A PROJECT REVIEW REPORT

ON

Different Types of Coating Used in Food Packaging

Submitted in the partial fulfilment for the award of

Post Graduate Diploma in Packaging (Semester-I)
2022 – 2023

Submitted by
RITESH YUVARAJ BORASE
PG/M/22/011

Under the guidance of

Dr. BABU RAO GUDURI
Joint Director Training & Education Department
Indian Institute of Packaging,
Mumbai E-2, MIDC, Area, Andheri East, Mumbai 400 093

ACKNOWLEDGEMENT
I am privileged for conducting a research work on the topic “Different types Of Caps And
Closures, and its Applications in packaging” in academic year 2022-23.

This project has exposed me towards the state-of-art technologies adopted in the industry.
The hard work and support from my guide Dr. Babu Rao Guduri (Joint Director of Indian
Institute of Packaging, Mumbai ) have helped me evolve through this project. I am greatly
obliged to my guide for his encouragement and support even under challenging situations.
He was my inspiration who showed and led me on the right path. His timely advice was
valuable. He provided moral and knowledge support which is a firm foundation for this
project, along with his valuable time.

I would also be pleased to acknowledge Dr. Subodh. K. Juikar Indian Institute of

PackagIing, Mumbai for their constant encouragement.

Last but not the least; I would thank my parents, family members and friends for their
priceless support throughout.
 RITESH YUVARAJ BORASE

PG/M/22/011

38TH BATCH

Index

1 Abstract
2 Introduction
3 Why coatings in packaging
4 Types of coatings
5 Literature review
6 references

1. Abstract
During recent years the market for convenience foods has grown rapidly. More and more
consumers prefer ready-to-use products because of their advantageous minimal input of time
and effort. The increasing awareness of health means there is a need for nutritious, high
quality ready meals. It is important to understand the crucial factors for food packaging for
ready to use food, namely food safety and quality. Packaging concepts have focused on
preventing microbial growth, so protecting consumers from food-borne diseases. The
combination with canned, retort and aseptic packaging showed improvements and
prolongation of the shelf life. Due to technological developments, the packaging industry is
continuously coming up with innovative packaging. Innovative packaging may add value to
the products if it's meets a need such as pollution control, recyclability, tamper proofing,
childproofing, easy to open, easy to store and easy to carry. The advance in food technology
and Packaging Technology have made it possible to extend the shelf life of these products
up-to a few years Packaging design plays an important role in product innovations and
product marketing. This is being driven by ecological challenges, policy, and consumer
demands In this project the review of Packaging of ready to use food products, Shelf-Stable
convenience food and Frozen convenience food ,material requirement ,selection criteria ,This
can help to better understanding about Packaging of Ready to Use Food products.

2. Introduction

During the past 10 years, the processed food scenario in many developing countries including
India has undergone a phenomenal change. A number of convenience foods have been
introduced in the market, and these foods are becoming a part and parcel of our daily life.
With the changing socio-economic pattern of life, and the increasing number of working
couples, convenience foods that save the time, labour and the drudgery of cooking, for the
housewife, are becoming popular. These foods have extended shelf life and are available off
the market shelves. The Food Agricultural Organization of the United Nations predicts a
world population of 9.2 billion by the year 2050. And by the same year the urban population
will increase to 70% . Due to the baby boom after the Second World War, the percentage of
people older years in Europe will increase to 26.9% by 2050. Concomitantly, consumer
demand for convenient foods is changing. The modern fast-paced way of life means that
more and more consumers are wanting to buy foods which are already prepared. Indeed,
ready-to-use food products are becoming even more popular because their convenience and
the little time required for preparation. Convenience foods must be easy to handle (in terms of
the packaging), have fresh appearance, be safe from a microbiological point of view and the
food should of course have a pleasant taste during the whole shelf life. The growing
awareness of human health is putting greater demands on the packaging industry. Minimally
processed fruits and vegetables are becoming more popular. Due to their essential vitamins,
minerals, and fibre’s, ready-to-eat fruits and vegetables will become even more important in
the coming years. Additionally, for elderly people they can provide great health advantages.
Ready to use meals in general benefit older people because they allow them to live
independently for longer and to live on their own, due to the easy handling of the food
products and the nutritious ingredients.

3. Why coatings in packaging

The coating is a process of applying a liquid form / molten form of the solution onto
the moving substrate. Common film substrates used in flexible packaging and food packaging
 include PE, PP, and PET. In addition, paper substrate and aluminium foils are commonly
used. The main benefit and purpose of the coating are to enhance the physical properties of
the packaging such as transforming the packaging into a better barrier towards external
factors to increase product shelf life. Another benefit and purpose of coating for packaging
are to enhance the aesthetic presentation of the packaged product to increase consumer
purchasing preference.

4. Types of coatings

 Dispersion barrier
 Dispersion is a new barrier option without the traditional coating layers. Good sealing
properties secure performance in use. The surface is finished with water-based dispersion
technology. That makes the board liquid and grease resistant during its use while it breaks
down in a recycling process like paper, providing high yield of recovered fiber when products
are recycled.
 Typical end uses: Grease resistant board for short food contact applications including fast
food and dry food packaging.

 Green PE coating
 PE Green is a fully renewable option to traditional PE (polyethylene) and provides excellent
humidity protection. PE Green is made of renewable, plant-based raw material, so you get a
barrier packaging that is 100% renewable as well as recyclable. In converting, it performs the
same way as PE and is therefore easy to introduce to production by customers. Typical end
uses: drinking cups and packages for frozen food, ice cream and yoghurt. HDPE-coated
paperboard for moisture-sensitive dry foods.

 PE coating
 PE, or polyethylene, is the most commonly used barrier coating. Polyolefin barriers, such as
LDPE and HDPE polymers, provide excellent humidity protection.
 Typical end uses: drinking cups and packages for frozen food, ice cream and yoghurt. HDPE-
coated paperboard for moisture-sensitive dry foods.

 Biodegradable coating “Bio”

 Biodegradable coatings are tailor-made polymers offering humidity, oxygen and grease
barriers and sealability. Our biodegradable coatings are compostable. However, the
biopolymer-coated paperboard can be easily recycled, too, which is usually the preferred end-
of-life option.
 Biopolymers can be produced from natural crops or from fossil raw materials. But the key is
that in the end the biopolymer-coated paperboard breaks down to humus and CO2. If you
choose our biopolymer-coated paperboard, you get a product that is recyclable or it can be
collected among other compostable waste that goes into industrial composting.Hardly any
application exists where a traditional PE coating could not be replaced by our biopolymer
 coating! Typical end uses: drinking cups, plates, trays and cartons for fresh foods, salads,
sandwiches and dairy products.

 PET coating
 PET provides a barrier and performs other functions. Black or white PET coatings that
provide heat resistance act as an excellent grease barrier and possess solid WVTR (water
vapour transmission rate) properties.
 Typical end uses: oven able trays, reheatable product packages and bakery products.

 PP coating
 PP or polypropylene coating offers heat resistance for microwave oven and is also suitable
for deep freezing. Good sealing properties secure performance in use.
 Typical end uses: cups and trays for microwave oven and frozen food.

 High-barrier coating “Barr”

 Our patented high-barrier coating consists of a multilayer EVOH and PE polymer structure. It
provides excellent oxygen, humidity and aroma protection. The high-barrier coated boards
and papers are also greaseproof.
 Typical end uses: delicate foods, chocolate, cereals and dairy products. Dry foods, such as
sweets, savoury and processed snacks, coffee and tea, milk and cocoa powders. Liquid
products, such as juices, soft drinks, green tea, water, soups, desserts and wines.

 High-barrier coating “Oxy Barr Al”

 Oxy Barr Al provides oxygen barrier. It has aluminium lamination on one side and optional
PE coating on the printing side of the board.
 Typical end uses: coffee and other very sensitive foodstuffs.
 Silicon oxide

Silicones offer a range of silicones designed to be applied on one or both sides of a paper or
film substrate. Also known as silicone coated release liners, they are used to protect sticky
surfaces and to ease their handling. Release liners are used in a wide array of markets and
applications where it is critical to achieve a perfect coating to protect and deliver materials
such as pressure sensitive adhesives (PSA) used in tapes and labels to their end
destination. Beyond protection of self-adhesive or sticky materials they are also fantastic
process aids and are used to enable casting and composite production processes and offer
non-stick hygienic solutions for cooking and baking.

 Aluminum oxide barrier coatings

AlOx coating is the application of a thin and highly transparent coating of aluminium
oxide on packaging films that gives the materials extremely high moisture and gas barrier
properties that rival those of aluminium foils and metalized Films. It is the only truly high-
barrier flexible packaging material available that is transparent and allows the packaged
product to be clearly visible.This not only provides a big marketing plus but also facilitates
operations like optical scanning/inspection and metal detection during and after the
packaging process, something that is not possible with aluminium foils or metalized
Films.The levels of barrier available from Alox Coated Films are far superior to those
provided by other transparent flexible packaging materials like PVDC-based structures and
EVOH coextrusions. Furthermore, moisture and gas permeabilities are not affected by high
levels of temperature or relative humidity and are independent of the base film thickness thus
enabling maximum downgauging of packaging materials. An important feature of Alox
Coated Films is that they are microwavable, which aluminium foils and metalized Films are
not. As they can be retorted as well, this makes them ideally suited for the packaging of
processed foods that can be microwave heated or cooked in the pack itself before
consumption.

 Silicone release coatings for eco-friendly baking and cooking liners

1. Reliable and consistent release force

2. Excellent adhesion to glassine, parchment papers, or hybrid papers
commonly used in the food industry
3. Are suitable for both single use and multi-use bakery market
4. Water repellent, greaseproof, high temperature resistant, non-stick coatings
with a range of release values to handle a variety of recipes, including those
with high fat content
5. Good machinability, fast cure, and low dusting for high-speed paper coating
operations to maximize throughput
6. Compatible with most on-line and off-line coating processes.

 SiOx Barrier coatings

In cans and glass jars, the moisture and oxygen barriers are provided by the dense nature of the
material. With thin plastic films, the situation is different. The molecular structure of polymer plastic
films is in the form of chains, oriented like a grid. The more these chains are linked together, the
better the barrier will be.Although not visible to the human eye, there are still many tiny holes through
which gas and moisture molecules can permeate. The finer the mazes of the grid, the better the
barrier will be. An SiOx coating on top of this grid closes the tiny holes and gaps and will form an
even, smooth, and almost impermeable layer (see Figure 2). In this way, it offers a high barrier
against gases, aromas, and water vapor.An SiOx coating can be applied to various types of
substrates. One particular coating, Ceramis, comprises a thin inorganic layer of silicon oxide that has
been evaporated in a vacuum environment to substrates like polyethylene terephthalate (PET),
oriented polyamide (OPA) and biaxially oriented polypropylene (BOPP). The solid silicon oxide is
heated by an electron beam and sublimates, then the vapor condensates, forming a very thin barrier
layer on the film that is conveyed on a cooling roll . The thickness of the crystal clear, thin layer is
between 40 and 80 nanometers according to the application.When used in packaging applications, it's
necessary to convert the SiOx film to a laminate in order to protect the SiOx coating from mechanical
damages during further processing. The lamination substrate enhances the moisture and oxygen
barrier of the structure.

5. Literature review

5.1 Gelatin-Based Films and Coatings for Food Packaging Applications

This review discusses the latest advances in the composition of gelatin-based edible
films and coatings, including nanoparticle addition, and their properties are reviewed along
their potential for application in the food packaging industry. Gelatin is an important
biopolymer derived from collagen and is extensively used by various industries because of its
technological and functional properties. Nowadays, a very wide range of components are
available to be included as additives to improve its properties, as well as its applications and
future potential. Antimicrobials, antioxidants and other agents are detailed due to the fact that
an increasing awareness among consumers regarding healthy lifestyle has promoted research
into novel techniques and additives to prolong the shelf life of food products. Thanks to its
ability to improve global food quality, gelatin has been particularly considered in food
preservation of meat and fish products, among others.

Gelatin-based edible films and coatings have already been proposed to protect, maintain
or extend the shelf-life of food products. Factors that should be considered when designing
this type of system include the chemical nature of food, controlled release mechanisms, food
organoleptic characteristics and additive toxicity, storage and distribution, physical and
mechanical properties of packaging materials and regulations to be applied in this framework.
Consequently, different types of additives could be added to improve or modify the final
properties in order to achieve suitable gelatin-based films or coatings for food packaging.
Recent studies have focused on interesting techniques to develop active packaging films and
coatings, including antimicrobial, antioxidant and other agents which can enhance the
biological features of food. These components are usually essential oils or extracts obtained
from plants and spices which exhibit antimicrobial and antioxidant properties.In order to
reduce the use of synthetic chemical additives in the food industry, the use of natural food
additives with antimicrobial and/or antioxidant properties without negative effects on human
health has increased in the last years. These natural additives are able to prevent or reduce the
deterioration of food caused by oxidation or microbiological effects, thus helping to preserve
and extend food shelf-life .

Antimicrobial Agents- The use of antimicrobial additives in gelatin-based films or

coatings for food packaging applications is a promising area, with the main goal being the
prolongation of food shelf-life based on retarding deterioration mechanisms inside the
package by using natural additives. A wide range of agents with antimicrobial properties has
been proposed, e.g., organic acids, bacteriocins, spice extracts, thiosulphates, enzymes,
proteins, isothiocyanates, antibiotics, fungicides, chelating agents, parabens and metals . The
research in this field is focused on the search for natural compounds to be used in active
packaging formulations as substitutions for synthetic additives. As a result, many studies
have been performed to propose the use of compounds obtained from natural sources with
antimicrobial characteristics (Table 1). These additives can be obtained from different
sources, including plants, animals, bacteria, algae, fungi and by-products generated during
fruit and vegetable processing.

Regarding meat products, gelatin has been used blended with chitosan as a coating to reduce
colour deterioration from red to brown as a consequence of a gradual accumulation of
metmyoglobin in the meat’s surface, mainly due to oxygen exposition and lipid oxidation of
beef steaks

Aside from meat and fishery products, other food products are also susceptible to be coated
or packaged into gelatin-based solutions or films. Potential applications of gelatin edible
films in the food industry may include the transport of gases (O2 and CO2), water vapour,
and flavours for fruits and vegetables

The use of gelatin-based edible films and coatings represents a stimulating route for creating
new food packaging materials. Due to the hygroscopic properties of gelatin, some research
studies have been conducted to evaluate the overall effect of the addition of different
substances such as crosslinkers, strengthening agents, plasticizers or additives with
antimicrobial or antioxidant properties to gelatin-based products to improve the functional
properties of gelatin-based edible films and the shelf-life of food products.

5.2 A Comprehensive Review of Biodegradable Polymer-Based Films and Coatings and

Their Food Packaging Applications

Films and coatings are types of packaging materials used widely in the food industry
for a variety of purposes. For example, they serve as protection against physical, chemical, as
well as biological damage to food. They are also helpful in preventing the loss of aroma,
flavor, antimicrobials, and antioxidants . They prevent oxygen, carbon dioxide, and moisture
loss, and are hence helpful in increasing the shelf life of food and improving the mechanical
integrity and handling characteristics of food . The production and usage of petroleum-based
polymer-generated plastic for manufacturing coatings and films have increased over recent
decades. According to Derraik et al. (2002), plastic can be defined as a synthetic or
semisynthetic organic polymer having good barrier properties against moisture, oil, and
gases, with strength characteristics and good resistant properties against stress and corrosion
[3]. It is cheap, lightweight, and easy to carry and handle, making it highly convenient for
daily use. Due to its abundant usage in various applications, the plastic industry in India is
worth between 3000 and 4000 crores [4]. It is believed that half of all plastic products which
are used in the food industry such as cutlery, plastic bags, coatings, and packaging material,
are designed to be thrown away. Moreover, the world production of plastics grew from 1.5
million metric tons in 1950 to 359 million metric tons in 2018 [5]. According to Sabbah et al.
(2017), more than 35 million tons of waste derived from various plastic products
 The efficiency of a coating depends on the method used to coat fruits, vegetables, and
other foods . The techniques used for this (dipping, spraying, etc.) are determined by the type
of the food to be coated, its surface qualities, and the coating’s objective. The adhesion
process, which involves diffusion between the surface area of the food product and the
coating solution, follows the coating operations [135,199]. Surface tension, density, shape,
size, coating thickness, and other physical factors, as well as food product attributes,
influence coating methods . Coatings are applied on food in the form of liquid suspensions,
emulsions, powders, and other forms. Drying, heating, chilling, and coagulation processes are
used to change the covering layers of food ingredients . Dip Coating Dipping is the most
popular way of coating a food product, which involves forming a thin film on the surface that
works as a semipermeable membrane to control moisture loss and gas transmission . Food
products are dipped in a prepared film formation solution to cover the surfaces of fruits,
vegetables, and meat products in this method. This process is divided into three phases.
Immersion and dwelling: This involve immersing the substrate at a steady speed in the
prepared coating solution to ensure complete interaction between the coating solution and the
product’s surface. Evaporation: The component’s coating composition must be diluted. After
dilution, a considerable amount of residual material of the coating is formed. After the
solvent has evaporated and the extra liquid has been removed, a thin film is produced .
Deposition: In this step, the precursor solution of the thin layer is formed on the surface of
food products such as fruits, vegetables, and meat products by deposition. In a past study,
dipping techniques were utilized to improve the shelf life and appearance of fruits and
vegetables, as well as other food products . Because the dipping procedure is usually
relatively short, the evaporation of solvents from the coating and crosslinking solutions is
overlooked. The dipping and draining times vary by study, although they usually last 30 s to
5 min. The method’s key benefit is that it coats the entire surface, even if it is intricate or
rough . The dipping method is extensively used to coat fresh vegetables with edible coatings.
In general, fruits and vegetables are submerged for 5–30 s in the edible coating formulation,
Materials 2022, 15, 5899 18 of 38 and most fruits are simple to coat. Dipping freshly cut fruit
in an antimicrobialcontaining aqueous solution is the most effective technique to increase
microbial stability. The most frequent way to prevent fresh fruit from browning is to use
antioxidant treatments as dips after peeling and/or cutting . Chitosan coating is carried out on
frozen salmon fish using the dipping method. This coating prevents pathogenic bacteria from
growing and extends the shelf life of the fish. Spray Coating The spraying method is
commonly utilized in industries on a broad scale due its low cost and high quality of end
product . In this method, a liquid solution is applied onto food products by spraying. The
liquid solution is converted into small droplets when it is sprayed. These droplets will have
larger surface area for the same amount of liquid solution. As a result, droplets will cover a
larger portion of the substance . With the use of nozzles, the spraying system distributes the
coating solution by forming droplets over the specified food surface area. Because of the high
spraying pressure (approximately 60–80 psi), the spraying technique requires less coating
material to obtain effective coverage . Furthermore, a thickness of 30 µm was best for
guaranteeing that water vapor and mechanical qualities were maintained, and therefore this
parameter must be carefully controlled . This approach can be classified into the following
types based on how the droplets form
5.3 Coating on Food Surfaces
Food coatings have different functions. They are a barrier that limits the contact of the
product with the environment, modifies the functional properties of foods, and contributes to
the control of the surface moisture preventing the agglomeration, adhesion, or disintegration
of food. The substances used mainly as coatings in solid foods are mono and disaccharides,
modified starches, polyalcohols, silicates, and other anti-wetting coatings.

Novel techniques include the development of edible coatings. These act as a layer that limits
the gaseous exchange between the food and the environment, generating a modified
atmosphere. Edible coatings are composed basically of polysaccharides and/or proteins that
have limited control of gas exchange and lipids that limit the loss moisture. Furthermore, to
increase its protective effect and control release, nanostructured systems have been used;
these include nanocomposites of organic and inorganic materials that exhibit a wide range of
possibilities that are necessary to explore with the purpose of increasing the shelf life,
security, and safety of minimally processed food or to reduce energy by refrigeration and the
use of plastic polymer packaging, thus reducing pollution. Edible coatings can be prepared
with by-products such as the peels, seeds, and wastes of pulp of fruit that are rich in
antioxidants, pigment, volatile compounds, and antimicrobial substances.

Fig. shown edible coating effect on food.

5.4 Review on Polysaccharides Used in Coatings for Food Packaging
Papers

Food packaging coatings are very important, as they provide a physical protection barrier for
food products during storage and transportation, maintain food safety in a way that satisfies
industry requirements and consumer desires, and minimize environmental impact by reducing
food waste. Paper based materials have been used for packaging of fluids and greasy foods
since the 1880s. During the 1970s–1980s, when plastics were introduced into food
packaging, paper-based materials lost their importance, being replaced in many uses.
Recently, packaging trends are dominated by sustainability action, largely fuelled by rising
anti-plastic sentiment, and studies are focused on green packaging based on renewable
resources that are recyclable, biodegradable and/or compostable [1]. The attention on
environmentally friendly alternatives prompted the food packaging industry to search for an
alternative reliable and sustainable coating product, both for support materials and for
polymeric ones. From this perspective, paper appears as the ideal packaging material, having
the advantages of high recyclability, biodegradability and compostability from renewable raw
material, in comparison with petroleum based packaging. Polysaccharides are carbohydrates
polymers consisting of repeating units of monosaccharides (hundreds and thousands) linked
by glycosidic bonds and formed by the condensation of monosaccharide residues through
hemiacetal or hemiketal linkages. The polysaccharides can originate from higher
photosynthetic plants, marine biomass, bacteria or fungi [9–12]. At the cellular level,
polysaccharides represent the reserve compounds in cytoplasm, or structural components of
the membrane and cell wall of organisms [13,14]. They are biocompatible, biodegradable and
non- Coatings 2020, 10, 566 3 of 24 toxic towards living organisms. These characteristics
give them the potential for broad applications such as: medicine, drugs delivery and food
packaging. In food packaging, polysaccharides have the potential to be used as coating
formulations for paper, edible coatings and films or to obtain bioactive and sensor materials
in active and intelligent packaging [15,16]. The most tested and applied polysaccharides in
the paper industry, that include coated paper for foods packaging, are presented in Figure 1.
When used in coatings or films for food packaging, polysaccharides present some drawbacks,
which are linked with their hydrophilic nature and crystalline structure, i.e., low water
resistance, poor barrier to water vapors, and properties dependence on the environment
humidity. However, to achieve the molecular structures of interest it is very important that
polysaccharides be chemically modified and functionalized. In recent years, this has became
a research topic and area that has been extensively studied. In addition, many fibers, other
biopolymers and environmentally friendly nanomaterials are combined with polysaccharides
to prepare novel formulations with desired properties for food packaging, including coatings
for paper/board packaging. Sometimes it is necessary to have a combination of more than two
packaging materials to provide the best packaging solution for certain food products. Bio-
polymer composite coatings for paper represent a sustainable alternative, providing the
opportunity to obtain barrier properties (low oxygen and water vapor permeability) and
specific functionalities for a fully protective food packaging. The literature survey shows that
polysaccharides are promising candidates to substitute petroleum based polymers in coatings
for food packaging paper. These biopolymers are biodegradable, have high availability in
nature, are non-toxic, and have film forming ability and good affinity for paper substrate with
positive effects on the mechanical strength. Moreover, they can provide very good barrier to
water, gases, aroma, and lipids, and serve as a biopolymer matrix for incorporation of active
agents for paper functionalization. The main disadvantage of polysaccharides is their
sensitivity to moisture that limits their large-scale utilization in barrier coatings for paper. The
presented review shows that there has been intensive research regarding the chemical
modification of polysaccharides, to introduce hydrophobic groups in their structure that
improve water resistance and rheological properties when used in barrier coatings for
packaging paper applications. Therefore, the finding of an appropriate route for chemical
modification—and the right combination of polysaccharides with other biopolymers,
nanofibers or nanofillers—will generate interest for the development and application of these
biopolymers in composite coatings for food packaging papers.

References

1. https://www.pffc-online.com/coat-lam/coatings/8832-siox-
barrier-benefits-1001
2. https://www.elkem.com/silicones/offer/papers-films-
coatings/release-coatings/bakery-
food/#:~:text=Silicone%20emulsion%20systems%20can%20be
,from%20sticking%20to%20pan%20liners.
3. Gelatin-Based Films and Coatings for Food Packaging Applications.
4. A Comprehensive Review of Biodegradable Polymer-Based Films and
Coatings and Their Food Packaging Applications.
5. Coating on Food Surfaces.
6. Review on Polysaccharides Used in Coatings for Food Packaging Papers