Extended shelf life

90 Pages·0.691 MB·English

by  Pira International Ltd

packaging > e-book
Extended Shelf Life Technologies
This report examines the technologies available to the
packaging industry to extend the shelf life of products. it
also includes a summary of the main end-use applications for
extended-shelf-life technologies, the leading suppliers and the
likely future trends and developments.
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Extended Shelf Life Technologies
Pira Business Intelligence
David platt
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table of contents
2 5
Executive Summary Packaging Technology Developments 4inorganic and organic Vapour coatings Outlook to 2015
Key Drivers active packaging 4 Silicon oxide coatings 4oxygen Scavengers
4consumer Lifestyle and Demographic changes 4oxygen Scavengers and Emitters 4 aluminium oxide coatings 4moisture Scavengers and Desiccants
4Growth in plastic packaging 4moisture Scavengers and Desiccants 4 carbon 4antimicrobial agents
4Barrier pET Bottles 4 moisture pads 4Edible coatings 4co2 Scavengers and Emitters
4Growing presence of Large retail chains 4 Desiccants Barrier Films 4antioxidants
4organic Food 4 Humectants 4 Biaxially oriented polyethylene Terephthalate 4modified atmosphere packaging (map)
active, map and intelligent packaging 4antimicrobial agents (BopET) 4 Safety concerns
Technology Developments 4co2 Scavengers and Emitters 4polyamides 4 appearance of map packaging
4active packaging 4Ethylene Scavengers and Emitters 4Liquid crystal polymers 4 alternatives to map appearing
4modified atmosphere packaging 4Ethanol Emitters 4polyethylene naphthalate (pEn) on the market
4intelligent packaging 4antioxidants 4polychlorotrifluoroethylene (pcTFE) 4modified interactive packaging (mip)
Barrier coatings, Films and Functional 4Flavour or odour absorbers and Emitters 4cyclic olefin copolymers (coc) 4Barrier films
additive Technology Developments modified atmosphere packaging (map) 4moisture-Barrier Films 4 oxygen and other Gas-Barrier Films
4Barrier coatings 4map Explained 4other Barrier Films 4 moisture-Barrier Films
4Barrier Films 4packaging Formats for map 4Barrier coatings and Film Developments 4 Food-contact Films
4Functional additives 4 Bags and pouches 4Food contact Films 4nanopackaging
End-Use Sector Developments 4 Horizontal Form-Fill-Seal Functional additives 4ormocers
outlook to 2014 4 Vertical Form-Fill-Seal 4anti-fogging agents 4Hyperbranched polymers
– Future Trends and Technology Developments 4 Tray Lidding 4atmospheric pressure plasma
4
4 Thermoform-Fill-Seal End-Use Sector Developments 4Sustainable Barrier coatings
1
Introduction and Methodology intelligent packaging Food 4intelligent packaging and active packaging
introduction and industry overview 4Time-temperature indicators 4Fresh and processed meat 4regulations and Legislation
4Key Drivers 4oxygen indicators 4Fresh Fish and Shellfish 4 European Union Legislation
4 consumer Lifestyle and 4Freshness indicators 4Fresh Fruit and Vegetables 4 U.S. Legislation
Demographic changes 4Leak indicators 4ready meals
4 Growing awareness of 4intelligent Sensors 4Dairy products
Health and wellness 4Biosensors 4Bakery products List of Tables and Figures
4 rising Urbanisation and Busy Lifestyles 4Gas indicators 4Snack Foods
4 Growing participation of 4Dried Foods and Soups
3
women in the workforce Barrier Coatings, Films and Functional Drinks
4 Growing numbers of Additive Technology Developments 4oxygen Scavengers
asset-rich/ Time-poor consumers introduction 4Barrier coatings
4 rise in number of Single-person and Barrier coatings 4Beer
Single-parent Households 4metallised Films 4wine and Spirits
4 Growth in plastic packaging 4organic Liquid coatings 4Juice Drinks
4pET Bottles with Gas-Barrier protection 4 polyvinylidene chloride (pVdc) 4Hot Beverages
4Growing presence of Large retail chains 4 Ethylene Vinyl alcohol (EVoH) 4ready-to-Drink Beverages
4organic Food 4 polyvinyl alcohol (pVoH) 4Dairy Drinks
Scope 4 acrylics nonfood
methodology 4 Epoxy 4pharmaceuticals and Health care
Definitions 4cosmetics and personal care
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packaging > e-book > extended shelf life technologies
Executive Summary
This report examines the technologies available to the packaging as plastics have become more common in these packaging
industry to extend the shelf life of products. it also includes a applications, concerns have arisen about their ability to allow the The key drivers for
summary of the main end-use applications for extended-shelf-life exchange of gases and vapours that can compromise the quality shelf-life extenders
technologies, the leading suppliers and the likely future trends and and safety of the packaged products.
in the packaging
developments. while there is some crossover between the types of
industry include
packaging technology that affects shelf life, this report classifies Barrier PET Bottles pET bottles with enhanced gas-barrier
changing consumer
the technology available as follows: protection are a key demand driver for pET packaging. Barrier
• active packaging pET bottles currently represent a small part of the total pET bottle lifestyles and
• modified atmosphere packaging (map) market, but demand for them is growing at a much higher rate demographics,
• Barrier coatings, films and functional additives than pET bottles as a whole. Growing interest in sustainability and growth of plastic
• intelligent packaging reductions in packaging-related co emissions are key drivers.
packaging,
2
advances in barrier
Key Drivers Growing Presence of Large Retail Chains national and
pET bottles, the
The key drivers for shelf-life extenders in the packaging industry international chains have dominated many of the retail markets in
growing presence of
include changing consumer lifestyles and demographics, growth advanced countries for many years. These large retail outlets have
of plastic packaging, advances in barrier pET bottles, the growing expanded the market for packaged food with their focus on cost large retail chains
presence of large retail chains and rising demand for organic food. reduction and shelf-life extension. and rising demand
for organic food.
Consumer Lifestyle and Demographic Changes The demand Organic Food There is growing demand for organic foods in
for increasingly sophisticated packaging is being driven by changes Europe and the U.S., and this requires longer distribution chains
in consumer lifestyles and demographic trends, which include and longer shelf lives. conventional shelf-life extenders, such as
growing awareness of health and wellness, rising urbanisation artificial preservatives, colours or flavour enhancers, do not meet
and busy lifestyles, the growing participation of women in the organic food regulations, so organic food manufacturers must find
workforce and an increase in number of single-parent households new ways to extend their products’ shelf life.
with children.
Active, MAP and Intelligent Packaging
Growth in Plastic Packaging The demand for packaging Technology Developments
materials to better protect their contents is rapidly increasing,
particularly in the food, beverage and pharmaceuticals industries. Active Packaging active packaging interacts with its contents
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packaging > e-book > extended shelf life technologies
Executive Summary
to extend shelf life and improve quality, product safety or usability. national and international food retail groups has also led to a
active systems are available in many forms, including sachets, highly competitive trading environment, with greater emphasis on
labels and films, and can be incorporated into flexible or rigid operational efficiency and competitive pricing. map is widely used
packaging designs. absorber or scavenger systems remove in the packaging of meat, seafood and minimally processed fruit
unwanted oxygen and compounds from a package to help extend and vegetables; it is also used for pasta, cheese, bakery goods,
shelf life, and emitters release compounds into the packaged poultry, cooked and cured meats, ready meals and dried foods.
contents or into the headspace of the package.
Effective map requires the right composition of gas mixtures.
Some of the most widely used active packaging technologies are The chemical and physical nature of the product must also be
oxygen scavengers, moisture scavengers, odour absorbers and considered. Two technologies are used for map packing: gas
self-venting films. other active packaging technologies are ethanol flushing and compensated vacuum. one of the main benefits
emitters, carbon dioxide scavengers or emitters, preservative of map is shelf life extension. Depending on the product, map
releasers, antimicrobial and antibacterial films and temperature- extends the time an item can remain on display anywhere from
controlled gas permeability. 50% to 500%.
Modified Atmosphere Packaging modified atmosphere Intelligent Packaging intelligent packaging refers to a system
packaging (map) describes the practice of modifying the that can carrying out functions such as sensing, detecting, tracing,
composition of the internal atmosphere of fresh or processed recording and communicating to facilitate decision-making. The
packaged foods in order to extend shelf life. value proposition for intelligent packaging is extended shelf life,
improved quality, enhanced safety and incorporation of additional
in Europe, map mainly involves the use of three gases—carbon information on the package and warnings about possible problems.
dioxide (co ), nitrogen (n ) and oxygen (o )—although other gases a package can be intelligent if it has the ability to track the
2 2 2
are used where the law allows. products are packed in a single gas product, sense the environment inside or outside the package, and
or a combination of these three gases, depending on the physical communicate this information to humans.
and chemical properties of the food.
intelligent packaging can contain external or internal indicators for
map has benefited from growing consumer demand for active product quality and history. it differs from active packaging
convenience food products as a result of changing demographics in that it consists of technologies that measure and integrate but
and changing work patterns and lifestyles. The development of do not respond and control. Unlike active packaging systems,
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packaging > e-book > extended shelf life technologies
Executive Summary
intelligent packaging has no effect on or within the product; it is ceramic coatings. But because all of these barrier solutions have
instead designed to convey information about the condition of the certain drawbacks such as cost, humidity sensitivity, opacity, or
product to the consumer. The term smart packaging is generally environmental restrictions, selecting the correct barrier packaging
applied to packaging that possesses the capabilities of both material is often rather difficult.
intelligent and active packaging.
Because there are several technology alternatives available, the
The primary technology driving intelligent packaging is indicators or packaging designer must understand not only the properties of
sensors. These indicators are called smart or interactive because they the barrier material but also the conditions that the package will
interact with compounds in the package and produce a signal that be subjected to in service. Using an expensive barrier coating in
can be read and communicated. Examples of external and internal a liquid packaging application may not be cost effective if the
indicators and their working principles are offered in Table 2.1. permeation rises rapidly with humidity, if permeation will be
lost due to handling of the package, or if there are performance
Barrier Coatings, Films and Functional inconsistencies from lot to lot.
Additive Technology Developments
Barrier coatings are used in a wide range of plastic packaging
Barrier Coatings Barrier properties are important to any products from carbonated beverage containers and boil-in-the-bag
packaging product that contains perishable contents. The food pouches to pharmaceutical drug blister packs. Barrier coatings
permeation of gases such as oxygen (o ) and carbon dioxide (co ) are one of several barrier technologies that are designed to keep
2 2
and vapours (e.g., H o, aromas, and flavours) through polymers is oxygen, moisture, carbon dioxide, and other infiltrating species out
2
a major challenge for packaging developers. There are, however, of the package to preserve the flavour, colour and freshness of its
several coating technologies that the producers of plastics can use content.
to solve this barrier problem.
Barrier coatings are continuing to evolve and complement
Several other barrier options have been proposed and utilised, emerging resins and manufacturing processes. an advantage of
including new polymers and composite materials for construction coatings over the other barrier technologies is the small amount
of the package itself. But also of importance are new constructions of material that is used. This reduces cost and improves recycling.
of packaging materials such as multilayer film, foil laminates, The disadvantage to coatings is that they need a separate step in
polyvinylidene chloride or ethylene vinyl alcohol coatings, the packaging material manufacturing process that often requires
evaporated aluminium film, and, more recently, vapour-deposited significant capital. By virtue of their thin gauge, coatings are also

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packaging > e-book > extended shelf life technologies
Executive Summary
susceptible to abrasion and other mechanical stress that is common Functional Additives
to packaging materials both during their manufacturing and use. a functional additive modifies the properties of the packaging to
impart certain desirable or beneficial functions. The functional
Barrier coatings include inorganic coatings such as aluminium oxide, additives used for their shelf life extending properties include anti-
silicone oxide, and amorphous carbon and organic coating such as fogging agents and antimicrobial agents, both discussed in section
polyvinylidene chloride, ethylene vinyl alcohol, and epoxy. There are 2—active packaging technologies.
many processes available for applying these coatings, ranging from
simple curtain, spray, or dip coating to fairly exotic vapour-deposition when water or moist air is trapped in a closed system,
processes. The performance and cost of the ultimate barrier coating condensation droplets form on the inner surface of the packaging
is dependent on these processing methods as well as the raw film when the temperature falls below the dew point. For this
materials used in the coating. nanotechnology is also providing reason, the development of plastic films with improved anti-fogging
materials and processes that are adaptable to barrier coatings. qualities is of growing importance for fresh food packaging.
The factors that drive barrier packaging are primarily shelf life, End-Use Sector Developments
cost, and consumer requirements. For instance, consumers using This section analyses extended shelf-life technology developments
products away from home often prefer smaller packs and more for key food, drink and nonfood packaging sectors: Food sectors
robust packaging. other driving factors include growing demand covered are fresh and processed meat, fresh fish and shellfish, fresh
for more environmentally friendly products, such as powder and fruit and vegetables, ready meals, dairy products, bakery products,
radiation-curable coatings. snack foods and dried food, soup, sauces, frozen food, pet food and
baby foods. Beverages covered are beer, wines and spirits, juice
Barrier Films Some plastic films possess barrier protection drinks, hot beverages, ready-to-drink beverages and dairy drinks.
properties in their own right. These films include polyamide (nylon) nonfood sectors are pharmaceuticals, health care, cosmetics and
and polyester films; they may form the primary barrier or be co- personal-care packaging
extruded or coated with higher barrier polymers such as EVoH and
pVdc. other barrier films covered in this report include liquid crystal Outlook to 2014 – Future Trends
polymers, polyethylene naphthalate, cyclic olefin copolymers and and Technology Developments
polychlorotrifluoroethylene (pcTFE). while the global economic recession has had a restraining impact
on shelf-life-extending technologies as manufacturers focus on cost-
reduction measures, there are undoubtedly opportunities for further
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