FOOD PROCESSING TECHNOLOGY

TECHNOLOGY PRACTICAL (IV)

SEMESTER VI

PRACTICAL 03

COMPARISON OF DIFFERENT PACKAGING

METHODS

NAME: J.A.N.GIMHANI

INDEX NUMBER: BST/17/025

DUE DATE: 2022.01.14

GROUP NUMBER: 01

DEPARTMENT OF BIOSYSTEMS TECHNOLOGY

FACULTY OF TECHNOLOGY

UNIVERSITY OF SRI JAYEWARDENEPURA

Date: 2021.11.29

Practical No: 03

Practical Name: Comparison of different packaging methods

Objectives:

 To get familiarized with different packaging methods

 To compare the effectiveness of each packaging method for the selected food items
 To identify importance of water activity of foods

Introduction:

Advances in food processing and food packaging play a primary role in keeping the food supply among
the safest in the world. After the process of food is complete, foods cannot to travel safely for long
distances from their point of origin without packaging. Therefore, food Packaging is one of the most
important processes in food industry which helps in maintaining the quality of food products during
storage, transportation and distribution. The principle role of food packaging is to protect food products
from outside influences and damage, to contain the food, and to provide consumers with ingredient and
nutritional information. The goal of food packaging is to contain food in a cost-effective way that
satisfies industry requirements and consumer desires, maintains food safety, and minimizes
environmental impact. There are many packaging materials used. Each type of packaging material has a
different role to play in packaging. Food packaging can retard product deterioration, retain the beneficial
effects of processing, extend shelf-life, and maintain or increase the quality and safety of food.

Packaging provides protection from 3 major classes of external influences: chemical, biological, and
physical. Chemical protection minimizes compositional changes Couse by environmental influence such
as, exposure of foods to gases, moisture, or light. Glass and metals provide nearly absolute barrier to
chemical and other environmental changes. Biological protection provides a barrier to microorganisms
(pathogens and spoilage microbes), insects, rodents and other animals. In addition to that, it maintains the
conditions to control senescence (ripening and aging). Physical protection provides a barrier to
mechanical damage that includes cushioning against the shock and vibration encountered during
distribution. Typically developed from paperboard and corrugated materials to provide physical barrier.

Packaging material plays a significant role in determining the shelf life of a food product. The selection of
right packaging materials and technology is very much important, which helps in maintaining the product
quality during distribution and storage. Packaging materials which have been traditionally used in food
packaging includes paper, paperboards, glass, metals and plastics. Today’s food packaging materials are
often combination of several other materials to exploit each material’s functional or aesthetic properties.
Materials:

Ingredients

 Raw peanuts (with shell) ~250 g

 Bitter gourd (Karawila) ~250 g
 Fish (whole fish) ~ 500 g
 Vegetable oil ~ 200 mL

Equipment

 Stainless steel knives

 Plastic containers x 4
 Stainless steel saucepan
 Sterilized glass bottles x 2
 Weighing scale
 Sealer
 Spoon
 Oil spoon
 Strainers
 Vacuum sealer
 Polythene
 Water activity meter

Procedure:

Task 1. Peanuts

The peanuts were removed from the shell and any damaged or irregular shaped peanuts were removed.
Then, the water activity of the raw peanuts were measured with seed coat on. A pan was used to roast the
peanuts and two tablespoons of vegetable oil were used before adding peanuts into it. After that peanuts
were roasted and they were divided into two portions. Then seed coat of one portion was removed. After
that, peanuts were packaged in a plastic container, in polyethene using sealer, and in polythene using a
vacuum sealer. After one week interval, the observations were taken.

Task 2. Bitter Gourd

Firstly, the bitter gourd was washed in running water to remove any dirt. Then the bitter gourd was sliced
into thinner slices with removing seeds. Then the water activity of raw bitter gourd was measured. After
that, sliced bitter gourd was blanched in hot water for two minutes and then they put into the cold water
and drained well. After they were drained enough, three quarters of them were deep fried in vegetable oil
until a slight golden color was achieved. Then, the fried bitter gourd slices were removed from the oil pan
and it was let to drain for some time and cold down to the room temperature. Then the water activity of
fried bitter gourd and raw-bleached bitter gourd was measured. Finally, fried and blanched bitter gourd
was packed separately in a sterilized glass bottle, in polyethene using a sealer, and in polythene using a
vacuum sealer. After one week interval, the observations were taken.

Task 3. Fish

Firstly, the fish was de-headed, de-scaled and cleaned. Then it was washed with running water to remove
any remaining scales. Fillets were prepared by carefully slicing the fish parallel to its backbone. Then the
water activity of raw fish was measured. After that, the fillets were cut into pieces by weighing about 50
g. then; these fillets were packaged in a plastic container, in polyethene using a sealer, and in polythene
using vacuum sealer. After one week interval, the observations were taken.
Observations:

Date: 2021.11.29

Practical No: 03

Practical Name: Comparison of different packaging methods

Observations:

Task 1. Peanuts

Table 1: Water activity result of packaged peanut

Packaging type Initial water activity Final water activity (after 01 week)
Roasted with Roasted without Roasted with Roasted without
shells shells shells shells
In polyethene using
0.782 (29.1 °C) 0.682 (29.7 °C)
sealer
In polythene using 0.711 (28.1 °C) 0.605 (28.1 °C)
0.749 (28.9 °C) 0.662 (29.7 °C)
vacuum sealer
In plastic container 0.695 (29.4 °C) 0.716 (29.7 °C)

A C
B

Figure 1: Roasted with shell peanut samples;

A: In polyethene using sealer, B: In polythene using vacuum sealer, C: In

plastic container
 A B C

Figure 2: Roasted without shell peanut samples;

A: In polyethene using sealer, B: In polythene using vacuum sealer, C: In

plastic container

Task 2. Bitter Gourd

Table 2: Initial Water activity of bitter gourd sample

Product type Water activity (initial)

Raw bitter gourd 0.978 (27.1 °C)
Raw blanched bitter gourd 0.982 (27.6 °C)
Fried bitter gourd 0.959 (27.1 °C)

Table 3: Water activity of bitter gourd sample after 01 week

Packaging type Water activity (after 01 week)

Raw blanched bitter gourd Fried sample
Vacuum packaging 0.977 0.980
LDPE packaging 0.985 0.979
In glass bottle 0.973 0.972
 a b C
d e f
A B
Figure 3: Initially packaged bitter gourd,

A: Raw blanched packaged bitter gourd; a: In glass bottle, b: In LDPE, c: In vacuum packaging;

B: Fried packaged bitter gourd; d: In glass bottle, b: In LDPE, c: In vacuum packaging

A B

Figure 4: After 01 week observations in glass bottle packaged sample;

A: Raw blanched sample, B: fried sample

A B
Figure 5: After 01 week observations in LDPE packaged sample;

A: Raw blanched sample, B: fried sample

 B A

Figure 6: After 01 week observations in vacuum packaged sample;

A: Raw blanched sample, B: fried sample

Table 4: Weight of Bitter gourd

Packaging type Raw blanched bitter gourd Fried sample

Initial weight After 01 week Initial weight After 01 week
weight weight
Vacuum packaging 28.1 g 28.1 g 13.3 g 13.3 g
LDPE packaging 26.2 g 26.1 g 11.4 g 11.3 g
In glass bottle 256.1 g 256.1 g 241.7 g 241.7 g

Task 3. Fish

Table 5: Water activity result of packaged fish

Packaging type Initial water activity Final water activity (after 01 week)
Freeze sample Refrigerated Freeze sample Refrigerated
sample sample
In LDPE using sealer 0.716 0.978 (29.5 °C)
In polythene using
0.965 0.962 0.908 0.978 (29.5 °C)
vacuum sealer
In plastic container 0.609 0.978 (29.5 °C)
 A B C

Figure 7: Initially packaged fish,

A: In plastic container, B: In polythene-sealer, C: In polythene vacuum sealer

A
B C

Figure 8: After 01 week observations of packaged fish

A: In plastic container, B: In polythene-sealer, C: In polythene vacuum sealer
Discussion:

Packaging materials plays a significant role in determining the shelf life of a food product. The selection
of right packaging materials and technology is very much important, which helps in maintaining the
product quality during distribution and storage (Malik et al., 2013).

The production of glass containers involves heating a mixture of silica, sodium carbonate, and calcium
carbonate and alumina to high temperatures until the materials melt into a thick liquid mass that is then
poured into molds. Glass has several advantages for food-packaging applications such as it is
impermeable to gases and vapors, so it maintains product freshness for a long period of time without
impairing taste or flavor. Glass has some disadvantages such as it is heavy weight adds to get high
transportation costs. Another concern is its brittleness and susceptibility to breakage from internal
pressure, impact, or thermal shock (Marsh, 2007).

Plastics are made by condensation polymerization or addition polymerization. Plastics are highly
malleable and so can be molded into different solid objects. The usage of plastic for food packaging is
increasing over traditional materials such as glass and metal due to its low cost and functional advantages
like thermo-sealability, optical properties, and unlimited size and shape. Plastics are synthesized by
addition, condensation or crosslinking polymerization of monomer units. There are two major categories
of plastics: thermosets and thermoplastics. There are various types of plastics available in world. PE is the
simplest, versatile and inexpensive plastic synthesized by polymerization reaction of ethylene.
Polyethylene (PE) was one of the first plastics used widely for food packaging. There are several types of
polyethylene in use today including Low-density polyethylene (LDPE) and High-density polyethylene
(HDPE). In this practical, LDPE and HDPE are used to packed peanut, bitter gourd and fish to find good
packaging type (Sarkar and Aparna, 2020).

 LDPE: it is flexible, easy to seal, strong, tough and resistant to moisture. LDPE is relatively
transparent and it is used in applications where heat sealing is necessary.
 HDPE: it is stiff, tough, strong, resistant to chemicals, permeable to gas and moisture, easy to
process and easy to form. HDPE is a stronger plastic and has a higher melting point than LDPE.

Vacuum packaging is widely use techniques in the food industry due to its effectiveness in reducing
oxidative reactions within the product at lower cost. The product is contained in a package made of a
material having low oxygen permeability and is sealed air tight after evacuating the air.

The free or available water in a food supports to microbial growth, and support to chemical and enzymatic
reactions and spoilage processes. This amount of water is free water which is called water activity and it
is more important for food stability, chemical and microbial, that total water content (‘w ) w = 0’, no
date).
Task 1. Peanuts

Initially, about 0.711 (28.1 °C) was given in peanuts which is roasted with shell. After one week, heat
sealer (0.782 at 29.1 °C) and vacuum sealer (0.749 at 28.9 °C) were given somewhat higher water activity
compare to in plastic container (0.695 at 29.4°C). And also, after one week peanut package in polythene
sealer was not given crispy texture (loss of crispiness in dry product) like just after fried, because it was
absorb moisture from inside of the package and loss the crispiness. Water activity is changed by
absorption of water. And also it was given some rancid flavor due to lipid oxidation compare to other
both packaging methods, because that polythene (LDPE) can exchange water and oxygen through the
packaging material. But in plastic container and vacuum packaged peanut was given crispy texture
without any rancid flavor. Therefore, this vacuum packaging and in plastic container is most preferred for
packaging method for both without shell and with shell fried peanuts.

Task 2. Bitter Gourd

Water activity of raw bitter gourd was 0.978. After blanching of that, it was given high water activity as
0.987. But just after frying that sample was reduced the water activity up to 0.959. Microbes cannot
multiply at water activity below 0.6. But packaged raw blanched and fried bitter gourd sample ware given
above 0.9 water activity. Therefore, at this point microbes can highly grow at this water activity level.
After one week, LDPE packaged and glass bottle packaged fried samples has grown some white fungus.
Fungi can highly grow under high water activity level. And also, after one week all these fried samples
were not given crunchy texture (loss of crispiness in dry product) like just after fried, because it was
absorb moisture from inside of the package. Water activity is changed by absorption of water. Vacuum
package condition is good for fried biter gourd sample compare to other two packaging method, because
there is no grown fungus within the product due to lack of oxygen.

After one week of raw blanched samples were spoiled due to microbial growth, water leaching out,
softening, and giving bad smell. These three methods are not suitable for packaging raw blanched bitter
gourd, because water activity is getting higher and spoilage happen very quickly.

Task 3. Fish

Initial Water activity for freeze fish sample was 0.965. but it was highly reduce in LDPE packaged and
plastic container packaged fish sample. Both of these are given some bad odor because of lipid in fish is
oxidized, Lipid oxidation is another major quality deteriorative process in muscle foods and resulting in a
variety of breakdown products which produce undesirable off-odors and flavors, because O2 may cause
off-flavors (rancidity due to lipid oxidation), color changes (discoloration of pigments such as
carotenoids), nutrient losses (oxidation of vitamin E, ascorbic acids, β-carotenoids) and accelerated
microbial spoilage thereby causing significant reduction in the shelf life of foods. And also, color in
muscle also changed, because . In fresh fishes contains myoglobin that can be exist in one of three
chemical forms. Deoxymyoglobin (purple color) is rapidly oxygenated to cherry red oxmyoglobin on
exposure to air. Over time, oxymyoglobin is oxidized to metmyoglobin which results in a brown
discoloration associated with a lack of freshness. But in vacuum packaged fish was given lower changes
of water activity, color and flavor compare to other packaging methods, because Low oxygen
concentrations lower the oxidation of oxymyoglobin to metmyoglobin. Therefore, in order to minimize
metmyoglobin formation in fresh red meat, oxygen must be excluded from the packaging environment to
below 0.05% or present at saturating levels. And also, Oxygen level in the package can be controlled by
using the vacuum packaging techniques in which, the present in the pack is completely evacuated by
applying vacuum and then package is sealed. So that oxygen available for the growth of microbes and
oxidation will be limited. This will help in doubling the shelf life of fish under chilled conditions.
Therefore, vacuum packaging method is most suitable for the packaging of fish (Mohan, 2017).

Comparison of advantages and disadvantages in modified atmospheric and vacuum packaging

methods

The most commonly used materials in MAP and Vacuum packaging are laminates of plastic films with a
very low permeability to oxygen and carbon dioxide. In the case of MAP, the low permeability is needed
to keep the gasses within the packages, while the opposite is the case in vacuum packaging. The two
packaging systems are quite different in respect to appearance and shelf life (‘Comparison of Modified
Atmosphere Versus Vacuum Packaging to Extend the Shelf Life of Retail Fresh Meat Cuts’, 1983).

Appearance of the product: for example, the appearance of MA-packed fish is very attractive to the
consumer, because a bright red color seems to be synonymous with freshness. It is the reason for the
increasing interest in acceptability of retail fresh fish packed in modified atmosphere. The color of the
fish packed in vacuum packs is purple because of the lack of oxygen. This presumably presents the
greatest drawback when selling vacuum packed fish.

Aroma and flavor: Using gas mixtures in MAP rich in oxygen may provide good growth conditions for
spoilage bacteria; they may simultaneously react with a great number of chemical components of the food
like fat in such a way that the flavor deteriorates gradually due to lipid oxidation process. And also, the
micro flora within the packs can consist of harmless Lactic Acid bacteria. The activities of these bacteria
simultaneously result in development of a sour odor. In the case of vacuum packaging, the food product
will retain its aroma and flavor for a longer period mainly due to lack of oxygen to oxidation and
microbial growth.

Shelf life: The shelf life of MA-packed (like meat and fish) is limited by the high content of oxygen and
by the activity of spoilage bacteria. MA-packed meat is usually labeled to be sold within 4 to 7 days after
packaging. Vacuum packaging of meat and fish like products indicates a considerably longer shelf life
compared to MA packaging.
 Table 6: Advantages and disadvantages of vacuum and MAP

Advantages of vacuum packaging Advantages of MAP

Reduces fat oxidation Product retains its vitamins, taste and reduces fat
oxidation
Reduces growth of aerobic microorganisms Reduces the growth of microorganisms
Reduces weight loss The product retains its form and texture
Reduces evaporation The natural color of the product is preserved
Reduces dryness of product Extends the shelf life of fish in chilled / refrigerated
storage by 2 – 3 times
Reduces freezer burn
Extends the shelf life
Disadvantages of vacuum packaging Disadvantages of MAP
Cannot be used for crispy products and products Cost of gases and packaging materials
with sharp edges
Requires high barrier packaging material to Capital intensive due to high cost of machinery
maintain vacuum
Creates anaerobic condition, which may trigger the Additional cost of gas analyser to ensure adequate
growth and toxin production of Clostridium gas composition
botulinum and the growth of Listeria
monocytogenes

Conclusion:

Food Packaging is one of the most important processes in food industry which helps in maintaining the
quality of food products during storage, transportation and distribution. The principle role of food
packaging is to protect food products from outside influences and damage, to contain the food, and to
provide consumers with ingredient and nutritional information.

Vacuum packaging method is most suitable method for the packaging of Fried peanut and fried bitter
gauds, because it is help full for protect their crispiness for long time and it will not giving bad flavor and
odor due to lipid oxidation. And also, this vacuum condition is not caused for the growth of
microorganisms due to lack of oxygen.

And also, vacuum packaging method is most suitable for the packaging of fish, because it will not giving
bad flavor and odor due to lipid oxidation. And also, this vacuum condition is not caused for the growth
of microorganisms due to lack of oxygen.
References:

‘Comparison of Modified Atmosphere Versus Vacuum Packaging to Extend the Shelf Life of Retail Fresh Meat
Cuts’ (1983), 35, pp. 60–64.

Malik, A. A. et al. (2013) ‘Stewart Postharvest Review’, (December). doi: 10.2212/spr.2013.4.7.

Marsh, K. S. (2007) ‘Food Packaging?Roles, Materials, and Environmental Issues’, (November 2017). doi:
10.1111/j.1750-3841.2007.00301.x.

Mohan, C. O. (2017) ‘Chapter 15 Vacuum packaging & MAP’, pp. 165–174.

Sarkar, S. and Aparna, K. (2020) ‘Chapter - 2’, (October). doi: 10.22271/ed.book.959.

‘w ) w = 0’ (no date), (01).