Lecture 4 Modified Atmoshere

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Controlled- or Modified-

Atmosphere Packaging
 (MAP)
Controlled- or Modified-Atmosphere Packaging

Modified atmosphere packaging (MAP) is the


imposition of a gas atmosphere, typically
containing an inert gas, such as nitrogen
combined with an antimicrobials active gas,
such as carbon dioxide, upon a packaged food
product to extend its shelf life.
Controlled- or Modified-Atmosphere Cont..

 The need for this technology for food arises


from the short shelf life of food products
such as meat, fish, poultry, and dairy in the
presence of oxygen.
Controlled- or Modified-Atmosphere Cont..
Controlled- or Modified-Atmosphere Packaging

 A reduction in the concentration of oxygen


and/or an increase in carbon dioxide
concentration of the storage atmosphere
surrounding, reduces the rate of respiration of
fresh fruits and vegetables and also inhibits
microbial and insect growth.

When combined with chilling , modified or


controlled atmospheres are an increasingly
important method of maintaining high quality in
processed foods during an extended shelf life.
Controlled- or Modified-Atmosphere Cont..

 There remain differences in, and some confusion


over, the terminology used.

Modified-atmosphere storage (MAS) and Modified-


atmosphere packaging (MAP) are the use of gases
to replace air around non-respiring foods without
further controls after storage or packing.
 MAS CAS
 MAP CAP
Controlled- or Modified-Atmosphere Cont..

 In controlled-atmosphere storage (CAS) and packaging (CAP), the


composition of gas around respiring foods is monitored and constantly
controlled, but with advances in ‘Active’ packaging systems the
distinction between MAP and CAP is no longer clear.

 Using MAP, you cannot control what happens after the produce is
packaged and respiration continues.
 With CAP (controlled atmosphere packaging), you can make alterations
to the storage conditions of the packaging during its lifespan

 In this lecture, MAP is used to refer to all methods to change


atmospheres in packed food regardless of whether or not the
atmosphere changes over time.
Development of Storage
Structure from Early to
Modern Modified
Atmosphere Storage (MAS)
Grain Storage
 Under ground Storage (MAS)
Above Ground Storage (MAS)
Grain Storage
 Modified Atmosphere Storage of Grains (MAS)
 It was demonstrated that in sealed containers, grain insects were
killed when they had used up most of the oxygen and had
produced relatively high concentration of carbon dioxide.

 It becomes clear that it is the process of respiration of the grain


and the pests in airtight storage which is responsible for the
protection of the stored products.

 Oxygen is being used up and carbon dioxide, water and heat are
produced according to the general equation for a six-carbon
sugar:

 C6H12O6+6O2 ------6CO2+6H2O+677.2 Kcal

 If this process had been CAS, the explosion could be controlled


Sealed Grain containers being exploded


Big Silos or Terminal Elevators
ModifiedAtmosphere
Packaging (MAP)
 What MAP ?
Modified Atmosphere Packaging
MAP
The normal gaseous composition of air is:
Volume per volume will be used throughout this chapter

Nitrogen (N2) =78.08%


Oxygen (O2) = 20.96% 99.07%
Carbon dioxide (CO2) =0.03%,
together with variable concentrations of water vapour and
traces of inert or noble gases

Many foods spoil rapidly in air (atmosphere ) due to:


 moisture loss or uptake
 reaction with oxygen
 the growth of aerobic microorganisms, i.e. bacteria and

moulds
 Normal physiological processes (over ripening,

senescence)
Modified Atmosphere Packaging
Microbial growth results in .
 changes in texture,
 colour,
 flavour and
 nutritional value of the food

Making it unpalatable and potentially unsafe for


human consumption
Packaging of foods in a modified gaseous
atmosphere can maintain quality and extend
product shelf life:
 by slowing chemical and biochemical deteriorative

reactions
 by slowing the growth of spoilage organisms
 by slowing the natural physiological processes
Modified Atmosphere Packaging

 In MAP gas exchange between the pack


headspace and the external environment may
also occur as a result of permeation across
the package material.
 Packing foods in a modified atmosphere can

offer extended shelf life for the product due


to
◦ Reduced respiration of the product
◦ Reduced activity of microorganisms
◦ Reduced activity of pests (for grains and fruits and
vegetables)
Modified Atmosphere Packaging
 Three main gases used in MAP are O2, CO2 and N2
 Noble or inert gases such as argon are in commercial use for
products such as coffee and snack products

 CO2 dissolves readily in water to produce carbonic acid


(H2CO3).
 Carbonic acid is a chemical compound that is frequently
utilised in the creation of soft drinks, artificially carbonated
sparkling wines, and other sparkling beverage

 Oxygen (O2) is highly reactive and supports combustion


 has a low solubility in water
 Promotes several types of deteriorative reactions in foods
including fat oxidation, browning reactions and pigment
oxidation
Modified Atmosphere Packaging
 Most of the common spoilage bacteria and
fungi require O2 for growth.

 Therefore, to increase the shelf life of foods,


the package atmosphere should contain a low
concentration of O2

In some foods a low concentration of O2 can


result in quality and safety problems can
result in physiological disorder of the product
and growth of food poisoning bacteria.
Modified Atmosphere Packaging

 MAP is of two type:


 (a) passive modification
 (b) active modification.
 In passive modification, the atmosphere is

modified as a result of a commodity’s


respiration, i.e., O2 consumption and CO2
generation.
 Passive modified atmosphere packaging

involves using a selected film type when


packaging a product.
Modified Atmosphere Packaging
 In active modification, the package headspace
is flushed with a known concentration of O2,
CO2, and N2
Active modified atmosphere
packaging displaces gases
in the package, replacing
them with a desired mixture
of gases
Modified Atmosphere Packaging
 Products differ in their tolerance to O2 and
CO2.
 For example, the optimal atmosphere for
Peas is 10% O2 and 7% CO2;
 For avocados it is 1% O2 and 10% CO2

 In MAP gas exchange between the pack


headspace and the external environment may
also occur as a result of permeation across the
package material
Modified Atmosphere Packaging
 .
 Packing foods in a modified atmosphere can

offer extended shelf life for the product due


to:
◦ Reduced respiration of the product
◦ Reduced activity of microorganisms
◦ Reduced activity of pests (for grains and fruits and
vegetables)
 It is essential that the food is of the highest
quality prior to packing in order to optimize
the benefits of modifying the pack
atmosphere
Modified Atmosphere Packaging

 Selection of a film of the correct permeability


to oxygen, carbon dioxide, and water vapor is
critical to the success of MAP of fruits and
vegetables.

 *If the film is too permeable to oxygen, the


product respires, produces ethylene, and
ripens.
 If the permeability is too low, anaerobic

conditions are soon reached and the product


ferments.
x
Modified Atmosphere Packaging

 Nitrogen (N2) is a relatively un-reactive gas


 has a low solubility in water and other food
constituents

 Nitrogen does not support the growth of


aerobic microbes and therefore inhibits the
growth of aerobic spoilage but does not
prevent the growth of anaerobic bacteria.
Gas Mixture used for selected MAP Food
Extension of Shelf life using MAP
Modified Atmosphere Packaging
 Nitrogen is inert and tasteless, with low solubility in both
water and fats. It is used to replace oxygen and thus inhibit
oxidation or the growth of aerobic micro-organisms.

 Oxygen is used in MAP to maintain the red colour of


oxmyoglobin in unprocessed meats, or to permit respiration
of fresh produce,

 But in other applications its level is reduced to prevent


growth of spoilage micro-organisms and oxidative rancidity.
Modified Atmosphere Packaging

However for products in which there is a


potential safety hazard, it is recommended
that one or more of the following criteria are
met:
• water activity is below 0.92
• pH is below 4.5
• use of sodium nitrite or other preservative
• the temperature is maintained below +3ºC.
Modified Atmosphere Packaging
 In fresh fruits and vegetables, a concentration of
 10–15% CO2 is required to control decay.

 Some crops can tolerate this level but most cannot


and MAP is unsuitable.

 A high CO2 concentration prevents mould growth in


cakes and increases the shelf life to 3–6 months.

Other bakery products (e.g.hamburger buns) have the


shelf life increased from 2 days to 3–4 weeks
Modified Atmosphere Packaging
 The shelf life of fresh red meat is extended
from 3 days to 7 days by packaging in an:
 80% O2 / 20% CO2 atmosphere
 at 0–2ºC

 In atmospheres the oxygen concentration is sufficient to


inhibit anaerobic bacteria.

 Pork, poultry and cooked meats have no O2 requirement


to maintain the colour, and a higher CO2 concentration
(90%) is possible to extend the shelf life to 11 days.
elected fruits and vegetables
Selection of MP Materials
 Selection of the most appropriate packaging
materials is essential to maintain the quality and
safety of MAP foods.
 Flexible and semi-rigid plastics and plastic
laminates are the most common materials used for
MAP foods
 MAP films are multilayer structures formed from
several layers of different plastics
 Using coextrusion, lamination or coating
technologies, it is possible to combine different
types of plastic to form films, sheets or rigid packs
Selection of MP Materials

Plastics laminating is a process where two or


more layers of material are put together to
create multi-layered plastic sheet using a
bonding agent.
 (Dunlop Adhesives' Laminated Plastic Adhesive, PVA )

The substrates making up the webs may consist


of films, papers, or aluminium foils.

Laminating improves the physical properties of a


plastic sheet, such as the impact strength,
stability, and sound insulation.
Selection of MP Materials
Benefits of Plastic Laminate for Food Packaging
 Durability.
 Easy to Installation....
 Easy to Clean.
 Good presentation of the products
 Protection : Laminating film protects printed

materials from scratches, spills, smudges,


and UV light.
 It also protects colors and reduces fading.
Selection of MP Materials
Disadvantages of Using Laminates
 Laminates are difficult to recycle.
 If the top layer get worn then whole laminate

sheet has to replaced.


 If laminate sheets are used for flooring, then

it's create very slippery surface.


 Laminates are difficult to bend.
 Adds Cost
Selection of MP Materials
A coating is the application of a liquid
material onto the surface of a solid
substrate and appears as a continuous or
discontinuous film after drying .
 Rust and corrosion-preventing coatings protect
your part from contamination and chemicals that
decrease its lifespan.
 Surface coatings include paints, drying oils and
varnishes, synthetic clear coatings, and other
products whose primary function is to protect the
surface of an object from the environment.
Selection of MP Materials
 Plastics packaging for MAP applications is
most commonly found in the form of:
◦ flexible films for bags,
◦ pouches,
◦ pillow packs or
 as rigid and semi-rigid structures for
◦ base trays,
◦ dishes,
◦ cups and
◦ tubs
Selection of MP Materials
 Plastics are widely used for packaging materials
and in construction of food processing plant
and equipment, because of their;
• flowable and moldable under certain
conditions, to make sheets, shapes and
structures
• generally chemically inert, though not
necessarily impermeable
• cost effective in meeting market needs
• lightweight
• provide choices in respect of transparency,
colour, heat sealing, heat resistance & barrier.
Selection of MP Materials
 Plastics can meet the needs of wide
temperature range:
 Deep frozen -40oC and storage -20oC…
 High temperature of retort sterilization

(121oC)
 Reheating packaged food producers by

microwave (100oC)
Radiant Heat (200oC)
Most packaging plastics are thermoplastic ,
they can be reaptedly softened and melted
when heated.
Manufacture of Plastics Packaging
 The plastic raw material, also known as resin, is
usually supplied by the polymer manufacturer in
the form of pellets.

 Plastics in powder form are used in some
processes.
 The first major step in the conversion of plastic
resin into films, sheets, containers etc., is to
change the pellets from solid to liquid or molten
phase in an extruder.
 The plastic is melted by a combination of high
pressure, friction and externally applied heat
Selection of MP Materials

 Generally, films are by definition less than


100µm thick (1micro is 0.000001 meter or
1x10-6 m)..
 Films used :
 to wrap products
 To overwrap packaging (single or group packs,
palletsized loads)
 To make sachets, bags and pouches, and is
combined with other plastics and other
materials in laminates, which in turn converted
in packaging.
Selection of MP Materials
 Plastic Manufactures in Ethiopia’s
 EAST AFRICA BOTTLING SHARE COMPANY. Addis Ababa
 NAZO P.L.C. Addis Ababa
 KIBRU TESFAYE IMPORT AND EXPORT CO. Addis Ababa
 JIGRA INTERNATIONAL BUSINESS PLC. Addis Ababa
 NIYO POLYMERS MANUFACTURING PLC. Addis Ababa
 WERETA INTERNATIONAL BUSINESS PLC. Addis Ababa
 UNIVERSAL PLASTIC FACTORY PLC.
 OROMIA PIPE FACTORY PLC.
What are the raw materials for plastic?

Plastics today are mostly made from natural materials


such as cellulose, coal, natural gas, salt and crude
oil through a polymerisation or poly condensation
process.

Going forward, plastics will increasingly be made from


waste, renewable materials or CO2.

.
Selection of MP Materials

 Plastic extrusion: Small plastic pellets


(Polymers) are melted and extruded through
a heated chamber by a screw.
 Molding: The molten plastic is injected into

the mold.
 Cooling and release:
 Parts being cooled in the mold until it is solid

enough to be ejected, either mechanically or


by compressed air.
Plastic Raw materials
Plastic Manufacturing
This fig. shows Extruder forming Plastic
Plastic Manufacturing
Cast Films
◦ Fg,2, Plastic films and sheets for packaging
Plastic Manufacturing
 With the blown, or tubular, film process,
orienting is achieved by increasing the
pressure inside the tube to create a tube with
a much larger diameter

 Cast films in flexible packaging because they


are considered to be though, if one tries to
tear them
Plastics for different packaging services
 Packaging materials for MAP
 The two most important technical parameters of
packs for MAP are gas permeability and moisture
vapour permeability.
 Packaging materials are classified according to
their barrier properties to oxygen into:
 1. Low barrier (>300 cc/ m2 ) for over-wraps on
fresh meat or other applications where
oxygen transmission is desirable
 2. Medium barrier (50–300 cc /m2)

 3. Ultra high barrier (10 cc /m2 ), which protect the


product from oxygen to the end of its
expected shelf life.
Barrier properties refer to the packaging's ability to resist the
absorption of light, moisture, and oxygen

Ethio- Vegfruit

Fresh –Cut Vegetable ready for export


Rigid Plastics
Bottles are made by extrusion blow moulding.
A thick tube of plastic is extruded into a bottle
mould which closes around the tube, resulting in
the characteristic jointed seal at the base of the
contain.
 Air pressure is then used to force the plastic into

the shape of the mould.


 After cooling, the mould is opened and the item

removed.
 Blow moulding is used for milk bottles High

Density Polyethylene (HDPE) and wide mouth jars.


Rigid Plastics Moulding
 Fig.3. Extrusion Blow Moulding
 Fig,4, Injection Blow moulding of Plastics
Thermoforming, Filling and Sealing

Plastic thermoforming is plastic manufacturing


process that applies a force (vacuum or pressure) to
stretch a sheet of heated thermoplastic material
Selection of MP Materials
 The following are the types of plastics used in
Industries as Packaging Materials
(Adaption /Adoption Technology )
• Polyethylene (PE)
• Polypropylene (PP)
. Ethylene Vinyl Alcohol (EVOH)
• Polyesters (PET, PEN, PC) (note: PET is referred
to as PETE )in some markets)
• Ionomers
• Ethylene Vinyl Acetate (EVA)
• Polyamides (PA)
• Polyvinyl Chloride (PVC)
• Polyvinylidene Chloride (PVDC)
• Polystyrene (PS)
Selection of MP Materials
 • Styrene Butadiene (SB)
 • Acrylonitrile Butadiene Xtyrene (ABS)
 • Polymethyl pentene (TPX)
 • High nitrile polymers (HNP)
 • Fluoropolymers (PCTFE/PTFE)
 • Cellulose-based materials
 • Polyvinyl acetate (PVA).
 Many plastics are better known by their trade

names and abbreviations


Selection of MP Materials
◦ Selected and Commonly used Plastic s in
Food Packaging (MP) include:
 Polyvinyl alcohol (PVOH)
 Ethylene vinyl alcohol (EVOH).
◦ Polyethylene (PE)
◦ Polypropylene (PP),
◦ Polyamide (nylons),
◦ Polyethylene terephthalate (PET)
◦ Polyvinyl chloride (PVC),
◦ Polyvinylidene chloride (PVDC)
Main Plastics used in MAP
 Polyvinyl Alcohol (PVOH)
 It is a copolymer ethylene and vinyl alcohol
 is an excellent gas barrier provided it is dry (water
soluble synthetic)
 In the presence of moisture, PVOH absorbs water,
causing the plastic to swell and become plasticized
 This could reduce the gas barrier properties of
PVOH are greatly reduced
 To solve this problem by providing greater
polymer stability for commercial use, PVOH is
copolymerized with ethylene to produce EVOH
(Ethylene vinyl alcohol ).
Main Plastics used in MAP
Gases such as oxygen, carbon dioxide and
nitrogen together with water vapour and
organic solvents permeate (infuse) through
plastics. The rate of permeation, depends on:
 type of plastic
 • thickness and surface area
 • method of processing
 • concentration or partial pressure of the

permeate molecule
 • storage temperature.
Main Plastics used in MAP)
 Ethylene vinyl alcohol (EVOH) is less sensitive
to the presence of moisture, and therefore, it
is widely used as a gas barrier layer in MAP
applications
 EVOH can easily be processed into plastic

films and structures


 It is always found laminated as a thin film,

usually in the order of 5μm thickness,


sandwiched between hydrophobic polymers,
Main Plastics used in MAP
 Polyethylene (PE) are structurally the simplest
group of synthetic polymers and the most
commonly used plastic materials for
packaging applications.
 There are several types of PE

◦ Low density polyethylene (LDPE) (density, 0.910–


0.925gcm−3) is generally used in film form
◦ high density polyethylene (HDPE) (density, 0.940 g
cm−3) is commonly used for rigid and semi-rigid
structures
 PE are characterized as poor gas barriers, but
their hydrophobic nature makes them very
good barriers to water vapour.
Main Plastics used in MAP
 Therefore, by itself, PE cannot be used as a
packaging material in MAP applications that
require a high barrier to gases

 PE melts at a relatively low temperature


ranging from approximately 100–120oC
Main Plastics used in MAP
 Polyamides (PA) Nylon
 Comprise the group of plastics commonly referred
to as nylons which have widespread application in
food packaging
 Nylons generally have
◦ high tensile strength,
◦ good puncture and abrasion resistance and
◦ good gas barrier properties
 Nylons are generally moisture sensitive (hydrophilic)
and will absorb water from their environment
 Moisture in nylon adversely affects their properties,
including gas barrier
Polyamides (PA) Nylon
 Under conditions of high relative humidity,
the gas transmission rate of nylon films
generally increases.

 Their relatively high strength and toughness


make them ideal as vacuum pouches for fresh
meat, where hard bone ends could puncture
other plastic materials.

 Nylon is generally laminated to PE which


provides the heat sealing properties.
Main Plastics used in MAP
 Polyethylene terephthalate (PET)
 It is the most common polyester used in food

packaging applications
 PET is

◦ a good gas and water vapour barrier,


◦ is strong,
◦ offers good clarity
◦ temperature resistant
 Crystalline PET (CPET) has poorer optical
properties but improved heat resistance
melting at temperatures in excess of 270oC
Polyvinyl chloride (PVC)
 Polyvinyl chloride (PVC)
 It has a relatively low softening temperature and good
processing properties and is therefore an ideal material
for producing thermoformed packaging structures.
 Unplasticised PVC has improved gas and water vapour
barrier properties which can at best be described as
moderate relative to the plasticised form with poor gas
barrier property
 Oil and grease resistance are excellent

 It is a common structural material in MAP


thermoformed base trays, where it is laminated to PE to
provide the required heat sealing properties.
Main Plastics used in MAP
 Polypropylene ( PP)
 is a versatile polymer that has applications in
flexible, rigid and sem-irigid packaging structures.
 It is foremed under high pressure and temperature
 MAP applications are generally for rigid base trays
 PP is a good water vapor barrier but a poor gas
barrier
 PP melts at approximately 170°C. It can therefore
be used as a container for microwaving low-fat
food products
Main Plastics used in MAP
 Polystyrene (PS)
 Pure polystyrene is a stiff, brittle material and
has limited use in MAP applications
 PS has many packaging uses and can be

extruded as a monolayer plastic film,


 coextruded as a thermoformable plastic

sheet, injection moulded and foamed to give


a range of pack types
 Expanded PS (EPS) has been used for many

years as a base tray for overwrapped fresh


meat, fish and poultry products
Main Plastics used in MAP
 Polystyrene (PS)
 is easily processed by foaming to produce a
rigid lightweight material, which has good
impact protection and thermal insulation
properties.
 It is used in two ways.
 The blown foam can be extruded as a sheet

which can be thermoformed to make trays for


meat and fish, egg cartons, a variety of fast
food packs such as the clam shell-shaped
container, as well as cups and tube.
Main Plastics used in MAP
 The foam can also be produced in pellet or
bead form which can then be moulded with
heat and pressure.
 This is known as expanded polystyrene or EPS.
 It can be used as a transit case for fresh fish,

with thick walls for insulation.


 The main disadvantage as a rigid or semi-

rigid container is the fact that it is brittle


 This can be overcome by blending with other

copolymer,
Main Plastics used in MAP
 Polyvinylidene chloride (PVDC)
 A copolymer of vinyl chloride and vinylidene
chloride) possesses excellent gas, water vapour
and odour barrier properties, with good
resistance to oil, grease and organic solvents.
 the gas barrier properties of PVDC are not
significantly affected by the presence of moisture
 The high temperature resistance enables uses in
packs for hot filling and sterilisation processes.
 PVDC coatings may be modified to produce
either a good heat-sealing polymer or a high-
barrier polymer
Gas and vapour barrier properties
 Packaging materials for MAP must have the
required degree of gas and vapour barrier
capability for the particular food application
 These molecules are transported across a

plastic package material by a mass transfer


process called permeation.
 Permeation is ‘the diffusional molecular
exchange of gases, vapours or liquid
permeants across a plastic material which is
devoid of imperfections such as cracks and
perforations’
Selection of plastic packaging materials
Several factors must be considered when selecting
package materials for MAP applications
 Food contact approval- Packaging materials in

contact with food must not transfer components


from the packaging to the food product in amounts
that could harm the consumer.
 Suppliers must provide evidence to demonstrate

that migrant levels from plastics packaging into


foods are below the recommended levels and that
plastic packaging is safe in its intended use.
Antifogging Properties
 Condensation (fogging) of water vapour on the inner
surface of food packs can occur when the
temperature of the pack environment is reduced
 It leads to poor product visibility and an aesthetically
unpleasing appearance of the pack.

 This can be overcome by applying antifogging agents


to the plastic heat sealing layer, either as an internal
additive or as an external coating

 It spreads the water as a thin film across the under


surface of the pack rather than collecting as visible
droplets
Sealability and Closure
 Heat Sealing Properties
 The most important function of packaging is to
ensure the protection and integrity of the product.
 This implies that the pack must be securely
sealed.

 Effective heat seals are essential for maintaining


the desired gas composition within the pack
 The ability to form effective heat seals through
contamination such as meat juices, powders, fats
and oils is an advantage in many applications
Sealability Cont..
 Heat seal quality is dependent on
◦ Seal material,
◦ seal width and
◦ machine operation settings such as temperature,
pressure and dwell time.
 Product protection and hence effective shelf life are
a function of the quality of sealing of the package.
 Sealing strength is influenced by the thickness of
the film web.
 With the same coating, a doubling of the base film
thickness almost doubles the seal strength.
Optical Properties
 Good optical properties, such as high gloss
and transparency, are essential for bag,
pouch and top web materials to satisfy
consumer demand for a clear view of the
product.
 To provide attractive appearance and shelf

impact, some base tray materials are


available in various colours.
 PVC trays are generally used in their natural

form to provide a transparent pack.


 Eg . The following processed /semi processed
foods
 Dairy products
 Fruits and vegetables
 Fish and fish products
 Cooked, cured and processed meat products
 Raw poultry
 Raw red meat
 X
Examples of plastic pre-formed trays for MAP
Mechanical Properties
 Resistance to tearing and puncture and good
machine handling characteristics are
important in optimising the packaging
operation and maintaining pack integrity
during forming and subsequent handling and
distribution
 For laminated plastics the ability of layers to

bond effectively together during the packaging


operation and during subsequent storage and
handling
Ethio- Vegfruit
 Fresh –Cut Vegetable ready for export
Processed Jam
Processed Jam

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