FRESH PRODUCE PACKAGING

ACTIVE AND INTELLIGENT

PACKAGING
By Nguyễn Thị Quỳnh Ngọc
MODIFIED ATMOSPHERE PACKAGING
How gas compositions affect the quality of
fresh food?
 Respiration and Ripening
• After harvested, fruits and vegetables continue
to respire
• Respirations result in:
- Reduction in the stored nutrients and produce’s
weight
- Changes in texture, flavor, color, and nutritional
composition
- Accumulation of carbon dioxide, along with
other metabolic byproducts
• Respiration plays a crucial role in determining
the post-harvest quality and shelf life of fruits
and vegetables
Overview of important features of cellular
respiration
 Respiration rate

• Respiration rate ~ the rate of CO2

production
• Rate of deterioration ~ rate of
respiration.
• Faster respiration, shorter life.
• Respiration increases
exponentially with Temperature.
 Respiration
• Postharvest respiration influences the product in following manner
✓ Reduced food value (energy value) for the consumer
✓Reduced flavor due to loss of volatiles
✓Reduced sweetness
✓Reduce weight
✓Dehydration
✓Release of heat that increases the costs of refrigeration
✓Release of CO2 → requiring extensive ventilation
 Respiration rate
• Respiration rate and storage life of selected foods
 Ripening
• Ripening is an important event in
the fruit life cycle and from the
consumers’ point of view.
• Typically involving many dramatic
changes, such as pigmentation,
flavor, aroma, respiration, ethylene,
texture, softening, sugar, and
organic acid.

https://ofags.com
 Physicochemical and Metabolic Changes
in Ripening
Ripening changes involve a multiplicity of biochemical, metabolic, and
molecular changes that affect the cell compartments, including:
• Compositional changes: sugar, acid, aroma
• Cell wall and texture changes
• Respiration
• Ethylene production
• RNA transcription and protein expression
• Oxidative stress
 Ripening
• Climacteric or nonclimacteric
• Climacteric fruits are characterized by a peak in ethylene synthesis
and respiration at an early stage of ripening.
 Ethylene production
• Ethylene is a gaseous ‘ripening hormone’ and has a central role in
climacteric fruit ripening
• Positive correlation between respiration rate and ethylene production
during fruit ripening

Front. Agr. Sci. Eng. 2021, 8(2): 314–334

 ETHYLENE EFFECTS
• Ethylene is a gas released by fruit and
vegetables due to injury, decay or during
ripening
• Ethylene is involved in regulation of
growth, ripening, senescence and
abscission processes → Most important
molecules in postharvest handling
• Effect of ethylene on harvested
horticulture commodities may be
desirable or undesirable
• Exposure of fruits and vegetables to
ethylene can stimulate respiration
• Fruits and vegetables are usually held in
containers, chambers, or rooms → allow
the accumulation of ethylene
 ETHYLENE SOURCES
• Endogenous
Increasing in ethylene production can occur as a result of fruit ripening,
disease and decay, exposure to chilling temperatures, and wounding.
• Exogenous
Ethylene is produced by internal combustion engines, smoke and other
sources of pollution. Other gases such as propylene and acetylene can
exert similar effects to those of ethylene, but only at much higher
concentrations.
Ethylene emitted from surrounding fruits/vegs
 ETHYLENE BIOSYNTHESIS

System 2

System 1

ACC synthase (ACS) and ACC oxidase ACO

10.15302/J-FASE-2021386
doi.org/10.1007/s00344-007-9002-y are encoded by multigene families in plants
10.1007/s00344-007-9002-y
ETHYLENE BIOSYNTHESIS

• Ethylene stimulate its own

biosynthesis in climacteric fruits
• First apple to ripen → give off
ethylene → nearby apple also
ripen → continues to ripen the rest
of the tree
 ETHYLENE BIOSYNTHESIS
• Ethylene production in climacteric and nonclimateric fruits
 BENEFICIAL USES OF ETHYLENE
• Promote full and uniform ripening (bananas,
avocado, mango and green-harvested
tomatoes)
• Promote color change (degreening) in citrus
Ripening chamber
fruit
BENEFICIAL USES OF ETHYLENE

https://www.bharatref.in/ripening-chamber.html
How gas composition affects fresh produce
quality?
• Oxygen:
• Respiration: aerobic
• Ripening
• Senescence
• Microorganism
• CO2
• Respiration: anaerobic
• Microorganism
• Ethylene
• Respiration
• Ripening
• Senescence
• Decay: petal falling, yellowing, chilling injury.
MODIFIED ATMOSPHERE PACKAGING
(MAP) METHODS

•Passive MAP
•Active MAP
 MODIFIED ATMOSPHERE PACKAGING
(MAP)
• PASSIVE MAP:
PASSIVE MAP uses the respiration of the produce and the transfer of gases
through the packaging to reduce O2 and increase CO2. This atmosphere can
potentially reduce respiration rate, ethylene sensitivity, and physiological changes
 Passive MAP

Passive MAP can be created by using natural air composition and relying on produce respiration to attain the
desired gas mixture
The equilibrium atmosphere that develops is derived from respiration rate, gas permeability temperature, and film
area relative to product weight.
 DESIGN OF MAP SYSTEMS
• The aim is to produce a stable atmosphere, where the rate of gas movement
through the plastic film equals the rate at which O2 is consumed and CO2 is
produced.
• Designing a MAP system for any product requires understanding of storage
conditions and the range of normal respiration rates under those conditions.

https://www.postharvest.net.au/

MAP of broccoli. Initially, the rate of respiration of the broccoli is greater than the rate of gas permeation through the film. After the package is sealed,
respiration reduces O2 and increases CO2 inside the bag. This inhibits respiration, until the rate at which gases diffuse through the plastic film equals
the rate of CO2 production/O2 consumption by the broccoli.
 DESIGN OF MAP SYSTEMS
Factors influencing optimal MAP for fresh or minimally
processed fruit and vegetables

• Each MAP design must be optimized for a

specific product.
• The MAP system must balance the processes Sensitivity to oxygen
of respiration, transpiration and gas and carbon dioxide
( max limit of CO2
permeation through the packaging that will and min limit of O2)
be occurring simultaneously
• Different mathematical models models can
be used to describe the rates of O2
consumption and CO2, ethylene and water
vapor generation from the product as a
function of the storage temperature, the
concentration of these gases in the packaging
headspace and the weight of the packaged
product.
 DESIGN OF MAP SYSTEMS
• The change in the composition of each gas in the packaging headspace
will depend on the metabolic processes of the packaged product and
the gas transfer through the packaging system.

• At equilibrium state: a kind of self-sustaining controlled atmosphere

system
 Respiration rate

O2 consumption and CO2 production rates (cm3 kg-1 day-1 ) and respiratory quotient at 20oC and
atmospheric air for different fresh produce
 Modified atmosphere packaging films
• Integral plastic films are usually 3–4 times more permeable to CO2 than to O2 and 10–20
times more permeable to CO2 than to N2
• In case of perforated films are different, gas exchange is through holes, so permeability to
O2 and CO2 is the same
macroperforated

microperforated
• One advantage of micro-perforated films is that their permeability is
determined by the number of holes created during manufacture. This
means packaging materials can be readily tailored for specific products
and purposes

Concentrations of O2 and CO2 inside a theoretical package made of either LDPE or a microperforated film. After 15 hours both packages have reached
equilibrium. That is, where respiration rate is equivalent to the rate of gas diffusion through the film. However, both O2 and CO2 are higher in the
microperforated film compared to one made of LDPE. This is due to LDPE's differential permeability to gases.
• Package permeability varies Polymer PO2 PCO2 PCO2 /PO2
considerably depending on the (cm3 mm/m2-h- (cm3 mm/m2-h- (cm3 mm/m2-h-
atm) atm) atm)
type and thickness of plastic,
manufacturing technique and LDPE 6666–8750 41662– 54687 6.25
surface area. LLDPE 2916–8333 15105– 43165 5.18

• Once the optimum concentrations HDPE 1666– 3041 9979– 18215 5.99
needed to extend storage life are PP 2083–3916 11706– 22008 5.62
known, films can be selected to Polyvinylidene 13–18 62–86 4.76
achieve this result at the chloride (PVDC)
anticipated storage temperature. General purpose

• An ideal package system should Polyvinylidene 1.3 4.95 3.81

chloride (PVDC)
equilibrate and maintain at the
levels of O2 and CO2 are known
Ethylene-vinyl 0.325 10.10 31.0
to be optimal for storage, alcohol (EVOH)
transport and handling through 32 mol %
out the market chain for a specific ethylene
commodity. Nylon-6 20–42.50 84–179 4.21
Nylon-11 521 2084 4.0
 Oxygen concentration inside the package

CO2 concentration inside the package

Browning index of the produce

• Each commodity has a safe range of oxygen and carbon dioxide based
on the tolerance of each to low oxygen and high carbon dioxide
 Recommended gas
mixtures for MAP

LWT - Food Science and Technology 43 (2010) 381–392

 Active Packaging
• In active packaging, MA conditions are created inside the packages by an
active modification and also using O2 , CO2 and ethylene scavengers within
the package.
 Active Packaging
Different systems can be used in active packaging to control the atmosphere/ package
environment:
Systems that retain/eliminate compounds
• Oxygen (O2 ) scavengers
• Carbon dioxide (CO2 ) scavengers
• Ethylene scavengers
• Moisture absorbers
• odor absorbers
Systems that release compound to food
• Preservative releaser.
• Carbon dioxide (CO2) emitter
• Ethanol emitter
• Flavor/aroma releasers
• Antimicrobial/antioxidant packaging
 Oxygen Absorbers
• Most commonly available O2 absorbers include Ferrous oxide
(FeO): Iron is main active ingredient in powdered form
becoming Fe2O3 and Fe3O4 and its hydroxides after absorption
of O2 .
• Ideally, one needs at least 65% relative humidity in the
atmosphere for the oxidation process to begin

• When all the iron powder has oxidized, the oxygen absorbers
are "loaded" and the absorbing action stops.
 Oxygen Absorbers

• The principle and chemical reactions of different oxygen scavenging agents

Bambang Kuswandi and Jumina

 CARBON DIOXIDE
EMITTERS/ABSORBERS
• Emitters: uses the reaction of sodium bicarbonate and hydrating agents such
as water with acidulated to produce carbon dioxide
• Absorbers: hydrated lime, activated charcoal, magnesium oxide.
 ETHYLENE ABSORBERS
• Potassium permanganate KMnO4 absorbed on celite, silica gel or
alumina pellets
• KMnO4 oxidize ethylene to CO2 and H2O

• Activated carbon, clays, zeolites

MODE OF ACTION OF ACTIVE PACKAGING

• Modification in the headspace composition.

- Selective permeability.
- Substances that retain or release gases or vapors.
- Flushing gas
• Modification in the food characteristics or composition.
- Release substances in food.
- Retained compound from the food.
• Temperature regulation of the packed product.
 Some applications of
active food packaging

Active and intelligent packaging, safety, and quality controls,

2020
Recent advances in active agents for active food
packaging
Recent advances in active agents for active food
packaging
 Antimicrobial packaging
• Antimicrobial food packaging is one of the special applications of active
food packaging that controls inside food and atmospheric conditions actively
and responsively
 The delivery of antimicrobial compounds

• Methods for incorporating antimicrobial agents into polymeric materials:

- The direct incorporation of antimicrobial agents into the polymers, deposition
through coating
- The application of very thin layers, spraying onto the polymer surfaces
- Immobilization by chemical grafting
- The use of polymers that exhibit intrinsic antimicrobial properties
The delivery of antimicrobial compounds
The delivery of antimicrobial compounds
MAP of fresh and minimally processed fruits
Optimal gas composition for fresh-cut produce
MAP of fresh and minimally processed vegetables
Effect of gas composition on fresh
and minimally processed
vegetables
 MAP of fresh and minimally processed
mushroom
• MAP is the simplest, most economical, and effective way of extending the shelf
life of fresh mushrooms

Recommended modified atmosphere

packaging conditions for different
mushroom cultivars
 MAP of meat and fishery products
• Elimination of O2 from the MAP
and enriching it with high CO2
concentration helps to reduce
microbial growth and oxidation of
fat and retain color, maintain the
texture, odor, and overall sensory
quality and appearance of aquatic
products.
• CO2 is the most important gas used
in MAP of aquatic products. The
inclusion of CO2 discharging
sachets is beneficial.
• Reduction of histamine formation
than normal air packages
• MAP can be combined with super
chilling processes
• Oxygen is mainly used to control the
color of fresh red meats, because color
is important to consumers in
determining their selection of the
product.
• Concentrations of oxygen in the range
of 0.5 to 1% cause irreversible
formation of metmyoglobin, thus
oxygen should either be provided in
high enough levels to maintain
oxygmyglobin or eliminated
• MAP for fresh red meat is usually
classified as high (80% O2, 20% CO2)
or low oxygen (30 to 65% CO2 and the
balance N2).
• Carbon monoxide has been used at low
levels (0.3 to 0.5%) with 60 to 70%
CO2 and 30 to 40% N2 to maintain the
cherry-red color of meat without the
adverse effects of high-oxygen MAP
packaging
• Poultry is packaged
using high CO2 to
inhibit Salmonella spp.
and Enterobacteriaceae
such as Escherichia coli
Schematic diagram for the configuration of a
suitable MAP system
 Schematic diagram for the
configuration of a suitable MAP
system (continue…)
Intelligent Packaging
Functions:
• To monitor and provide information
of product quality and safety
• To facilitate the decision-making
• To enhance food safety
• To reduce food loss
• To provide information
• To warn about possible problem

Food Packaging and Shelf Life

Volume 36, April 2023, 101044
 Intelligent Packaging
• “Intelligent packaging materials” is a class of packaging materials that
can monitor the condition of either the packaged food or the
environment inside the package which includes temperature, pH, etc.,
and provides this information to the user
• The intelligent systems can be classified into three categories:
1. Sensors systems.
2. Indicator systems.
3. Radiofrequency identification (RFID) systems.
 Sensors systems

• (i) receptor, or the sensing part of a

sensor, which transforms the
physicochemical signal into a form
of energy
• (ii) transduction element, which
transforms the physicochemical
signal from the receptor into a
useful analytical signal
• (iii) signal processing unit, where
the transducer output is processed
to get the desired output form; and
(iv) display unit, where
quantifiable results are displayed
in analog or digital form
 Sensors systems
• Biosensors: Biological materials including antigens, enzymes and
nucleic acids to detect specific analytes in the purpose of diagnosis of
food quality and its safety.
 Sensors systems
Commercial Sensor systems

Detects the contamination in packaged foods

Flex Alert Fresh fruits, Coffee bean, Nuts throughout the supply chain. They are
(www.flex-alert.com) and Seeds particularly designed against Escherichia coli,
Salmonella spp and aflatoxins

Ocular sensors fixed in transparent packages

O2xyDot ®
All by-products to calibrate oxygen over rapid, sensitive and
(www.oxysense.com)
non-destructive measurements
TIME TEMPERATURE INDICATOR (TTI)
• TTIs integrate the exposure to temperature over time by accumulating the effect of such
exposures and exhibiting a change of color (or other physical characteristic)
• TTIs work based on the change of chemical, electrochemical, enzymatic, mechanical, or
microbiological principles, commonly presented as a color change or intensity color change.
• TTIs can be used to help ensure food safety by indicating when a product has been exposed to unsafe
temperatures. This information can be used to prevent food spoilage and foodborne illness.
• Here are some of the benefits of using TTIs in food packaging:
✓ Improved food safety: TTIs can help to prevent food spoilage and foodborne illness by indicating when a
product has been exposed to unsafe temperatures.
✓ Reduced food waste: TTIs can help to reduce food waste by indicating when a product is no longer safe to
eat.
✓ Improved supply chain management: TTIs can help to improve supply chain management by providing
information about the temperature history of a product. This information can be used to identify problems
in the supply chain and to take corrective action.
✓ TTIs are a valuable tool for food safety and supply chain management. They can help to improve food safety,
reduce food waste, and improve supply chain management.
• Here are some examples of how TTIs are used in food packaging:
✓ Freshness indicators: Freshness indicators are used to indicate the freshness of food products. They typically
use a chemical reaction to change color over time. For example, a freshness indicator on a package of meat
might turn from green to red as the meat ages.
✓ Temperature indicators: Temperature indicators are used to indicate whether a food product has been
exposed to unsafe temperatures. They typically use an electronic sensor to measure temperature. For
example, a temperature indicator on a package of milk might turn from green to red if the milk has been
exposed to temperatures above 40 degrees Fahrenheit.
✓ Logistics indicators: Logistics indicators are used to track the temperature history of a food product during
transportation and storage. They typically use an electronic sensor to measure temperature. For example, a
logistics indicator on a shipment of frozen food might track the temperature of the food throughout the
entire transportation and storage process.
 TIME TEMPERATURE INDICATOR (TTI)
• Diffusion-based TTI
contains thin layers from paper, film, glue, and so on
With increases in temperature above a certain level, the ink
goes to different layers and color of the indicator changes
• Three types:
1. Critical temperature indicators
2. Partial history indicators
3. A full history indicator which records the complete
temperature profile along the food supply chain
 TIME TEMPERATURE INDICATOR (TTI)
• Microbial TTI
Microbial TTI system was developed based on lactic acid bacteria
(LAB)

Indicators: Bromothymol blue and methyl red

 TIME TEMPERATURE INDICATOR (TTI)
• Microbial TTI
Ex: a versatile microbial TTI based on the violacein formation, a violet
pigment produced by the microorganism Janthinobacterium sp. during
early growth, depending on temperature and intrinsic properties of the
growth medium

the gradual alteration of the spot color from pale yellow to dark violet (observed endpoint).
TIME TEMPERATURE INDICATOR (TTI)
• Commercial available
TIME TEMPERATURE INDICATOR (TTI)
 Some examples of commercial TTIs and
their working principles

Active and intelligent packaging, safety, and quality controls, 2020

 Some examples of commercial TTIs and
their working principles

Active and intelligent packaging, safety, and quality controls, 2020

 Freshness Indicators
• Freshness indicators supervise the quality of food products during storage and transportation.
This system sense the metabolites (markers) as quality-indicating parameters (glucose, organic
acids, ethanol, volatile nitrogen compounds, biogenic amines, carbon dioxide, ATP degradation
products, and sulphuric compounds)
 Some examples of freshness
indicator that have been
applied for fruits and
vegetables

Active and intelligent packaging, safety, and quality controls, 2020

 Freshness Indicators
• Principles of indicators and sensors based on metabolites.
Freshness Indicators

Trends in Food Science & Technology

Volume 118, Part A, December 2021, Pages
285-296
 Freshness Indicators
• Illustration of color changes in the indicator films in response to
variation in the food pH due to the production of volatile compounds
Application of Natural Colorant Incorporated Biopolymer-Based
pH-Sensing Films for Indicating the Freshness of Various Food
Products
 Application of Natural Colorant Incorporated
Biopolymer-Based pH-Sensing Films for Indicating
the Freshness of Various Food Products

anthocyanin

curcumin
 Freshness Indicator

Current Research in Food Science

Volume 4, 2021, Pages 932-936
 Freshness Indicator
• The ripeSense® sensor works by reacting to the aromas released by the fruit as
it ripens.
 Freshness Indicators

Shukla, A. K. (2022). Food Packaging, Springer Singapore Pte. Limited.

Freshness Indicators
 Gas indicators
• O2 indicators can be included in packaging to indicate the effective
absorption of all O2 , and to warn if there is a breakdown in the O2 barrier.
 O2 indicators
• An oxygen indicator is included as a solution to provide information
about the oxygen concentration in the package (especially in modified
atmosphere food packaging (MAP))

IOP Conf. Series: Earth and Environmental Science 749 (2021) 012009
CO2 gas indicator
Carbon dioxide is the main
product of microbial metabolism.

• An example of a CO2 gas

indicator: (a) a CO2-sensitive
packaging film prepared by
BTB− /TBA+ ion-paired dye,
and (b) the color changes in
the CO2 indicator at 20◦C
through three days of storage
 Radio frequency identification (RFID)
• Advanced form of data information carrier that can identify and trace a
product.
• An RFID tag is far more detailed than the data contained in a barcode,
creating new opportunities to improve inventory productivity, margins,
store operations execution, and the overall customer experience.
 RFID System
• Here are the working principles of RFID in food packaging:
1.RFID tags: RFID tags are small, electronic devices that contain a
unique identifier and data about the product. The tag is attached to
the food packaging.
2.RFID readers: RFID readers are devices that emit radio waves and can
read the data from RFID tags. The reader is typically located at a
doorway or other entry point in a warehouse or distribution center.
3.RFID system: The RFID system consists of the RFID tags, RFID readers,
and software that manages the data. The software can be used to
track the movement of food products, trace the origin of food
products, and improve inventory management.
 RFID tag
• a data carrier
• A tag consists of a microchip connected to an antenna
• Three types: Active, semi-active and passive

Different structures of RFID Tags

Commonly Used RFID Antennas. (a) Typical planar disk antenna.
(b) Bent dipole antenna. (c) Coupled antenna. (d) Single-ring
monopole antenna
 On-going Application of RFID sensors in food
packaging
• RFID sensors are mostly based on a resonant frequency shifting method to transmit sensing data
• Temperature sensor
For ex: a customizable temperature threshold sensing in cold chain applications based on melting points of
coconut and grapeseed oil which are determined to be 18 and -10oC

Asymmetric Circular Split Ring Resonator Asymmetric Circular Split Ring Resonator (ASCRR)
(ASCRR) overlayed with superstrate for performance when coated with 4:1 :: coconut: grapeseed oil.
temperature sensing application
On-going Application of RFID sensors in food
packaging

• pH monitoring
• Gas monitoring
• Humidity monitoring
• Integrity monitoring
 RFID vs Barcode

2011 IEEE Control and System Graduate Research Colloquium

RFID vs Barcode
Commercially used
smart RFID tag

Future Foods
Volume 6, December 2022, 100198