Plastic Films in Food Packaging: Materials, Technology and Applications

413 Pages·2013·11.23 MB·English

by  Sina Ebnesajjad

PLASTIC FILMS IN FOOD
PACKAGING
PLASTICSDESIGNLIBRARY(PDL)
PDLHANDBOOKSERIES
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President,FluoroConsultantsGroup,LLC
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sectorsusingplasticsandadhesives.
PDL is a series of data books, reference works and practical guides covering plastics engineering, applications, processing, and
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Copyrightr2012ElsevierInc.Allrightsreserved.
PLASTIC FILMS IN FOOD
PACKAGING
Materials, Technology, and Applications
Edited by
Sina Ebnesajjad
President, Fluoroconsultants Group, LLC
AMSTERDAM(cid:129)BOSTON(cid:129)HEIDELBERG(cid:129)LONDON
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First published 2013
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Contents
Preface.................................................................................................................................................................xiii
1 Introduction to Use of Plastics in Food Packaging....................................................................1
1.1 Background.................................................................................................................................................1
1.2 Polyolefins...................................................................................................................................................1
1.2.1 Polyethylene......................................................................................................................................2
1.2.2 Polypropylene...................................................................................................................................4
1.2.3 Specialty Polyolefins........................................................................................................................4
1.3 Polyester......................................................................................................................................................5
1.3.1 Specialty Polyesters..........................................................................................................................5
1.4 Polystyrene..................................................................................................................................................7
1.5 Polyvinyl Chloride......................................................................................................................................7
1.6 Polyvinylidene Chloride.............................................................................................................................8
1.7 Polyamide....................................................................................................................................................8
1.7.1 Nylon 6.............................................................................................................................................8
1.7.2 Nylon 12...........................................................................................................................................9
1.7.3 Nylon 66.........................................................................................................................................10
1.7.4 Nylon 66/610..................................................................................................................................10
1.7.5 Nylon 6/12......................................................................................................................................10
1.7.6 Polyamide 6/69 (Nylon 6/69).........................................................................................................11
1.7.7 Amorphous Polyamides..................................................................................................................11
1.8 Ethylene(cid:1)Vinyl Alcohol Copolymer.......................................................................................................11
1.9 Renewable Resource and Biodegradable Polymers.................................................................................12
1.9.1 Ethyl Cellulose................................................................................................................................14
1.9.2 Polycaprolactone.............................................................................................................................14
1.9.3 Polylactic Acid................................................................................................................................14
1.9.4 Poly-3-hydroxybutyrate..................................................................................................................15
1.10 Summary.................................................................................................................................................15
References........................................................................................................................................................15
2 Polypropylene Films....................................................................................................................17
2.1 Unoriented Film........................................................................................................................................17
2.2 Cast Film...................................................................................................................................................17
2.3 Biaxially Oriented Film............................................................................................................................18
References........................................................................................................................................................20
3 PE-Based Multilayer Film Structures.........................................................................................21
3.1 Introduction...............................................................................................................................................21
3.2 Polymer Selection.....................................................................................................................................24
3.3 Mechanical Properties...............................................................................................................................26
3.4 Barrier Properties......................................................................................................................................27
3.5 Polymer Sealability...................................................................................................................................31
3.6 Adhesive Polymers...................................................................................................................................33
3.7 Applications for Flexible Packaging Film Structures..............................................................................35
v
vi CONTENTS
3.7.1 Medical Packaging..........................................................................................................................36
3.7.2 Food Packaging...............................................................................................................................38
3.8 Summary...................................................................................................................................................49
References........................................................................................................................................................50
4 Biaxially Oriented Films for Packaging Applications...............................................................53
4.1 Introduction...............................................................................................................................................53
4.2 Orienting Technologies.............................................................................................................................53
4.3 Oriented Film Types—Applications.........................................................................................................56
4.3.1 BOPP Films....................................................................................................................................56
4.3.2 BOPET Films..................................................................................................................................62
4.3.3 BOPA Films....................................................................................................................................64
4.3.4 Biaxially Oriented Polystyrene Films............................................................................................66
4.3.5 Other Biaxially Oriented Films......................................................................................................66
4.3.6 Film Oriented in Transverse Direction..........................................................................................68
4.4 Trends for Oriented Films........................................................................................................................69
References........................................................................................................................................................69
5 Development of High-Barrier Film for Food Packaging...........................................................71
5.1 Introduction...............................................................................................................................................71
5.2 Background...............................................................................................................................................72
5.3 Improvement of Barrier Properties of Films............................................................................................74
5.4 Review of Permeation...............................................................................................................................77
5.5 Multilayer Flexible Packaging Structures................................................................................................78
5.6 Measurement of Barrier Properties of Films............................................................................................86
5.6.1 Oxygen Test Methods.....................................................................................................................86
5.6.2 Water Vapor Test Methods............................................................................................................89
5.6.3 Carbon Dioxide Test Methods.......................................................................................................90
References........................................................................................................................................................91
6 Applications of Polypropylene Films.........................................................................................93
6.1 Automotive Applications..........................................................................................................................93
6.1.1 Exterior Automotive Applications.................................................................................................93
6.1.2 Interior Automotive Applications...................................................................................................96
6.1.3 Under-the-Hood Automotive Applications....................................................................................98
6.2 Medical Applications................................................................................................................................98
6.3 Appliances...............................................................................................................................................100
6.3.1 Small Appliances..........................................................................................................................100
6.3.2 Large Appliances..........................................................................................................................102
6.4 Textiles and Nonwovens.........................................................................................................................104
6.4.1 Floor Coverings and Home Furnishings......................................................................................104
6.4.2 Automotive...................................................................................................................................104
6.4.3 Apparel..........................................................................................................................................104
6.4.4 Industrial Applications and Geotextiles.......................................................................................106
6.4.5 Nonwovens....................................................................................................................................106
6.5 Packaging................................................................................................................................................106
6.5.1 Plastics Versus Other Packaging Materials..................................................................................106
6.5.2 Use of Polypropylene in Packaging.............................................................................................108
6.5.3 High-Crystallinity and High-Melt-Strength Grades.....................................................................109
6.5.4 Clarified Polypropylene................................................................................................................109
CONTENTS vii
6.5.5 Metallocene Polypropylene..........................................................................................................109
6.5.6 Rigid Packaging............................................................................................................................110
6.5.7 Film...............................................................................................................................................112
6.5.8 Barrier Packaging.........................................................................................................................114
6.6 Consumer Products.................................................................................................................................114
6.7 Building and Construction......................................................................................................................117
References......................................................................................................................................................118
7 Emerging Technologies in Food Packaging: Overview......................................................... 121
7.1 Introduction.............................................................................................................................................121
7.2 Innovations in Food Processing and Packaging.....................................................................................122
7.3 Food Packaging Technologies................................................................................................................122
7.3.1 Extra Active Functions of Packaging Systems............................................................................122
7.3.2 Modified Atmosphere Packaging.................................................................................................123
7.3.3 Edible Films and Coatings...........................................................................................................123
7.4 New Food Processing Technologies.......................................................................................................124
7.5 Future Trends in Food Packaging...........................................................................................................124
References......................................................................................................................................................125
8 Introduction to Active Food Packaging Technologies........................................................... 127
8.1 Introduction.............................................................................................................................................127
8.2 Drivers for Choice of Active Packaging................................................................................................128
8.2.1 Economic Advantage....................................................................................................................128
8.2.2 Process Engineering Limitations..................................................................................................129
8.2.3 Time-Dependent Processes...........................................................................................................129
8.2.4 Secondary Effects.........................................................................................................................130
8.2.5 Environmental Impacts.................................................................................................................130
8.2.6 Enhanced Convenience.................................................................................................................130
8.3 Forms of Active Packaging....................................................................................................................131
8.3.1 Localized Effects..........................................................................................................................131
8.3.2 Whole-Package Activity...............................................................................................................131
8.3.3 Edible Coatings.............................................................................................................................132
8.4 History of Active Packaging...................................................................................................................132
8.4.1 Active Packaging for Processed Foods and Beverages...............................................................132
8.5 Impact on Packaging Materials and Processes.......................................................................................135
8.5.1 Material Properties........................................................................................................................135
8.5.2 Process Adaptation.......................................................................................................................135
8.6 Active Packaging and the Distribution Chain........................................................................................136
8.7 Regulatory Environment.........................................................................................................................136
References......................................................................................................................................................137
9 Oxygen-Scavenging Packaging................................................................................................ 139
9.1 Introduction.............................................................................................................................................139
9.2 Reviews...................................................................................................................................................139
9.3 History.....................................................................................................................................................139
9.3.1 Package Inserts.............................................................................................................................140
9.3.2 Packaging Materials as Oxygen Scavengers................................................................................141
9.4 Application to Food and Beverage Packaging.......................................................................................145
9.5 Future Opportunities...............................................................................................................................147
References......................................................................................................................................................148
viii CONTENTS
10 Antimicrobial Packaging Systems......................................................................................... 151
10.1 Introduction.........................................................................................................................................151
10.2 Food Safety.........................................................................................................................................151
10.2.1 Spoilage of Food Products......................................................................................................151
10.2.2 Food-Borne Illness..................................................................................................................151
10.2.3 Malicious Tampering and Bioterrorism.................................................................................152
10.3 Antimicrobial Packaging.....................................................................................................................152
10.4 Antimicrobial Agents..........................................................................................................................153
10.4.1 Chemical Antimicrobial Agents.............................................................................................153
10.4.2 Natural Antimicrobial Agents.................................................................................................155
10.4.3 Probiotics.................................................................................................................................155
10.5 System Design.....................................................................................................................................156
10.5.1 Antimicrobial Mechanisms.....................................................................................................156
10.5.2 Microbiocidal..........................................................................................................................156
10.5.3 Microbiostatic..........................................................................................................................163
10.5.4 Functioning Modes and Volatility..........................................................................................163
10.5.5 Nonvolatile Migration.............................................................................................................164
10.5.6 Volatile Migration...................................................................................................................164
10.5.7 Nonmigration and Absorption................................................................................................165
10.5.8 Shapes and Compositions of Systems....................................................................................165
10.6 Commercialization..............................................................................................................................166
10.6.1 Technical Factors....................................................................................................................166
10.6.2 Regulatory, Marketing, and Political Factors.........................................................................173
References....................................................................................................................................................174
11 Damage Reduction to Food Products During Transportation and Handling..................... 181
11.1 Introduction.........................................................................................................................................181
11.2 Functions of Packaging.......................................................................................................................181
11.2.1 Containment............................................................................................................................181
11.2.2 Protection.................................................................................................................................182
11.2.3 Communication.......................................................................................................................183
11.2.4 Utility.......................................................................................................................................183
11.3 Food Product Categories.....................................................................................................................184
11.3.1 Meats.......................................................................................................................................184
11.3.2 Seafood....................................................................................................................................185
11.3.3 Vegetables and Fruits..............................................................................................................186
11.3.4 Processed Versus Nonprocessed.............................................................................................187
11.4 Food Product Distribution Environment.............................................................................................187
11.4.1 Harvesting...............................................................................................................................187
11.4.2 Packing....................................................................................................................................188
11.4.3 Shipping...................................................................................................................................188
11.4.4 Storage and Shelf Life............................................................................................................188
11.5 Major Causes of Food Spoilage/Damage in Supply Chain...............................................................189
11.5.1 Microbiological Spoilage........................................................................................................189
11.5.2 Biochemical.............................................................................................................................189
11.5.3 Chemical..................................................................................................................................189
11.5.4 Macrobiological Spoilage.......................................................................................................189
11.5.5 Physical...................................................................................................................................189
11.6 Packaging Materials............................................................................................................................189
11.6.1 Paper........................................................................................................................................190
11.6.2 Plastic......................................................................................................................................191
CONTENTS ix
11.6.3 Metal........................................................................................................................................192
11.6.4 Glass........................................................................................................................................192
11.7 “Smart” Packaging..............................................................................................................................193
11.7.1 Active Packaging....................................................................................................................193
11.7.2 Modified Atmosphere Packaging...........................................................................................193
11.7.3 Controlled Atmosphere Packaging.........................................................................................194
11.7.4 Intelligent Packaging...............................................................................................................194
11.8 Trends in Protective Food Packaging of 2000 and Beyond..............................................................194
11.8.1 Food Packaging Trends...........................................................................................................194
11.8.2 Damage Reduction Trends......................................................................................................196
References....................................................................................................................................................197
12 Food Packaging Machinery.................................................................................................... 199
12.1 Introduction.........................................................................................................................................199
12.1.1 Containment............................................................................................................................199
12.1.2 Protection.................................................................................................................................199
12.1.3 Communication.......................................................................................................................199
12.1.4 Utility.......................................................................................................................................199
12.2 Filling Machines..................................................................................................................................201
12.3 Volumetric Fillers...............................................................................................................................201
12.3.1 Piston Fillers............................................................................................................................201
12.3.2 Diaphragm Fillers....................................................................................................................202
12.3.3 Timed Flow Fillers..................................................................................................................202
12.3.4 Auger Fillers............................................................................................................................202
12.4 Weight Filling.....................................................................................................................................203
12.4.1 Net Weight Fillers...................................................................................................................204
12.4.2 Gross Weight Fillers...............................................................................................................204
12.5 In-Line or Rotary Fillers.....................................................................................................................204
12.5.1 In-Line Fillers..........................................................................................................................204
12.5.2 Rotary Fillers...........................................................................................................................205
12.6 Cap Application Machines..................................................................................................................205
12.6.1 Chucks and Clutches...............................................................................................................207
12.6.2 Chuck-Type Press-On Cappers...............................................................................................207
12.6.3 Roller-Type Press-On Cappers...............................................................................................207
12.7 Induction Cap Sealing.........................................................................................................................207
12.8 Flexible Packaging..............................................................................................................................209
12.9 Form-Fill-Seal Equipment..................................................................................................................209
12.9.1 Vffs Equipment.......................................................................................................................209
12.9.2 Hffs Equipment.......................................................................................................................210
12.9.3 Tffs Equipment........................................................................................................................210
12.10 Canning Machinery............................................................................................................................211
12.11 Carton Filling and Closing Machinery...............................................................................................212
12.11.1 Carton Filling........................................................................................................................212
12.12 Metal Detectors..................................................................................................................................213
12.12.1 Typical Metal Detectors.......................................................................................................214
13 Compostable Polymer Properties and Packaging Applications.......................................... 217
13.1 Introduction.........................................................................................................................................217
13.2 Biodegradable Polymers from Renewable Resources........................................................................218
13.2.1 Poly(lactic acid)......................................................................................................................218
13.2.2 Polyhydroxyalkanoates...........................................................................................................220