Innovations in Edible Films

76 Pages·2007·0.57 MB·English

by  Pira International Ltd

Innovations in Edible Films
Part of the SFF biomaterials programme, published August 2007
Published by
Pira International Ltd
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Contents
List of tables v 4
List of figures vi
Executive summary vii
1
Applications of edible films in
packaging and products 21
Food applications 21
Introduction 1 Pharmaceutical applications 24
Objective of the report 1 Lifestyle applications 26
Scope 1 Agriculture applications 26
Methodology 1 Cosmetic, health and wellness
Definitions 1 applications 27
2 5
Market background of edible films 9 Comparison between different types
What are edible films? 9 of edible films 29
Edible coatings/films 9 Advantages of whey protein-based films
Benefits of edible films 9 over films sourced from other proteins 29
Bio-based packaging material 10 Thermal diffusivity of protein and gum-
Packaging waste solution 10 based edible films 29
Surfacing of edible films 11 Water vapour permeability of different
Composition of edible films 11 protein-based edible films 29
Functions of edible films 12 Comparison between hydrocolloid, lipid
Key usage areas for edible films 13 and composite edible films 30
6
Commercial edible coatings 13
3
Market dynamics and competitive
Edible films technology 15 environment 31
Agricultural polymers – cereal, vegetable Competitive environment 31
and animal proteins 15 End users of edible films 32
Corn zein 15 Key manufacturers of edible films 32
7
Wheat gluten proteins 16
Soya proteins 17
Whey protein/milk protein 17
Casein 19
Polysaccharides 19 Outlook 47
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Innovations in Edible Films
Contents
Edible films industry future activity and 8
outlook 47
Edible coating to replace aluminium foil in
nougats 47
Improved edible coating in fresh fruits and Legislation and regulations for edible
vegetables to kill E. coli bacteria 47 films 65
Future research and development 50 Biodegradable polymer films 65
End user industry outlook 53
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List of tables
3.1 Amino acids from zein isolates 15 7.4 Effect of concentration of essential
3.2 Codex international standard for oils on water vapor permeability
wheat gluten 16 (WVP) and oxygen permeability (O P)
2
5.1 Suitability of different edible film properties of apple purée edible
types to barrier requirements 30 films 49
6.1 Major European food 7.5 Effect of concentration of essential
manufacturers 32 oils on the tensile properties of apple
6.2 Major edible film manufacturers 32 purée edible films 50
7.1 Possible new applications and
developments of edible films 47
7.2 Bactericidal activities (BA50 values)
of essential oils against E. coli O157:
H7 in apple purée film forming
solution (APFFS)a incubated for 3,
30, and 60 min at 21°C
7.3 Antibacterial activity of essential oils
incorporated into apple purée edible
films against E. coli O157:H7 49
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List of figures
6.1 Retail sales of edible films 31
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Executive summary
This report, Innovations in Edible Films, traces the journey of edible film and its various
visible benefits, right down to its future applications and technical innovations. Explaining
what it means, the report reviews the need for edible film formats in the modern-day
context, as an effective solution and alternative to packaging waste.
The report also illustrates the composition of edible film, its multi-pronged functions,
benefits, primary usage and application areas, and makes a comparison between various
types of edible films. An insight into the competitive environment is also provided, along
with a description of the key suppliers and consumers. Market trends and developments
in edible films and their significant impact on various other industries are also analysed,
along with a description of the rapidly growing end-user markets, promising forecast
growth prospects and newer avenues and frontiers to explore.
In particular, the following aspects are discussed:
 Definitions of some commonly used terms, including examples and practical
applications for the same, thus enabling a reader new to the subject to comprehend
seemingly difficult concepts.
 Basic definition and understanding of the edible film concept in respect of edible
coatings, an explanation of the broader picture (i.e. an introduction to bio-based
packaging material, of which edible films are a part), and an analysis of the benefits,
composition, functions and key usage areas of edible films.
 A detailed analysis of edible films technology used, pertaining to agricultural
polymers, i.e. cereal and vegetable proteins (such as corn zein, wheat gluten and soya
proteins) and animal proteins, and manufacturing processes employed with regard
to them, such as the wet or solvent process and the dry process. This section also
incorporates a brief overview of future edible film technology and innovations.
 Diverse application areas for edible films in food (fresh meat, ready meals, dairy
products, fruits and vegetables, snack foods and frozen foods), pharmaceuticals,
lifestyle products, agriculture, poultry protection, cosmetics products, health and
wellness products, and other miscellaneous spheres.
 A comparative study of the various types of edible films, enumerating key issues
such as the advantages of whey-based proteins over films with other protein sources,
thermal diffusivity of protein and gum-based edible films, water vapour permeability
of various protein-based edible films, and a comparison between hydrocolloid, lipid
and composite edible films. This chapter also includes examples of commercially used
edible coatings.
 A broad perspective on the market dynamics and competitive environment for edible
films. This includes a brief discussion on market sizes and an analysis of industry
growth catalysts, e.g. Listerine’s first mover advantage strategy and competitive
activity.
 Relevant company profiles of major edible film manufacturers, including BioProgress
plc, Watson Inc., MonoSol LLC, Rapid Dissolve Technologies Ltd, HealthSport Inc.,
Ascona Ingredients Ltd, Helikon Foods Ltd, Paladin Labs Inc., Hydratech Innovations,
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Innovations in Edible Films
Executive summary
ABC Farma International, Atlas Operations Inc., and CWS Packaging. A brief study of
the current and future trends in end-user industries is also given, including packaged
food and pharmaceuticals.
 An insight into the future activity and outlook for edible films, through product and
packaging innovations. Case studies analysed include the replacement of aluminium
foil in nougats with edible films, and the killing of E. coli bacteria in fresh fruits and
vegetables through edible film coatings.
 Future research and development activities expected, in the form of patented
edible RFID tags, nano-laminated edible films, etc. An overview of edible films’ end
user industry outlook in the spheres of pharmaceuticals, biotechnology and dairy;
issues concerning food safety/contamination and microbiology, and future trends
expected in food packaging (where edible films will play a significant role), as well
as the outlook for sea food, frozen food, functional genomics, and nutraceutical and
functional foods.
 An analysis of future industry trends envisaged with respect to food engineering, food
laws and regulations, and the relevant regulations and legislations impacting edible
films. The report also includes a list of major packaged foods and pharmaceuticals
manufacturers, who are potential end user consumers of edible films for the future.
Summary Edible films have been in use for more than 100 years. It started with the application of
wax coatings to fruit and vegetables to prevent moisture loss. As well as ensuring the
freshness and increased shelf life of a product, edible packaging is also environment
friendly, as no packaging waste is generated. Edible film is used in food packaging for
fresh fruit and vegetables, raw meat, ready meals, frozen foods, dairy products, etc., and
pharmaceutical products. Recent developments in edible film research has led to the
inclusion of value-added features, such as edible coatings that kill harmful bacteria, the
introduction of digestible and edible RFID tags that could have interesting pharmaceutical
applications, and films that add nutrients to food products; research has also brought
new materials to make edible films cheaper and more commercially viable. The future of
edible films and their application is thus inevitably linked to advances made in end-user
industries in sectors such as biotechnology, microbiology, genomics and pathogenomics.
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Introduction
Objective of the The main body of this report analyses and examines the concept and role of edible
report films, and their composition, benefits, functions and key usage areas. It also provides
a comprehensive insight into the various edible film technologies in vogue and the
applications of these films in packaging and products, with an illustrative comparison
between different types of edible films. The report highlights the market dynamics
and competitive environment, which includes the major edible film manufacturers and
consumers. Finally, the report dwells on the future scenario and research and development
initiatives for the edible films environment, also commenting on the end-user market
outlook, and the legislative and regulative environment governing these films.
Scope  A market background of edible films;
 Different types of edible films technology;
 Various edible film applications in packaging and products;
 Comparison between different types of edible films;
 Market environment for edible films – major suppliers and consumers;
 Future activity and innovations envisaged for edible films, including end-user
industries outlook;
 Legislation and regulations impacting edible films.
Methodology The methodology used in preparing this report has been extensive secondary and desk
research from a varied number of diverse sources, including hard and soft copy published
data through various online databases, company websites, company annual reports,
industry presentations, technical manuals, press articles and media reports, and relevant
magazines and journals.
Definitions Carboxymethylcellulose (CMC)
A cellulose derivative with carboxymethyl groups, formed by the reaction between
alkali and chloroacetic acid. The functional properties of CMC depend on the degree of
substitution of the cellulose structure and on the chain length of the cellulose backbone.
It dissolves quickly in cold water and is primarily used for controlling viscosity without
gelling. Its viscosity reduces during heating and may be used to improve the volume yield
during baking by encouraging gas bubble formation. Viscosity control can be effectively
used as a thickener, phase and emulsion stabiliser, and also as a suspending agent. CMC
has a high water-holding capacity, which is stable even at low viscosity, a property used
for reducing fat uptake into dried foods. It is also used as an emulsion stabiliser in ice
cream, and in other, non-food products, e.g. toothpaste, laxatives, diet pills, water-based
paints, detergents and paper products. It is also used as a lubricant in non-volatile eye
drops (artificial tears). It is generally non-toxic and non-allergenic.
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Innovations in Edible Films
Introduction
Cellulose acetate
Cellulose acetate (CA) was initially prepared in 1865 by the French chemist Paul
Schutzenberger and industrially patented in the UK in 1894. A factory was started during
the First World War to make acetate dope for waterproofing and stiffening the fabric of
aeroplane wings. CA in combination with plasticisers like diethyl and dimethyl phthalate
produces a plastic material that can be heat softened and forced under pressure into a
cool mould. These materials are tough, with good gloss and transparency properties, and
have a natural feel. Commercially, CA is made from processed wood pulp. The pulp is
processed by using acetic anhydride to form acetate flake from which products are made.
As it comes from wood pulp, CA is biodegradable and comes from renewable resources. In
another process of manufacturing CA, cotton is treated with acetic and sulphuric acids.
CA fibres are comfortable, breathable and absorbent, and can be dyed different
colours and combined with a range of other fibres such as rayon, cotton or silk, which
makes the material suitable for use in textiles and clothing. CA sheets are used for
manufacturing spectacle frames and, due to its natural feel and toughness, for producing
tool handles. Other uses include wound dressings, personal hygiene products, absorbent
clothes and wipes, specialty papers and filter media, including cigarette filters.
Current good manufacturing practice
Current Good Manufacturing Practice (CGMP) gives the basic principles, procedures
and resources required to ensure an environment suitable for manufacturing products
of an acceptable quality. It is a widely accepted term used worldwide for the control
and management of manufacturing and quality control testing of pharmaceutical
products. The process of sampling is limited to the performance of the samples, and
the final conclusion of the product quality is dependent on the samples. Current good
manufacturing practice adopts a holistic approach towards keeping a control of the
manufacturing and quality systems.
CGMP is characterised by the process of documentating every process, activity and
operation involved in the manufacture of drugs and medical devices. Every aspect of
the processes, activities and operations involved is covered. It is mandatory to ensure
that all manufacturing and testing equipment has been qualified as suitable for use.
It is also a requirement to validate according to predetermined specifications, all
operational methodologies and procedures (i.e. manufacturing, cleaning, and analytical
testing) utilised in the drug manufacturing process. This practice is very useful, enabling
traceability of specifications, and manufacturing methods used in cases of product failure
in the market. Over 100 countries worldwide (primarily in the developing world) follow
WHO’s (World Health Organization’s) version of GMP. The European countries generally
follow the European Union’s GMP (EU-GMP) version, while the US adheres to the Food
and Drug Administrations version of GMP. The FDA (Food and Drug Administration)
enforces GMPs in the US, while national regulatory agencies perform GMP inspection
in the European Union. More specifically, in the UK, inspections are carried out by
Page  © Copyright Pira International Ltd 2007