PACKAGING

SYLLABUS:

UNIT –I

Introduction of the , origin of food packaging ,functional of packaging , primary elements of package forms , material and decoration, various package forms tubes, tetra packs-cans, .

UNIT-II

Packaging materials-classification-flexible and rigid, properties advantage and limitations-aluminium , , tinned, steel plate, board, , flexible films, bio films, laminates and other decoration , graphic designs , suitable .

UNIT –III

Packaging methods and performances- including restorable plastic packaging, asepetic packaging, shrink packaging and other recent packaging technology.

UNIT- IV

Packaging specifications and control of packaging quality, food labelling, food adulteration, food laws and standard national and international consumer proliferation acts. 7 SEVEN TYPES OF PLASTICS:

1. Polythene terephthalate (PET)

2. polythene terethalate second grade

3. High density polythene (HDP)

4. Low density polythene(LDP)

5. polythene (PP)

6. polystyrene or Styrofoam

INTRODUCTION OF PACKAGING:

Packaging is the science art and technology of enclosing protecting products for distributing , storage , sale and use. Packaging also evaluating and producing package.

HISTORY OF PACKAING:

The first package used the natural materials available at the time.

Example- I

Baskets, wooden , woven , processed material were used to form package as they were developed.

Example -II

Glass, bronze, vessels.(ion, aluminium)

MODERN PACKAGING VESSELS:

Tin plate at 18th century . cello pane 20th century . the purpose of packaging .

PACKAGING LABELLIING(STICKER):

Labelling is any written electronic or graphic communication on the package or on a separate but associated label

PHYSICAL PROYECTION:

The package require production from , vibration, electrostatic, discharge ,compression, . PACKAGEING TESTING:

Package testing involves the measurement of a characteristics or property involve in packaging. Testing can be a qualitative and quantitative procedure.

FOOD PACKAGING:

Packaging means a co-ordinated system of preparation of goals / for shipment distribution , storage and marketing at optimum costs, compatible with the requirements of the product.

1. It has a protective role as a means of ensuring safe delivery of the products in sound conditions to the final user as a minimum cost.

2. Packaging includes the art , science technology used initially and during transportation along with the selling and technical methods and work process related to the above preparation.

3. Packaging can also be defined as materials used for the containment , protection, handling, delivery and presentation of goods.

4. Packaging can be divided into 3 broad category:

i)primary

ii)secondary

iii)transmit primary :

primary packaging is the wrapping of handled by the consumer70% is used for the liquid items and drink which is often discarded.

It is the one which comes in contact with the food (eg) can or . There fore primary containers must be non- toxic and cause no colour, flavour or other foreign chemical reactions.

Secondary:

Secondary packaging is the term used to describe larger cases or that are used to group quantities of primary packaged foods for distribution and display in shops food do not come in contact with the packaging material.

Transmit:

Transmit packaging refers to the wooden , board and plastic wrapping and containers that ate used to collate transport which facilitates loading and unloading.

FUNCTIONS OF PACKAGING:

Packaging serves 3 major functions ,

1. Protection

2. Preservation and

3. Promotion

1. Protection against a variety of assaults including physical damage , chemical attack and contamination from biological vectors including micro-organisms insects and rodents.

2. Aid consumers in using products

3. Packaging make the product easier to utilized and convenience

4. Containment of the product convenient unit quantities serve to utilize or group product together in useful number or amounts.

5. Packaging enables communication and education the package which identifies the product for the consumer

BASIC PACKAGING MATERIALS:

1. Any physical material which serves as a covering , wrap or seal for an object or material is a packaging material.

2. Selection of the kind of packaging and packaging material in based on the type of food that needs to be packaged .

3. Before deciding upon the kind of packaging material to be used , one must know the requirements of a package in order to be commercially functional.

REQUIRMENTS:

1) Non-toxic

2) Protect against contamination from micro organisms.

3) Filter out harmful UV light

4) Be transparent

5) Be easy to open 6) Be disposed of easy

7) Meet size / shape and weight requirements

8) Be low cost

9) Provided resistance to physical damage

10)Be compatible with the food.

UNIT –II

ASEPTIC PACKAGE:

Aseptic package is the thermally processed and sterilized liquid product or packed into previously sterilized condition to produce self stable.

PACKAGING MATERIAL

Classification of food packaging material :

Packaging material can be classified as flexible packages or rigid packages .

Packaging material Flexible packaging Rigid packaging

Bags, bubble, wrap tubes, Blisters, bottles, cartilage trays

Stand- of –pouches, foam, etc.,

Cushioning materials.

FLEXIBLE PACKAGE:

A package capable of being headily deformed by hand , including being bent, flexed or twisted . packages made of relatively thin materials such as , plastics, folts, film and their combinations come under thin category.

PAPER:

a. The term paper refers to materials with a gram mage lets than 225g/5gm2 paper has number if advantages they are:

b. It can be produced in many grades and be converted to many different form especially boxes or carton.

c. It can be recycled and it is bio reproduce able.

d. It can be easily combined with other material to make laminated or coated packs.

e. It can be produced with different depress of capacity.

f. Most widely packaging material in lump of weight. It accounts for 43% by weight of all packaging and are used to pack 25% of all goods.

g. Paper board is thicker, more rigid, and used to construct single layer carnet.

2. Flex board is made by combine of layers of stone papers and is used to construct shipping carnet.

3. Paper used in primary are treated coated or laminated to improve their protective properties.

4. Paper From wood and reprocessed wood paper or Paper bleached and coated or imprenated with waxes, resino , plastics and laminated of aluminium to improve if strength.

a. Draft paper is the strongest of papers and unbleached form used for grocery bags.

b. Aid treatment of paper pulp modifies the cellulose and give me to water and oil resistant parchments’ of comiduble strength these paper are called grease proof or glassine paper.

Examples of uses of paper packaging :

PAPER EXAMPLE OF USES

Kraft Multi wall sacks lines for corrupted boards

Sulphite Small bags, pouches waxed papers, , holds shape, decor table, foldily endurance , stiffness, laminated to.

Grease proof Paper for bakery products, fatty foods

Glassine Odour resistant and grease proof bags, suitable for wax to make them water resistant for dry cereals , potato chips, dried soups, cake mixes , coffee, sugar.

Vegetable pouchment High wet strength and grease resistant bags , wrappers or lines for boxes used for meat, fish, fats etc,.

Waxed paper Soft wrapping paper for bread, fruits etc,.

CARD BOARD:

Appropriate for packing materials wrapping it is used in the form of boxes, sheets, corrugated card board. Thicker than paper and protect foods from mechanical damage.

Paper board and their uses:

TYPES OF BOARD USES

White broad Ice creams , chocolate

Paper board Egg tray , tray for fruits. Fibre board Juice concentrate, confectionary nuts.

Chip board Tea, cereals.

Laminated paper board carton. UHT foods

Pressed paper board Ready to cook meals

PLASTICS :

1. Most common packaging material and are of the most difficult to dispose off.

2. They are light, strong, cheap to manufacture if is for these that they are used so much. as an alternative to cardboard glass packaging materials.

3. Plastics packaging accounts for 20% of the art of at packaging and53% of all. Goods are packaged it plastics . almost 10% of our rabid consists of different types of plastics .they are a problem in land fills as they are bulky, they contaminate and degrade slowly.

4. They are a wide range of plastics used in packaging, the types and most common uses are shown below.

PET Polythene terephthalate Frizzy drink, bottles over needy meal trays

HDPE High density polythene Bottles for milk and watching of liquids.

PVC Poly vinyl chloride Tool trays ,bottles for squats, mineral water, meat products

LDPE Low density Carries bags of bin links

PP Poly propylene Margarine tubs, microovaleable meals trays.

PS polystyrene Yoghurt bags ,egg , plastic cutlery, for electronic goods of trays

PA -

Nylon buffs, fat foods

PVD - Poultry, tea, coffee. Ethyl vinyl alcohol Fat foods.

EVOH

LLDP - bags, bread wali bottles

Lamination flex extrusion Polycarbonate Flexible plastic foods

RIGID PACKAGES:

Products the need to be tram ported to long distance and the one the lequine extra care are packaged in ligid containers or boxes.

Some common rigid containers are other melamine used in plastic plates and cups.

GLASS:

An ideal material for foods, especially liquids. It is the traditional vessel in the home. Its weight, shape may involve some difficulties for transport and storage glass amounts for 20% of the weight of all packaging and 10% of all goods are packaged in glass.

Glass is chemically inert and an absolute barrier to the of o2 or water vapour. Glass is formed from oxides of metals, with the most common sand. The only limitation is its solubility to breakage and be reduced by the proper choice of coating are of commonly waxes. And silicon coating also improves the glass appearance of the glass containers.

MEATALS:

Two basic types of alloyed metals used in food packaging are steal and aluminium metal constitute of 14% of all goods are packaged using metal.

STEEL:

Steel is used primarily to make rigid can.

Tin is used for all steel can as a thin layer coating in inhibit and named on tin can . tin is not completely resistant to corrosion, but its rate of reaction with many food materials is considerably slower than that of steel.

Tin is expensive and so replaced by corrosion resistant steel alloy, with thinner metallic or polymeric coatings which help steel resist corrosion the materials is termed thin free steel.

ALUMINIUM:

Appropriate for packaging foods for drinks such as soft drinks ,beans, aluminium is often used. All is attractive, light, strong at the same time, it requires lot of raw materials energy to make it. Majority of cans of soft drinks, al. follate made of aluminium.

It is also sucked very for thin beverage can that contain internal thermal pressure such as soda or bear. Foil is used in many packaging application. When rolled thin al acts as a very good bamer to 02 and H20 vapour transmission but is very fragite. Strength is added by laminating the toil to a stronger material such as paper, or these conditions makes to produce high quality package.

EDIBLE FILMS:

Edible films are used as are of the packaging materials, food materials can be protected from loss of volatiles or reaction with other food ingredient by being encapsulated in protective edible materials. Food materials such as amylase ,starch and the proteins seine and casein. When solubilised can be cast to give sheets of edible films on drying.

Edible film are also used to coat fresh fruits and vegetables to reduce Montour lose and provide increased resistance to growth of surface moulds, the most common and older edible file is wax . Apples are waxed for appearance and improved keeping quality.

WOOD & CLOTH MATERIALS:

Woven cloth such as jute bags and cotton bags are used to a limited extent, mostly for bulk shipment of grain& flour wire wound load strips have been used to make order to form fruits & vegetables. Solid wooden crafts are also used for transporting iced fish.

LAMNATES:

Flexible materials (paper, plastic film, thin metal foils) differ with respect to water vapour Transmission, oxygen permeability, light transmission, burst strength etc.. Multi layers or laminates of these materials that combine the best features if each can be used to produce. Packaging materials with combined properties of al foils ., commercial laminates containing up to many as eight different layers are commonly custom_ designed for a particular product. WEIGHT OF PACKING MATERIAL:

PERCENTAGE OF PACKED GOODS:

REPORT POCH:

Report pouch is a type of food packaging create by made from multiple layers of flexible , allourity for the sterile packaging of a wide variety of food thermo- stabilized height calm meal such as ready to eat , which can be eaten cord, warmed by submerisity in hot water or through the use of a flameless ration healed ,a meal component introduced by the military in 1992. Report pouches are used in , space food, and compity food.

A report is a flexible and metal foil laminate pouch that is used as an alternative t traditional industrial methods . A pouch is a boy with 3 or 4 wide seals , which can store liquid with in some varieties have a bottom guest of as known as stand up pouch.

A report pouch is constructed from a flexible metal – plastic laminate which is able to with stand thermal processing via sterilization. The food is just prepare, even raw or semi cooked , and then scarlet into report pouch. The pouch is then hated to 240-250 F for several minutes under high pressure wide report or autoclave machines. The food inside id cooked, similar to pressure cook. This process reliably like all commonly occurring the packaging process s very similarly to ,expert that package itself is flexible. The structure does not allow permeation of goes from outside into the pouch. The particular report pouches used for several products consist of few layers bonded in a lamination machine starting from outside, the layers are:

a. Polythene PET-provides a gloss of rabid layers , may be printed inside.

b. Nylon B1-oriented polyamide/ provide puncture resistance.

c. Aluminium A1 provides a very thin but barrier.

d. Food provide cast poly propthalene .

This layer method renders the packaging recycle able of use, the must either be increased or disposed of in a land till. The cup of a pouch is thinner than regular cans or bottles, and the energy required to convert is less than of metals. Paper board is skin and eyes during sparing operations. Pesticides also affect the inguinal organs of the body after they are absorbed continued exposure for long periods causes liver or kidney problems and also cause mutate resulting in birth defects.

Linden is one of the most harmful oregano- chlorides. It consumed over a period of time , it affects the nervous system, liver, kidney ,pancreas, nasal and mucosa membrane. Linden priority symptoms include heads ache, dizziness, gastro intestinal disturbance, numbness, and weakness of the extremities, apprehension and hunger irritability.

CONTAMINATS FROM PLASTC:

Plastics are widely used in contact with food stuffs , namely in food processing equipment food utensils and as food packaging In their manufacture numerous additives are used depending on the type of produced polymer . These additives include plastcizers , antioxidant, catalysts, suspension and emulsifying agents stabilizers and polymerization inhibitors, pigments, filters etc,. The additives are bound either chemically or physically into the polymer and may be present in their original or an altered form. In addition the polymerization process may leave trace quantities of residual monomer or low molecular mass polymer in the plastic . These substances can be of concern if present in amounts more than specified it is therefore necessary to specify the purity o the polymer to be used food and / or drinking water. This is exactly what is meant by the term “food grade plastics” – which we often see on the plastic containers packaging materials or utensils.

The extent of which the migration of containers into food. Occur will depend upon factor such as the contact area , the rate of transfer the type of plastic material the temperature and the contact time.

The migration substances from the plastics into food is also related to the type of food packaged .Alcoholic beverages and edible fats and oils will extract substances more readily than dry food such as cereals.

The high molecular mass polymer in plastics itself does not pose a toxic hazard , being inert and essentially insoluble in food monomers which make up the polymer are very reactive and biologically aggressive. Some of them have been shown to cause allergic effects to damage the liver and reproductive functions and to cause cancer.

Plasticizers are used to assist processing and flexibility to plastics they can be present in food packaging materials in significant amounts and have potential to migrate into food .The migration of plasticizers can be aggravated by heat and by the presence of a food into which the plasticizers chemical will dissolve (for example oil, acid or alcohol ) we will learn more amount contamination from plastics from unit II(already i giving the notes for unit II).

UNIT-III

Recent developments:

Against the conventional material there has emerged increased usage of newer material derived synthetically . Some polymeric plastic material are polystyrene , poly vinyls , polyvinydines and derivatives , vinyl acetate polyethylene and poly combination

Polystyrene is principally made into tubes for ice creams, packs for eggs, sausages, and small is not to be used for wrapping halwas and sweets .Recycled bags made from the simplest of all plastics polymer namely, polyethene or polythene as commonly known have relatively low preserving quantities material such as polyesters vinyl acetate derivatives and multilayer films are made out a combination of different materials have good preserving characteristics for food products

Biscuits say cracking fresh mouths on end and cakes retain their softness even weeks due to tough packages .

PLASTIC :

Plastic crates are well established in the dairy industry ,bottled beer, mineral water, and soft drinks .High density polyethene is used for milk crates expanded polystyrene employed as a shipping containers for grapes and also for cured and fresh fish.

HIGH BARRIER PASTICS:

Previously for infinite barriers glass and metal were used poly vinyl indene chloride , ethyl vinyl alcohol and ethyl alcohol (polymers are found to fulfilled the requirements of high barrier properties.

These are used as combined or films a recent development combines scavenging with barrier plastics to provide a near perfect barrier.

RESTORABLE POUCHS:

It is a flexible pouch capable of with standing autoclave (about 120)when a food product is packed is commercially sterile and can be self stable with out refrigeration restorable pouches are constructed from the following combinations PET // Aluminium/foid primer/ Adhesive)p.p

MICRO OVENABLE PACKAGES:

The most commonly material used today is crystallized (PET) in the form of trays . The advantages of using these trays are with respect to flexibility in shape and design and resistance to oils and grease.

High barrier resins like EVOH and PVDC are generally used in contact with the foods to overcome these losses of food flavours.

ASPECTIC ROCESSING AND PACKAGING:

For flexible aseptic package : paper coated or laminated with PET and EVA blends or are used the material chosen depending on the required products like milk, yogurt other dairy products items, fruit juices, sauces, wines and soya milk drinks.

MODIFIED ATMOSPHERE PACKAGNG /GAS FLUSHING/VACUM PACKAGING:

These are packaging for extending the life of food products by changing the atmosphere surrounding the food inside the package.

Vacuum packaging removes all or partial air form the package to prevent oxidation of foods.

EDIPLE FILMS AND COATINGS:

The film can be consumed with the packaged product and there is no packaging to dispose of they are readily degradable even of they are not consumed ,

1. Can provide nutritional value to foods . 2. Flavours can be incorporated in these films.

3. Can be carrier of antimicrobial or antioxidant agents.

Wheat protein in the form of purified wheat gluten commercial wheat gluten and corn protein as corn zein have been tried as edible films.

SHRINK WRAP PACKAGING:

It is a system where heat shrinkable thermoplastic film is wrapped around an articles or a group of articles and made to shrink around it by application of heat to achieve a skin light package canned food products bottles , of all types can be shrink wrapped.

Shrink wrapping saves packaging material cost. It also saves storage space the packaging in lighter shrink wrapping saves transportation costs.

It is expected now a days the packaging material to be environmental friendly or eco friendly that is it should not have great many problems for mankind and hazards to the environment corrugated boxes are eco friendly , preferred for exporting .They can be effectively replaced for conventional wooden boxes which need to destroy the trees, recyclability of packaging is desirable as to preserve the resources of the packaging material for future generation.

UNIT –IV

PACKAGING OF SPECIIFIC FOODS:

CEREALS:

Use of linden impregnated bags for storing wheat results in complete elimination of minutes within one month and checks the attack by insects other than o.surimensis gradually .Bags of coarse jute fabric laminated with polyethelene film are better for storing wheat flours than superior grade costly jute bags.

High quality rice and wheat flour in 300 gauge HDPE and semolina in 100 gauge HDPE shows a shelf life of 6 and 4 months respectively at 30 c and 90 -25 relatively humidity.

MEAT AND FISH:

Most of the meta fish sold in India is in unpacked form .Meat is packed only n some organised meat factories in bacon factories and n export houses the main purpose of packaging is to protect the meat products form microbial contamination light oxygen and any physical damage simple packaging systems might be quite useful for domestic market modern packaging systems like vacuum packaging , packaging will boost up the export market.

FRUITS AND VEGETABLES:

But packages for fresh products for bulk packaging of fresh produce abundantly available plant materials like bamboo spilt locally available green leaves are used as cushioning material.

Bucket shaped bamboo basket is widely used for packaging mangoes . Its efficiency has been improved by optimising thickness and width of the vertically woven splits of bamboo and cushioning of paddy straw as a central core.

Improvements in the food processing technology have lent a thrust to the packaging , industry adopted on a large scale.

NUTRITION LABELLNG OR FOOD LABELLING:

The food industry contributes to nutrition education by offering products that correspond of the current need of consumers and by informing them of product ingredients and nutritional characteristics.

Nutrition labelling is refers to the standardised presentation of nutrient content of food generally the claims fall into some broad categories.

FOOD LAWS:

1. Prevention of food adulteration act,1945.

2. The name , trade name or description of food contained in the package .

3. The name ingredients used in the product in descending order of their composition by weight by weight by volume as the may be,

4. In case both colour and flavours are used in the product , the label should mention.

5. If gelatin is used as an ingredient .A declaration should be made using the words “ gelatine animal orgin”.

EDIIBLE OLS PACKGING ORDER,1988: The edible oils should be packed in a and marked and labelled in manner specified in schedule of the act, the containers label should necessarily have the brand name , name and address of the packer , description of contents , net mass / volume batch number month and tear of manufacture.

THE FRUIT PRODUCTS ORDER,1955:

Every manufacture shall comply with the set requirements in regard to packaging and labelling of containers of fruits products .

MEAT FOOD PRODUCTS ORDER, 1973:

1. Name of the product, date of manufacture , net weight/volume , name and address of the manufacturer.

2. Unauthorised use of words ,pictures, etc,. Shoeing limitation is prohibited.

3. List of any permitted preservatives and additives added.

MILK AND MILK PODUCTS:

The products should comply with all packaging and labelling requirements recommended under the order.