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Humidity regulating packaging materials

Conference Paper · January 2011

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Sven Sängerlaub C. Stramm

Munich University of Applied Sciences Fraunhofer Institute for Process Engineering and Packaging IVV
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 Humidity Regulating Packaging Materials

Sven Saengerlaub1,2, Maik Boehmer3, Preeti Singh2, Cornelia Stramm1 and Horst-
Christian Langowski1,2

1
Fraunhofer IVV, Freising, Germany
2
TUM, Chair of Food Packaging Technology, Freising-Weihenstephan, Germany
3
HTWK-Leipzig, Fakultät Medien, Leipzig, Germany

Abstract

Deliquescent salts, such as sodium chloride (NaCl), absorb considerable amounts of

water vapour, when their substance-specific threshold value for the relative humidity
(RH) is exceeded. The salts dissolve in the absorbed water vapour. For NaCl the
threshold is around 75% RH at 20 °C, where it absorbs more than 2.7 gH2O/gNaCl. The
water vapour is released when the environmental RH drops. Deliquescent salts are
therefore suitable to regulate the RH. To be utilized in flexible packaging materials
deliquescent salts are dispersed in a polymer matrix. It must contain cavities that store the
forming salt solution like a sponge. Suitable production processes are orientation and
foaming. During orientation the salt particles detach from the polymer matrix forming
cavities. The porosity of the polymer matrix is an important limiting factor for absorption
capacity of the film.

Results for the development of humidity regulating films are presented. By stretching or
foaming a porosity of at least >25% (v/v), by foaming and subsequent stretching a
porosity of >50% (v/v) were achieved. The humidity regulating behaviour of developed
films as well as results for packaging trials with fresh Agaricus mushrooms have been
described.

Sven Saengerlaub et al. TAPPI PLACE Conference Bregenz 2011

Introduction

For several packaging applications, films are desirable that adjust and regulate the
relative humidity (RH) inside closed packagings formed thereof. Such films must absorb
and desorb water vapour. This property is called in this paper as ‘humidity regulation’.
Promising applications areas are packagings for fresh foods. With these products, water
vapour condensates when the temperature fluctuates. The condensate is unattractive for
consumers. Furthermore it is beneficial for microbial growth. The unsolved task at these
products is the prevention of water vapour condensation without drying out the product.
Another potential application area for humidity regulating films is fruits and vegetables.
They have a longer shelf life when they are stored in their optimal RH condition. It is
between 80 and 95% RH.

The intention of the presented project was the development of humidity regulating films
suitable for the fresh food packaging market.

Attractive humidity regulating substances are deliquescent salts. One example is sodium
chloride (NaCl). When the substance specific threshold of 75% RH is exceeded NaCl
absorbs water vapour (Fig. 1). It dissolves in the absorbed water vapour. The absorbed
quantity is higher than that for desiccants. They absorb 0.2 – 0.5 gH2O/gsubstance.

24
M oisture content [gH2O/ gNaCl]

23 °C
22
20 7 °C
18
16
14
12
10
8
6
4
2
0
70 75 80 85 90 95 100
Relative humidity/ equilibrium humidity [% ]

Fig. 1: Water vapour sorption isotherm of NaCl

The salt solution formed has a higher volume than the dry salt. Therefore humidity
regulating polymer structures with dispersed salts need to have pores. The pores store the
salt solution like a sponge. Pores are formed (1) by foaming with a foaming agent
(chemical foaming) (Fig. 2) or by pressing a gas into the polymer melt during film
extrusion (physical foaming). (2) Pores are formed by stretching. During the stretching
the polymer matrix detaches from the salt particles. Pores are formed. In the centres lay
the salt particles. (3) Both processes are combined by stretching a foamed polymer
structure.

Sven Saengerlaub et al. TAPPI PLACE Conference Bregenz 2011

Fig. 2: Microscopic pictures of porous polymer structures; upper row: transmission,
lower row: cross-section; left: foamed; middle: biaxially oriented; right: foamed and
subsequently biaxially oriented

Materials and Methods

Sample production
(1) As humidity regulating substance NaCl (Siedespeisesalz extrafein, Esco) was
used. It was first milled to a particle size of particle size of D (v, 0.5) = 30 µm.
(2) Then a masterbatch of PE with 60% w/w NaCl was produced.
(3.1) With the masterbatch, foamed and non-foamed PP-films were extruded.
(3.2) Additionally a PP-compound (HP525J, from LyondellBasell) was produced from
the masterbatch and pressed on a platen press (341-50-12 x 12, Loomis products
Kahlefeld GmbH) to discs.
(4.1) The plates films were oriented on laboratory stretcher (Karo IV from Brückner
Maschinenbau GmbH & CO. KG) at a temperature of 130 to 145°C and a
stretching ratio of 1,4 x 1,4 – 5 x 5.
(4.2) The films were deep drawn to trays. Table 1 shows the film structures of the films
that were deep drawn to trays. They were used for tests with mushrooms.

Table 1: Film structures of the trays for tests with mushrooms

Test number Film structure Remarks
Test 1 PP without NaCl, reference
Test 2 PP / PP 6 wt. % NaCl / PP 45 µm with sealing layer, slowest absorption
Test 3 PP / PP 6 wt. % NaCl without sealing layer, faster absorption
Test 4 PP / PP 12 wt. % NaCl without sealing layer, faster absorption
Test 5 PP / PP 18 wt. % NaCl without sealing layer, fastest absorption, highest
capacity

Sven Saengerlaub et al. TAPPI PLACE Conference Bregenz 2011

Porosity
The porosity P of the films was calculated from the density of the non-stretched films df,n
and the density of the stretched films df,s according to equation 1.

 d 
P = 1 − f ,s  ⋅ 100%
 d 
 f ,n 

Ellipsoid model
The pores formed during stretching of unfoamed films have the shape of ellipsoids. The
volume of an ellipsoid is calculated from the axis of the ellipsoid (equation 1). The
extension of the axis equals the stretching ratio.

1
V= ⋅π ⋅ d x ⋅ d y ⋅ d z (1)
6
From equation 1 the correlation between the porosity and the stretching ratio can be
calculated (equation 2).

SR − 1
P= ⋅ 100 % (2)
d salt d salt
− + SR
y salt ⋅ d polymer d polymer

P: porosity of film ysalt: salt content (0-1)

SR: stretching ratio dsalt: density of salt
dpolymer: density of polymer matrix

Humidity absorption and desorption of films

The humidity absorption and desorption of films was measured gravimetrically. The
samples were stored at different RH. For the desorption measurement the samples were
first stored at 100 % RH and afterwards stored at a lower RH. To achieve an absorption
by one side the samples were fixed with self-adhesive aluminium foil (Fig. 3).

aluminium foil
humidity regulating film
aluminium foil

Fig. 3: Sample preparation

Sven Saengerlaub et al. TAPPI PLACE Conference Bregenz 2011

Packaging trials
An experimental batch of mushrooms consisted of 12 packages filled with 100 g of fresh
Agaricus mushrooms (of similar size). They were packaged in trays with NaCl in the
active layer (Table 1). The trays were closed with a PP lid (no. of perforations per
package were 18 for 1 mm diameter perforations) by Multivac T250 traysealer under
atmospheric conditions. At time intervals of 2 days (after 2, 4, 6, 8 sampling days), 3
trays were taken for a quality assessment and then disposed. Analyses were run in
triplicate for each replicate (n = 2 x 3). Means and standard deviations were calculated for
the observed values. Microbial growth (total plate count) and sensorial characteristics
were monitored in samples throughout the storage period. The Lightness (L*) was
measured on the packaged mushroom samples by a colour meter (Colorflex Model
45º/0º, Minolta Chroma Meter CR-300 Series). The weight of the mushrooms was
recorded for calculating weight loss/gain during storage.

Results

Porosity
The porosity of the films depended on the production process:
• foaming: 30 % v/v
• biaxial orientation: up to 40 % v/v; higher salt content and higher stretching ratio
resulted in higher porosity
• foaming and subsequent biaxial stretching: 70 % v/v; stretching ratio 3 - 20;
biaxial orientation

Ellipsoid model
The original ellipsoid model did not correlate well with measured results for the porosity.
The model was empirically adapted (equation 3) which resulted in a better correlation
(Fig. 4).

y salt
V pores = (SR − 1) ⋅ m film ⋅ ⋅ (2,118 − 0,49 ⋅ ln (SR )) (3)
d salt

50
0,06 gNaCl/gfilm
0,12 gNaCl/gfilm
40
Porosity [% v/v]

30

20

10

0
1 3 5 7 9 11 13 15 17 19 21 23 25

Stretching ratio

Sven Saengerlaub et al. TAPPI PLACE Conference Bregenz 2011

 Fig. 4: Correlation between porosity and stretching ratio of a biaxially oriented PP-film
with NaCl-particles

Humidity absorption/desorption
The foamed and subsequently oriented films absorbed around ten times faster vapour
than foamed or stretched films with salt. The capacity was more than 0,5 gwater/gfilm. The
results can be transferred to deep drawing too. The deep drawing process is similar to
orientation. At foamed and subsequently oriented films the proof of concept for humidity
regulation was shown. These films absorbed and desorbed water vapour.

Packaging trials with Agaricus mushrooms

Trays with NaCl in the active layer absorb water vapour from mushrooms. The water loss
increases with the NaCl-content of the trays. It was more than 4 gwater/100gmushrooms after 4
days, mushrooms packaged in trays with 18 % w/w NaCl in the active layer. The quality
parameters of the mushrooms deteriorated less due to water vapour absorption by the
trays with NaCl:
• less condensed water
• better colour preservation
• less microbial growth

Acknowledgement

Our research in mushrooms was financially supported by the Bavarian Research

Foundation (project number AZ-737-07, PDOK-52-07) and the industrial project partners
EK-Pack Folien GmbH, ES-Plastic GmbH & Co. KG, Gabriel-Chemie Deutschland
GmbH, Multivac Sepp Haggenmueller GmbH & Co. KG. Furthermore we thank Karoline
Seibel und Elisa Lehmann who supported the project .

Sven Saengerlaub et al. TAPPI PLACE Conference Bregenz 2011

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