Active packaging

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The terms active packaging, intelligent packaging, and smart packaging refer to amplified packaging systems used with foods, pharmaceuticals, and several other types of products. They help extend shelf life, monitor freshness, display information on quality, improve safety, and improve convenience. [1]

Contents

The terms are often related and can overlap. Active packaging usually means having active functions beyond the inert passive containment and protection of the product. [2] Intelligent and smart packaging usually involve the ability to sense or measure an attribute of the product, the inner atmosphere of the package, or the shipping environment. This information can be communicated to users or can trigger active packaging functions. Programmable matter, smart materials, etc. can be employed in packages. Yam, Tashitov, and Miltz have defined intelligent or smart packaging as:

. . . a packaging system that is capable of carrying out intelligent functions (such as detecting, sensing, recording, tracing, communicating, and applying scientific logic) to facilitate decision making to extend shelf life, enhance safety, improve quality, provide information, and warn about possible problems. [3]

Depending on the working definitions, some traditional types of packaging might be considered as "active" or "intelligent". More often, the terms are used with new technologically advanced systems: microelectronics, computer applications, nanotechnology, etc.

Moisture control

For many years, desiccants have been used to control the water vapor in a closed package. A desiccant is a hygroscopic substance usually in a porous pouch or sachet which is placed inside a sealed package. They have been used to reduce corrosion of machinery and electronics and to extend the shelf life of moisture-sensitive foods. With pharmaceutical packages, a common method is to include a small packet of desiccant in a bottle. Other methods of including desiccants attached to the inner surface or in the material have recently been developed. [4] [5]

Corrosion

Corrosion inhibitors can be applied to items to help prevent rust and corrosion. Volatile corrosion inhibitors (VCI) or vapor phase corrosion inhibitors can be provided inside a package in a pouch or can be incorporated in a saturated overwrap of special paper or plastic film. Many of these are organic salts that condense on the metal to resist corrosion. Some films also have VCI emitting capability.

Films are available with copper ions in the polymer structure, These neutralize the corrosive gas in a package and deter rust.

VCIs create a neutral environment in the packaging. It works on the principle of difference in vapour pressure and causes reaction with metals and non-metals, and with moisture to prevent corrosion. There are different forms of VCIs available, such as papers, plastics, HDPE papers, oils, foams, chips, aluminum barrier foils, bubble, and emitters that can prevent corrosion at many stages.

Metal chelation

Iminodiacetate functionalized polypropylene films used as antioxidant active-packaging materials Conceptual illustration of metal-chelating active packaging technology.jpg
Iminodiacetate functionalized polypropylene films used as antioxidant active-packaging materials

Trace transition metals in foods, especially iron, can induce oxidative degradation of many food components, especially lipids, and cause quality changes of the products. Metal-chelating active packaging materials are made by immobilizing metal-chelating active compounds onto traditional active packaging material. The surface immobilized metal-chelating compounds can scavenge the transition metals from the product and enhance the oxidative stability of the product. [6] The metal-chelating active packaging technology is also antioxidant active packaging that will extend the shelf-life of consumer products by controlling the oxidation. The metal-chelating active packaging technology is known to be able to remove synthetic food preservatives (e.g. EDTA) from the food product. This technology can be used to address the increasing consumer demand for additive free and 'clean' label food products.

Oxygen control

Oxygen scavengers or oxygen absorbers help remove oxygen from a closed package. Some are small packets or sachets containing powdered iron: as the iron rusts, oxygen is removed from the surrounding atmosphere. Newer systems are on cards or can be built into package films or molded structures. [7] In addition, the physical characteristics of the packaging itself (oxygen transmission rate - OTR) can dictate how effective an oxygen absorber can be, and how long it will stay effective. Packaging with a low OTR will let less oxygen in the closed package through the polymer barrier itself. [8]

Atmosphere

With some products, such as cheese, it has long been common to flush the package with nitrogen prior to sealing: the inert nitrogen is absorbed into the cheese, allowing a tight shrink film package. The nitrogen removes oxygen and interacts with the cheese to make the package functional.

More recently, other mixtures of gas have been used inside the package to extend the shelf life. The gas mixture depends on the specific product and its degradation mechanisms. Some package components have been developed that incorporate active chemistry to help maintain certain atmospheres in packages.

Oxygen scavengers, carbon dioxide generators, ethanol generators, etc. are available to help keep the atmosphere in a package at specified conditions.

Temperature monitor

Some temperature indicators give a visual signal that a specified temperature has been exceeded. Others, time temperature indicators, signal when a critical accumulation of temperature deviation over time has been exceeded. When the mechanism of the indicator is tuned to the mechanism of product degradation, these can provide valuable signals for consumers.

Digital temperature data loggers record the temperatures encountered throughout the shipment. This data can be used to predict product degradation and help determine if the product is suited for normal sale or if expedited sale is required. They also determine the time of the temperature excess: this can be used to direct corrective action.

Thermochromic inks are sometimes used to signal temperature excess or change. Some are reversible while others have a permanent change of color. These can be used alone or with other packaging functions such as barcodes.

The inks can also signal a desired temperature for consumers. For example, one type of beer can has ink that graphically shows when an ideal drinking temperature is achieved. [9]

Controlling package temperatures

A Unitized Group Ration - Express self-heating field ration Army.mil-2008-03-06-232636.jpg
A Unitized Group Ration – Express self-heating field ration

For critical vaccines, insulated shipping containers are passive packaging to help control the temperatures fluctuations seen even with a controlled cold chain. In addition, gel packs are often used to keep the temperature of the contents within specified acceptable temperature ranges.

Some newer packages have the ability to heat or cool the product for the consumer. These have segregated compartments where exothermic or endothermic reactions provide the desired effect. [10] Self-heating food packaging is available for several products.

Dispensing

Some packages have closures or other dispensing systems that change the contents from a liquid to an aerosol. These are used for products ranging from precision inhalers for medications to spray bottles of household cleaners.

Some dispensing packages for two-part epoxy adhesives do more than passively contain the two components. When dispensed, some packages meter and mix the two components so the adhesive is fully functioning at the point of application.

The ability of a package to fully empty or dispense a viscous liquid is somewhat dependent on the surface energy of the inner walls of the container. The use of superhydrophobic surfaces is useful but can be further improved by using new lubricant-impregnated surfaces. [11]

Radio-frequency identification

RFID chip built into drug package Faltschachteln mit integriertem RFID-Tag.jpg
RFID chip built into drug package

Radio-frequency identification (RFID) chips are becoming more common with the introduction of smart labels that are used to track and trace packages and unit loads throughout distribution. Newer developments include recording the temperature history of shipments and other intelligent packaging functions. RFID can be integrated into labels: smart labels.

Security

A variety of security printing methods, security holograms, and specialized labels are available to help confirm that the product in the package is not counterfeit. RFID chips are being used in this application also.

Electronic article surveillance (on the product or on the package) is used to help counter shoplifting.

Microwave packaging

Metallised films are used as a susceptor for cooking in microwave ovens. These increase the heating capacity and help make foods crisp and brown. Plastic microwavable [12] containers are also used for microwave cooking.

Shock and vibration

Shock detectors have been available for many years. These are attached to the package or to the product in the package to determine if an excessive shock has been encountered. The mechanisms of these shock overload devices have been spring-mass systems, magnets, drops of red dye, and several others.

Recently, digital shock and vibration data loggers have been available to more accurately record the shocks and vibrations of shipment. These are used to monitor critical shipments to determine if extra inspection and calibration is required. They are also used to monitor the types of shocks and vibrations encountered in transit for use in package testing in a laboratory.

Antimicrobial control

Some engineered packaging films contain enzymes, antimicrobial agents, scavengers, natural pigments and other active components to help control food degradation and extend shelf life and safety. [13] [14] The mechanism focuses on preventing the growth of pathogenic or spoilage microorganisms. [15]

Meat absorbent pads meat diapers can contain antibacterials and have materials to signal contamination. [16]

Bar Codes

Bar codes have long been used with packaging to identify an item, facilitate routing, communicate locations, etc. there are many varieties of linear bar codes. Some are stacked to provide more information. Two dimensional Matrix codes can have a higher information density.

QR Codes can be used on packaging to provide additional information on the product via a smartphone scan. [17] With digital printers, unit-level QR Codes can become the equivalent of a unique identifier or URL for each packaging, and enable other interactions with consumers such as providing specific information on product traceability, [18] or deploying loyalty programs. [19] Unit-level QR Codes are easy to counterfeit if additional security features are not used, but the scan data generated can be used for active brand protection. [20] A digital watermark or secure graphic can be inserted into the QR Code to make it copy-sensitive and let consumers authenticate products with a higher security level.

The GS1 digital link [21] is a standard for embedding GS1 standardised product identifiers into the unique identifier, which allows the same QR Code (or other data carrier) to provide information to consumers, retailers and supply chain. [22]

Printed codes can be combined with security printing for expanded uses. For example thermochromic ink can be used to activate, change, or deactivate a code based on the item’s temperature history. [23] [24]

Other developments

Chlorine dioxide pouches placed inside fruit-packing boxes kill pathogens but don't damage fruit. Fruit box with pouches.jpg
Chlorine dioxide pouches placed inside fruit-packing boxes kill pathogens but don't damage fruit.

Edible films have been developed to allow consumers to eat the package along with the product.

Packaging materials including silver nanoparticles have been shown to extend the shelf life of some foods. [26]

Special packaging has been developed for shipping organs which keeps them alive during extended shipments. The organs are alive and fresh for transplanting. [27]

Several packages used by Canadian cannabis corporations use active packaging to monitor THC levels throughout the production process. This is being implemented in order to ensure consistency between products to improve supply chain management as well as offer consumers improved value of purchase.[ citation needed ]

Regulations

Active packaging is often designed to interact with the contents of the package. Thus extra care is often needed for active or smart packagings that are food contact materials. [28]

Food packagers take extra care with some types of active packaging. For example, when the oxygen atmosphere in a package is reduced for extending shelf life, controls for anaerobic bacteria need to be considered. Also when a controlled atmosphere reduces the appearance of food degradation, consumers need to retain a means of determining whether actual degradation is present.

See also

Related Research Articles

<span class="mw-page-title-main">Food preservation</span> Inhibition of microbial growth in food

Food preservation includes processes that make food more resistant to microorganism growth and slow the oxidation of fats. This slows down the decomposition and rancidification process. Food preservation may also include processes that inhibit visual deterioration, such as the enzymatic browning reaction in apples after they are cut during food preparation. By preserving food, food waste can be reduced, which is an important way to decrease production costs and increase the efficiency of food systems, improve food security and nutrition and contribute towards environmental sustainability. For instance, it can reduce the environmental impact of food production.

<span class="mw-page-title-main">Corrosion</span> Gradual destruction of materials by chemical reaction with its environment

Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials by chemical or electrochemical reaction with their environment. Corrosion engineering is the field dedicated to controlling and preventing corrosion.

<span class="mw-page-title-main">Desiccant</span> Substance used to induce or sustain dryness

A desiccant is a hygroscopic substance that is used to induce or sustain a state of dryness (desiccation) in its vicinity; it is the opposite of a humectant. Commonly encountered pre-packaged desiccants are solids that absorb water. Desiccants for specialized purposes may be in forms other than solid, and may work through other principles, such as chemical bonding of water molecules. They are commonly encountered in foods to retain crispness. Industrially, desiccants are widely used to control the level of water in gas streams.

<span class="mw-page-title-main">Packaging</span> Enclosure or protection of products for distribution, storage, and sale

Packaging is the science, art and technology of enclosing or protecting products for distribution, storage, sale, and use. Packaging also refers to the process of designing, evaluating, and producing packages. Packaging can be described as a coordinated system of preparing goods for transport, warehousing, logistics, sale, and end use. Packaging contains, protects, preserves, transports, informs, and sells. In many countries it is fully integrated into government, business, institutional, industrial, and for personal use.

<span class="mw-page-title-main">Shelf life</span> Length of time that a commodity may be stored before it degrades

Shelf life is the length of time that a commodity may be stored without becoming unfit for use, consumption, or sale. In other words, it might refer to whether a commodity should no longer be on a pantry shelf, or no longer on a supermarket shelf. It applies to cosmetics, foods and beverages, medical devices, medicines, explosives, pharmaceutical drugs, chemicals, tyres, batteries, and many other perishable items. In some regions, an advisory best before, mandatory use by or freshness date is required on packaged perishable foods. The concept of expiration date is related but legally distinct in some jurisdictions.

<span class="mw-page-title-main">Food browning</span> Food process

Browning is the process of food turning brown due to the chemical reactions that take place within. The process of browning is one of the chemical reactions that take place in food chemistry and represents an interesting research topic regarding health, nutrition, and food technology. Though there are many different ways food chemically changes over time, browning in particular falls into two main categories: enzymatic versus non-enzymatic browning processes.

<span class="mw-page-title-main">Oxygen scavenger</span> Substance able to chemically absorb oxygen in the surrounding air

Oxygen scavengers or oxygen absorbers are added to enclosed packaging to help remove or decrease the level of oxygen in the package. They are used to help maintain product safety and extend shelf life. There are many types of oxygen absorbers available to cover a wide array of applications.

<span class="mw-page-title-main">Modified atmosphere</span>

Modified atmosphere packaging (MAP) is the practice of modifying the composition of the internal atmosphere of a package in order to improve the shelf life. 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. In food, oxygen is readily available for lipid oxidation reactions. Oxygen also helps maintain high respiration rates of fresh produce, which contribute to shortened shelf life. From a microbiological aspect, oxygen encourages the growth of aerobic spoilage microorganisms. Therefore, the reduction of oxygen and its replacement with other gases can reduce or delay oxidation reactions and microbiological spoilage. Oxygen scavengers may also be used to reduce browning due to lipid oxidation by halting the auto-oxidative chemical process. Besides, MAP changes the gaseous atmosphere by incorporating different compositions of gases.

<span class="mw-page-title-main">GS1</span> Organization for barcode standards

GS1 is a not-for-profit, international organization developing and maintaining its own standards for barcodes and the corresponding issue company prefixes. The best known of these standards is the barcode, a symbol printed on products that can be scanned electronically.

Nanotechnology is impacting the field of consumer goods, several products that incorporate nanomaterials are already in a variety of items; many of which people do not even realize contain nanoparticles, products with novel functions ranging from easy-to-clean to scratch-resistant. Examples of that car bumpers are made lighter, clothing is more stain repellant, sunscreen is more radiation resistant, synthetic bones are stronger, cell phone screens are lighter weight, glass packaging for drinks leads to a longer shelf-life, and balls for various sports are made more durable. Using nanotech, in the mid-term modern textiles will become "smart", through embedded "wearable electronics", such novel products have also a promising potential especially in the field of cosmetics, and has numerous potential applications in heavy industry. Nanotechnology is predicted to be a main driver of technology and business in this century and holds the promise of higher performance materials, intelligent systems and new production methods with significant impact for all aspects of society.

<span class="mw-page-title-main">Vacuum packing</span> Method of removing air from package prior to sealing

Vacuum packing is a method of packaging that removes air from the package prior to sealing. This method involves placing items in a plastic film package, removing air from inside and sealing the package. Shrink film is sometimes used to have a tight fit to the contents. The intent of vacuum packing is usually to remove oxygen from the container to extend the shelf life of foods and, with flexible package forms, to reduce the volume of the contents and package.

<span class="mw-page-title-main">Food packaging</span> Enclosure and protection of nutritional substances for distribution and sale

Food packaging is a packaging system specifically designed for food and represents one of the most important aspects among the processes involved in the food industry, as it provides protection from chemical, biological and physical alterations. The main goal of food packaging is to provide a practical means of protecting and delivering food goods at a reasonable cost while meeting the needs and expectations of both consumers and industries. Additionally, current trends like sustainability, environmental impact reduction, and shelf-life extension have gradually become among the most important aspects in designing a packaging system.

Aseptic processing is a processing technique wherein commercially thermally sterilized liquid products are packaged into previously sterilized containers under sterile conditions to produce shelf-stable products that do not need refrigeration. Aseptic processing has almost completely replaced in-container sterilization of liquid foods, including milk, fruit juices and concentrates, cream, yogurt, salad dressing, liquid egg, and ice cream mix. There has been an increasing popularity for foods that contain small discrete particles, such as cottage cheese, baby foods, tomato products, fruit and vegetables, soups, and rice desserts.

Produce traceability makes it possible to track produce from its point of origin to a retail location where it is purchased by consumers.

A time temperature indicator (TTI) is a device or smart label that shows the accumulated time-temperature history of a product. Time temperature indicators are commonly used on food, pharmaceutical, and medical products to indicate exposure to excessive temperature.

<span class="mw-page-title-main">Drug packaging</span> Packaging for pharmaceutical preparations

Drug packaging is process of packing pharmaceutical preparations for distribution, and the physical packaging in which they are stored. It involves all of the operations from production through drug distribution channels to the end consumer.

<span class="mw-page-title-main">Package testing</span>

Package testing or packaging testing involves the measurement of a characteristic or property involved with packaging. This includes packaging materials, packaging components, primary packages, shipping containers, and unit loads, as well as the associated processes.

<span class="mw-page-title-main">Retort pouch</span> Type of food packaging

A retort pouch or retortable pouch is a type of food packaging made from a laminate of flexible plastic and metal foils. It allows the sterile packaging of a wide variety of food and drink handled by aseptic processing, and is used as an alternative to traditional industrial canning methods. Retort pouches are used in field rations, space food, fish products, camping food, instant noodles, and brands such as Capri-Sun and Tasty Bite.

<span class="mw-page-title-main">Shelf-ready packaging</span> Form of product packaging

Shelf-ready packaging (SRP) and retail-ready packaging (RRP) refers to the packaging of a product so that it is delivered to a retailer in packaging which is optimized for efficient stocking and sale.

A volatile corrosion inhibitor (VCI) is a material that protects metals from corrosion. Corrosion inhibitors are chemical compounds that can decrease the corrosion rate of a material, typically a metal or an alloy. NACE International Standard TM0208 defines volatile corrosion inhibitor (VCI) as a chemical substance that acts to reduce corrosion by a combination of volatilization from a VCI material, vapor transport in the atmosphere of an enclosed environment, and condensation onto surface in the space, including absorption, dissolution, and hydrophobic effects on metal surfaces, where the rate of corrosion of metal surfaces is thereby inhibited. They also called vapor-phase inhibitors, vapor-phase corrosion inhibitors, and vapor-transported corrosion inhibitors.

References

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Further reading