application

SELECTING OXYGEN SCAVENGER TYPES

Harmless Oxygen level in headspace

Absorption rate Nature of food

Compact size and capacity Water activity

Oxygen Scavenger Type

Ascorbic acid oxidation

Enzyme activity (moisture dependent)

Immobilised yeast on a solid material

PUFA (e.g. olec and linoleic acids)

Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut

OS with iron oxidation

 1 gram Fe reacts with 300 ml O2 (Vermeiren et al, 1999)

Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut

OS with Ascorbic acid

2AA + O2 → DHAA + H2O

Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut

Enzyme-based oxygen scavengers

• Two molecules of glucose are needed to reduce one molecule of

Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut

Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut

COMMERCIAL OS AVAILABLE IN INDONESIA

Ageless (Mitsubishi Gas Chemical Co.

FreshPax (Multisorb Technologies Inc)

Atco (Emco Packaging Systems)

Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut

Ageless formats available: sachet, pressure-sensitive label and card

Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut

FreshPax Oxygen Scavenger

Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut

Oxygen Scavenger Application

Nugraha E. Suyatma - Teknologi Pengemasan Pangan Lanjut

Oxygen Scavenger Application