ACTIVE PACKAGING INDUSTRY LEAFLET AUTHORS

Adriane Cherpinski Correa IATA, Spain

Anouk Dantuma KCPK, The Netherlands

Filomena Silva University of Zaragoza, Portugal

Idalina Gonçalves University of Aveiro, Portugal

Linda Vecbiskena Latvian State institute for Wood Chemistry, Latvia

Marc Delgado-Aguilar University of Girona, Spain

Marit Kvalvåg Pettersen Nofima, Norway

Nathalie Lavoine NC State University, Dept. Of Forest Biomaterials, College of Natural Resources, United States EDITORS

Patrycja Sumińska Anouk Dantuma ZUT-CBIMO, Poland KCPK, The Netherlands

Steve Brabbs Sanne Tiekstra DuPont, Luxembourg Bumaga, The Netherlands 1

Traditional packaging materials such as , and cardboard are designed to be as inert as possible. Modern packaging strategies however, seek to promote an additional active role to assist in maintaining the product’s quality. Such packaging concepts are called active packaging.

They are deliberately made to contain substances that interact with the atmosphere inside the packaging or the packaged product. In other words, active packaging concepts are used to actively extend the shelf-life of a wide array of products, varying from cosmetics, pharmaceuticals, electronics and construction materials to fresh products such as cut flowers, fruits, vegetables, fish and meat.

In this leaflet, you will find an overview of active packaging technologies, its uses and benefits as well as the ways in which it can be integrated in packaging. 2 3

The term active packaging does not Emitters or releasers are active Adaptors form a third category of active refer to a single technology, but to a packaging technologies that release packaging technologies. These solutions wide variety of technologies that tackle substances (i.e. ethanol, CO2, moisture, do not absorb or release substances but various specific challenges in different , flavours, colouring cause desirable chemical or biological ways. However, a general distinction can agents, etc.) into the packaging and changes in the packed product and/ be made between three types of active can be used for different reasons. An or in the microbial life present in the packaging technologies. important application is to compensate packed product or the packaging’s inner for the absorption of components atmosphere. For example: a packaging Scavengers, also known as absorbers, into the or the loss of substances material that reduces the growth of are active packaging technologies via migration thereof through the micro-organisms through the reactive that absorb substances from the packaging material. Release-agents compounds that are immobilized (fixed) packaging’s inner atmosphere or from are typically encapsulated in order to on the material surface. Because the or the packed product, and are the most achieve a controlled or triggered release active substances are immobilized, they commonly used type of active packaging of the released substances. Different do not migrate into the atmosphere. technology. Especially moisture and encapsulation materials can be used. This means that they have a long-lasting oxygen scavengers are frequently used, The effects of emitters wear off over effect but only function when in contact since oxygen and moisture both are time. with the product. often involved in deteriorative reactions and are important causes of quality loss and degradation in (food) products Scavengers and organic compounds. Common examples are with silica gel. Oxygen These moisture scavenger sachets are Moisture Ethylene already part of our everyday life, as they are usually found inside of electronic products or for clothing items. Most scavengers absorb a specific substance, but some only absorb a substance above a certain threshold; Potassium chloride, for example, Biological Moisture absorbs water vapour only above 87% relative humidity. These types of Adaptors Emitters scavengers are also known as regulators. Chemical Nutrients 4 5

All active packaging concepts have handling, which means that although To start with the product and its reasons bread dry out too fast, and removal of one thing in common: they interact a technology might tackle the right and mechanisms of quality loss, it is too high quantities of gases can cause with the packaged product and/or the cause of quality loss, it might still not important to know what determines the packaging to deform or tear due atmosphere inside the packaging in deliver the desired results when it is not the shelf-life of the product. The shelf- to pressure differences. Therefore, it is order to prevent quality loss and prolong correctly processed or handled or stored life of a product depends on the various important to know exactly how much . As you already learned in for too long. This means that to find an intrinsic properties of the product, of a substance should be absorbed or the previous section, different types active packaging technology that works which include pH, nutritive value, released in which timeframe, in order of active packaging work in different well for your application, it is important the natural presence or absence of to determine the type and quantity of ways and tackle different causes of to thoroughly understand your product antimicrobial agents, breathability and the active packaging technology that is quality loss. In addition thereto, every and how it is produced and processed as biological structure, and of external suitable for the specific application. technology has its own requirements well as the causes and mechanisms of factors such as the length of the supply regarding processing, storage and quality loss for each specific situation. chain and storage conditions such as Knowledge of the value chain of the temperature, relative humidity and product is also important. Especially the air composition. These factors will the processing and handling of the determine the chemical, biochemical, packaging material and the length of physical and microbiological spoilage of the value chain are of relevance. Some products, and thus also the shelf-life of active materials are volatile, and are the product. Depending on the spoilage thus not suitable to be exposed to mechanism(s) of the product, a specific high temperatures. Using such active type of active packaging technology can packaging technologies for (food) be selected that will be beneficial to the products that are heated for e.g. specific product. preservation reasons would thus not make sense. The length of the intended In addition thereto, one should also lifespan of the product is also important, consider the strength of the effect of the as the duration of packaging activity specific active packaging technology. should be adapted to that. This is important because in some cases, when the active technology absorbs The table on the following pages or releases too much of a certain provides an extensive overview of substance, the active technology can various active packaging technologies, actually have adverse effects on the their technical composition, action lifespan of the packaged product. For mode and application areas. example, absorbing too much moisture from bread packaging can make the 6 7

TECHNOLOGY TECHNICAL COMPOSITION ACTION MODE APPLICATION AREAS

Oxygen absorbers reduce the oxygen level in the packaging, , bread, bakery goods, nuts, milk powder, coffee, tea, Oxygen absorbers can be based on oxidation of , ascorbic acid, photosensitive oxidation, thereby preventing oxidation reactions and growth of aerobe beans, grains, pasta, meat, fish, drinks, ready-made meals, Oxygen enzymatic oxidation (i.e. glucose oxidation), unsaturated fatty acids, rice extract or yeast bacteria and fungi. Also prevents discoloration of fresh meat spices, soups & sauces, products containing vitamins A, C and/or scavengers immobilized on a solid substrate. and keeps out pests in for example museum environments. E, artwork conservation (musea)

CO2 absorbers can be based on calcium hydroxide and sodium hydroxide or potassium hydroxide, Removal of CO2 from the packaging prevents rupturing of Meat, fish, poultry, beer, cheese, coffee, dough, flowers CO2 scavengers calcium oxide and silica gel. the packaging during storage due to CO2 build-up. Absorbing trays for meat, fish, poultry, bread, ready-made meals, Reduction of moisture level in the packaging reduces the Moisture absorbers can be based on glycerol, clay, silicon oxide, propylene glycol, polyacrylates and cut fruits and vegetables, blisters for powdered pharmaceutical Moisture growth of bacteria and fungi and prevents weakening of cellulose nanofibers. The most commonly used moisture absorbers are those based on silica gel. products, hardware products, metal goods, clothing items, scavengers -based packaging materials due to water uptake. electronics, artwork conservation (musea)

Reduction of ethylene levels in the packaging slows down Import and export of fresh fruits and vegetables (especially Ethylene absorbers can be based on aluminium oxide and potassium permanganate, carbon or Ethylene the natural ripening process of fresh fruits, vegetables and apples, apricots, bananas, mangoes, cucumbers, tomatoes, zeolite. scavengers flowers. avocados, carrots, potatoes) but also cut vegetables, cut flowers SCAVENGERS (absorbing technologies) SCAVENGERS

Slow down the growth of fungi and bacteria, thereby Ethanol is encapsulated in silicon dioxide to achieve a slow-release of ethanol vapour. Bread, dried fish products Ethanol emitters extending the products’ shelf-life.

Sulphur dioxide reacts with active substances such as calcium Dehydrated white vegetables, various heat-treated , The mechanism of sulfur dioxide release can be based on either the chemical reaction between sulphite with water, or functions through the hydrolysis various processed foods, unprocessed foods such as fresh fruits, Sulphur dioxide sodium metabisulfite (active materials) and water (external), or on the reaction of an organic acid of metabisulphite. These emitters are used as a bleaching vegetables, cut flowers, meat and fish products, cosmetics, emitters with calcium sulphite (both in the packaging). agent to prevent discoloration of (white) food products, as pharmaceuticals an anti-oxidant and for its antimicrobial properties. CO2 emitters are most commonly used in combination with CO2 emitters can be based on ferrous carbonate or a mixture of ascorbic acid and sodium oxygen absorbers. For example: ascorbic acid-based sachets Meat products, MAP-packed products CO2 emitters bicarbonate. are both oxygen absorbers and CO2 emitters at the same time. Antimicrobials are typically encapsulated and are released Examples of antimicrobial agents used in release systems include acid anhydride, alcohol, once a trigger, such as a certain (high) humidity level, Meat & fish products, fruits, vegetables, cut flowers, schoes and Antimicrobial bacteriocins, chelators, , antioxidants, organic acids, (components of) essential oils and is present in the packaging. Antimicrobials are used as leather goods, archives emitters polysaccharides. preservatives. Addition of aromas and/or flavours can improve the aroma of fresh products or enhance the flavour of food once Flavours and aromas are released slowly and evenly in the packaged product during its shelf life or Bread, meat and other applications, fun-element in packaging Aroma and the package is opened. Gradual release of aroma’s and/

EMITTERS (releasing technologies) release can be controlled to occur during opening the package or food preparation. for detergents, perfumes, air fresheners, etc. flavour emitters or flavours can offset the natural loss of taste or smell of products with long shelf lives.

Examples of anti-oxidants in food products are vitamin C, vitamin E (tocopherol), resveratrol and citric acid. Next to that, certain minerals such as selenium, chromium and zinc are important Antioxidants neutralize harmful free radicals, thereby Dehydrated foods and fat-containing foods emitters because they are part of enzymes that function as antioxidants. In the body, uric acid also functions preventing oxidation and extending the product’s shelf-life. as an antioxidant.

Contact-based antimicrobials and antioxidants are immobilized (fixed) on the matrix of the packaging material. Examples of antimicrobial agents used for contact systems include titanium dioxide, silver, zinc, Meat & fish products, fruits, vegetables, cut flowers, cosmetics, Contact-based Because they do not migrate into the atmosphere, they calcium or natural preservatives such as nisin, and vegetable oils at nanoscale. medicines, medical equipment antimicrobials have a long-lasting effect but only function when in contact

ADAPTORS with the product. Antimicrobials are used as preservatives. 8 9

Active packaging technologies can be Alternatively, the packaging material In packaging materials that consist of As a top layer, the active components integrated in the packaging material in itself can be active by nature, or be multiple layers, the so-called multilayer- can be added by means of , several ways. One widely used method is made active by blending the active materials, there are even more possible or – in of paper and board the insertion of a separate entity, which components into the bulk of the ways of incorporating one or more active – via surface sizing. Depending on the contains the active material (e.g. silica material or adding it to the surface of functionalities in the material structure. materials and processes used, this can gel), inside the packaging, just before the material via coating or lamination be done either during the production of sealing. processes. the material itself, or during conversion.

As a core layer, the active component Active materials can be can also be sandwiched between two integrated in the packaging by or more non-active layers. When the means of a separate element. envisioned material is a type of folding boxboard or solidboard, it is possible to incorporate the materials directly during board production. In this situation, the active components will be blended into Active agent can be integrated the paper pulp that is used to produce into the packaging material. the middle layer(s) before pressing the layers together. Alternatively, the active material layer can also be combined with the other layers through lamination in a conversion step. Active agent can be integrated onto the packaging material. Different active properties in each layer is also possible when working with multilayer structures. By blending different active components in each layer of the final structure it is possible Active agent can to achieve a multilayer material with be the packaging material. various active functionalities. Again, for folding boxboard or solidboard this can be done during board production. For all other materials, lamination is the easiest Schemes are taken after reference [1]. Schemes are taken after reference [2]. way to achieve such materials. 10 11

Each of the methods described in this The table below provides an overview Successful market introduction depends approximately 1.3 billion tonnes or one section have their advantages and of the different integration methods on more than technological viability third of the produced food for human drawbacks, in the sense that not all and their advantages and drawbacks of a new technology; costs have to consumption is wasted [4]. Preservation options are available for all materials in terms of applicability. It compares correspond with the gained benefit, of food is an efficient method for and active technologies. For example, between different ways of integrating legislative and regulatory issues must saving food, obtain optimal shelf life volatile release substances won’t be active technologies in paper and board be addressed, and broad consumer and preventing from being wasted. suitable for being added in the bulk of packaging. acceptance is required. More on these Quality preservation results in a higher paper or plastics because they would challenges is written in the roadmap of market value for all types of products be damaged by the heat that is typical Whether or not a specific active WG2 (Working Group 2). and increases competitive value, but in the production processes of these packaging technology is able to deliver In this section, we present to you the also makes the value chain as a whole materials. In other cases, a certain way certain effects or opportunities is opportunities and challenges active more efficient, as less arable land, water, of integrating the components in the dependent on many factors, including packaging has to offer. Legislation on fertilizer, raw materials, fuel, etc. is material simply doesn’t make sense the composition of the active material the topic is briefly explained. required to supply the same amount of for practical reasons; adding active and the product it is used on. Therefore, consumers. Another advantage is that technologies that require contact with we recommend to always contact the OPPORTUNITIES by using active packaging technologies, the packaged product in the bulk of a producer of the active material to learn the need for chemical preservatives thick , for example, does whether or not it is suitable for your The introduction of active packaging inside foodstuffs, textiles, etc. becomes not make the material more effective application and which effects can be has been regarded as a response to redundant. This way, products are more than adding a thin layer of the active achieved. continuous changes in market trends natural but still the quality is maintained material to the surface of the board. and consumer demands [3]. Active and safety guaranteed (lower risk on packaging concepts (materials and food poisoning, allergies, etc.). SACHETS TOP LAYER IN LAMINATE CORE LAYER IN IN BULK methods) are a promising development, OR SURFACE TREATMENT LAMINATE because they can deliver several benefits Active packaging technologies can also Suitable for contact-based N Y N Y* active components to producers, brand-owners and retailers deliver new logistic opportunities. For in all sectors in terms of economics, example, a longer shelf-life for products Requires active component to N Y/N** Y/N* Y be heat-resistant logistics and sustainability. For example, enables producers of fresh produce such Multiple active functions as active packaging concepts are able as cut flowers, fruits and vegetables Y N Y/N*** Y possible to maintain the quality and extend the increased flexibility in production, Accidental ingestion possible Y N N N shelf-life of a wide variety of products and to store their products longer, Easy consumer apprehension N Y Y Y throughout the value chain, the most which is especially beneficial from an May affect processing methods/ apparent benefit is a reduction in food economic viewpoint during the peak N Y Y Y equipment waste, loss of products and economical season, when market prices are often value. Food waste is an environmental, low due to overproduction. Storing * less suitable for thick materials; ** depends on processing method; social and economic challenge – products for just a few more days can *** depends on total amount of layers in laminate 12 13

increase profitability, thus supporting business opportunities that can increase by most brand-owners. In addition Regulation states that no food contact the economic health of especially economic health and competitiveness of thereto, communication of the benefits materials shall transfer constituents agricultural and horticultural businesses. companies. And there’s more to come! towards the consumers and value chain into food levels that endanger human For local production, increased shelf-life stakeholders is often considered to be health (Art.3 EC/1935/2004). Specific is not always needed (or wanted due to As the technical developments in the as challenging as it is important. Earning requirements for different food contact freshness perspective). However, active field of active packaging are ongoing, the trust of consumers and making sure materials are also allowed in the packaging can contribute to inhibit or it is expected that active packaging they understand the effects is not always regulation. However, under European reduce the deteriorative processes. technologies such as oxygen scavengers easy, especially when it comes to finding community law, specific regulations Thus, the quality of fresh product after will be improved further in the coming components in their food that are have not been adopted for paper and selected end of storage may be higher/ years, leading to even greater impacts unknown and thus might be considered board packaging materials. Specific improved compared to concepts without with lower dosages of active materials. unsafe or undesired. requirements are present for active and active packaging. This could result intelligent packaging. According to in potential increased profitability. CHALLENGES Thirdly, there is a challenge related the framework regulation, packaging Another potentially interesting logistic to availability of active packaging materials may only release substances benefit of extended shelf-life is that Like with any other technology, active technologies. As is quite typical for novel into the food that are regulated as new transportation routes or methods packaging technologies also have some technologies, the market for most active food additives or food flavorings. become feasible. From this viewpoint, it challenges that should be considered. packaging technologies is not very Additional safety requirements for will become possible to import products Probably the main challenge of active mature yet, in the sense that there are active and intelligent packaging is set from farther away, or choose to follow packaging is that there is no ‘one size only a few producers of active packaging in Regulation EC 450/2009. The use of the cheaper route of transporting fits all’-solution. Because there are materials, which can be considered risky active and intelligent packaging for overseas instead of airfreighting. almost as many different technologies by especially larger brand-owners who product marketed by companies has as there are applications, it always are considering using such technologies. to be accompanied be a declaration Further down the value chain, active require some thinking, developing and In addition thereto, suppliers often of compliance including consumer packaging can also bring other, testing before one reaches the point demand a minimum order size that is information at the retail stage. less obvious benefits. In packaging of actually implementing an active too high for most brand-owners that are processes, for example, active packaging packaging technology. Adaptation of interested in testing the use of active For non-food products, these allows packages to be filled faster the technology to a specific application packaging technologies. regulations do not apply, which means it and/or for thinner packaging films to is almost always required to achieve is simpler to implement active packaging be used, as scavenging and emitting the best effects, as improper use of LEGISLATION technologies for non-food applications. technologies can compensate for the active packaging technologies, such as However, this does not mean there is no lower amounts of gases added to MAP adding too much absorbing capacity, Materials that are intended to get in legislation to keep in mind. packages during filling and for the may have adverse effects. Therefore, the contact with food is regulated under lower barrier properties of thinner films. decision to implement such technologies the EU Framework Regulation EC More information can be found in the Each of these possibilities deliver new is often one that is not taken lightly 1935/2004. Article 3 in the Framework ActInPak Legislation leaflet [5]. 14 15

A series of short-text leaflets on the [1] Nathalie Lavoine. (2013). More information on this topic can also topic of active packaging has been Design, processing and be found in the book: published. characterization of innovative functional bio-nano-materials for Cerqueira, M.A., Lagaron, J.M., On the right, there are clickable links to packaging. Pastrana, L.M., Martins De Oliveira web versions of the ActInPak's Active Soares Vicente, A.A. (2018). packaging leaflets in various languages [2] Kenniscentrum Papier & Karton. Nanomaterials for : named after their country of origin. (2015). materials, processing technologies and Innovatieboekje 5: Actieve safety issues. Micro & Nano Technology Verpakkingsmaterialen. Books. Elsevier. Web: https://www.elsevier.com/books/ [3] Vermeiren, L., Devlieghere, F., nanomaterials-for-food-packaging/ Van Beest, M., De Kruijf, N., cerqueira/978-0-323-51271-8 Debevere, J., et al. (1999). Trends in Food Science and Technology, 10 (3), pp 77-86.

[4] United Nations Environment Programme (2013). Quickfacts. Web: http://www.unep.org/ wed/2013/quickfacts/

[5] COST FP1405 ActInPak (2018). Legislation on AIP. Web: https://legislation.actinpak.eu COST FP1405 ActInPak aims to identify and overcome the key technical, social, economic and legislative barriers to a successful deployment of renewable fibre- based functional packaging solutions such as active and intelligent packaging. Currently, 43 countries are involved in the network, with participants representing 209 academic institutions, 35 technical centers, and 83 industrial partners.

For more information, please visit the ActInPak website: www.actinpak.eu

COST (European Cooperation in Science and Technology) is a funding agency for research and innovation networks. Our Actions help connect research initiatives across Europe and enable scientists to grow their ideas by sharing them with their peers. This boosts their research, career and innovation. www.cost.eu