Modern Processing, Packaging and Distribution Systems for Food Modern Processing, Packaging and Distribution Systems for Food

Edited by FRANK A. PAINE, B.Sc., C.Chem., F.R.S.C., F.I.F.S.T., F. Inst. Pkg Secretary-General International Association of Packaging Research Institutes and Adjunct Professor, School of Packaging Michigan State University

Blackie Glasgow and London

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Distributed in Canada by Macmillan of Canada Division of Canada Publishing Corporation 164 Commander Boulevard Agincourt, Ontario MIS 3C7 © 1987 Blackie and Son Ltd First published 1987 Softcover reprint of the hardcover 1sr edition 1987 All rights reserved. No part of this work covered by the copyright hereon may be reproduced or used in any form or by any means-graphic. electronic. or mechanical. including photocopying. recording. taping. or information storage and retrieval systems-without written permission of the publisher.

British Library Cataloguing in Publication Data Modem processing, packaging and distribution systems for food. I. Food industry and trade I. Paine, F.A. 664 TP370 ISBN 978-1-4684-8594-3 ISBN 978-1-4684-8592-9 (eBook) DOl 10.1007/978-1-4684-8592-9 For the USA and Canada

Photosetting by Best-set Typesetter Ltd Preface

The progress that has been made over the last decade in the preparation, development, processing, and marketing of food has to a large extent been made possible by innovations and developments in the ways that thermo• plastics, in conjunction with , metal foils, and other materials, have been combined and formed into the appropriate configurations to provide the properties required. Much has been said, written and published about retort pouches, packaging and aseptic preservation processes, and even more about the newer methods of distribution and retailing of all kinds of food. However, all of this material needed to be digested, condensed into a logical framework and appraised, and possible further developments considered. In many instances, the original research and development was carried out in conjunction with one or more of the research organisations in membership with IAPRI, the International Association of Packaging Research Institutes, and it was felt that a book which attempted to provide a review of the more important developments would be useful to practitioner and student alike. This volume therefore aims to provide the food technologist with a more comprehensive understanding of the packaging aspects of the marketing and distribution of food; the packaging technologist with an insight into the basics of food technology that must influence his thinking; and the business executives concerned with food and its distribution with a readable account of past achievements and possible future developments. The student and industrial trainee should also benefit from a study of the ways in which these developments have taken place. Each of the chapters was written by a senior member of one of the leading IAPRI Institutes which has made a study of the subject matter and can consider the future possibilities with the least commercial bias. As it was thought desirable that each chapter should provide a complete picture of its area, there is inevitably a small overlap between certain chapters. However, this has been kept to a minimum by cross-referencing. My personal thanks are due to all of the authors for improving the format of their chapters from the layout that I originally suggested, and for accepting the relatively small amount of editing that was needed to bring the work into what, I trust, is an integrated account of the more recent developments in .

FAP Contents

1 Retortable plastic packaging R.C. GRIFFIN The origin of retorting as a food process 1 Traditional packaging 2 Metal cans 2 2 Advantages and disadvantages 3 Thermal processing 4 Spoilage organisms 4 Factors influencing growth 4 Disadvantages of can and geometry 7 The 8 Materials 8 Pouch fabrication 10 Filling, closing, and air evacuation 10 Retorting 11 Testing requirements 11 Economics 13 The market for the retort pouch 13 The evolution of plastic retortable packages 14 The foil laminated tray 14 Rctortable plastic materials 14 Retortable thermoformed plastic 16 Rctortable pressure-formed plastic containers 16 Retortable injection blow-moulded plastic containers 17 Other candidates 17 Summary 18 References 19

2 Aseptic packaging FRANK A. PAINE Introduction 20 Heat processing 20 21 New trends in retorting 22 The basis of sterility calculations 23 Product" sterilization 25 Sterilization of the packaging 27 Web sterilization 28 sterilization 29 Some fundamental aspects: reducing the bacterial load 29 Maintaining sterile conditions during plant operation 31 Presterilization of the 31 The production (and protection) of satisfactory seals and closures 32 Systems available and possible developments 32 References 35 viii CONTENTS

3 Modified atmosphere packaging RICHARD INNS Introduction and history 36 Reasons for use of modified atmospher packaging 37 Technical requirements 38 Safety 40 Applications 41 Vegetables 41 Meat packaging 42 Poultry packaging 43 Fish products 43 Bakery products 44 Other products 44 Packaging materials 45 Limitations of MAP 45 Testing of modified atmosphere packs 50 References and further reading 51

4 Use of irradiation techniques in food packaging KIRSTEN NIELSEN Historical introduction 52 The technology 53 Techniques 54 Low-dose gamma-irradiation 54 Low-dose electron-beam irradiation 55 Applications 55 Inactivation of pathogens 55 Disinfection of cereals and flour products 56 Sterilization of packaging materials for the food industries 56 Disinfection of herbs and spices 56 Extending the life of perishable foods 56 Inhibiting sprouting 57 Decontamination of soils 57 Sterilizing food for prolonged storage 57 Legislation 57 Standardization 59 Effects on packaging 60 References 61

5 Shelf-life prediction DENNISJ. HINE Incentives for shelf-life prediction studies 62 Factors in the shelf-life prediction process 63 The mechanisms of deterioration 63 Water vapour 63 Oxidation 64 Light 65 Volatiles 65 Temperature 66 Basic shelf-life prediction data 66 Th:! moisture absorption isotherm 67 Oxygen absorption 68 The storage climate 68 Values for package permeability 70 Water vapour 70 Oxygcn 72 CONTENTS IX

Vapour permeability 75 Light transmission 75 Shelf-life prediction techniques 75 Deterioration by loss or gain of moisture 76 Deterioration by oxygen absorption 79 Deterioration by a number of causes 81 Influence of package imperfections on 82 Multiple package distribution 83 In conclusion 83 References 84

6 for liquids ARVE IVERSEN Introduction 86 History and development 87 Principles of production 88 Converting 88 Filling and sealing 88 Materials 90 Hygiene 92 Mechanical strength 92 Barrier 93 Seals 95 Permeability to gases and water vapour 95 Material compatibility 97 Light 98 Aseptic packaging of liquid foods 99 Tetra Brik Aseptic 102 Packaging material 103 Quality control 103 Distribution 103 Resources and energy 105 Marketing aspects and competition 107 References 108

7 Packaging of carbonated beverages LOA KARJALAINEN Historical background 110 Other developments 115 Carbonated beverages and the environment 118 of beverage packages 120 Economics 124 The impact of legislation 125 Volume of beverage packaging systems 126 Future trends or wishful thinking? 129 References 130

8 Physical distribution today IVANKA DIMITROV A Background and definitions 132 The structure of physical distribution and the importance of packaging 134 New aspects of physical distribution 138 Costs of distribution 139 References 144 CONTENTS x

9 Packaging for consumer convenience INGRID FLORY Introduction 146 Non-packaged foods 146 Changing social and economic climate 147 Lifestyles and food orientation 148 Recent developments 149 New plastic materials 149 Nutritional supplement in Tetra Brik Aseptic 151 School programmes 151 Opening and reC\osing function 154 Let Pak 154 Cekacan 158 Microwave cooking 158 Microglas 159 Future developments 160

Index 161 List of contributors

Ivanka Dimitrova Project Leader, The Swedish Packaging Research Institute, Torshamnsgatan 24, 9, S-163 93 Spanga, Stockholm, Sweden. Ingrid Flory Consultant and Project Leader, c/o The Swedish Packaging Research Institute, Torhamnsgatan 24, Box 9, S-l63 93 Spanga, Stockholm, Sweden. Roger Griffin Visiting Lecturer, School of Packaging, Michigan State University. East Lansing, Michigan 48824-1223, USA. Dennis Hine Principal Consultant, Packaging Division, Pira, The Research Association for Packaging, Leatherhead, Surrey, KT22 7RU, UK. Richard Inns Director, Packaging Division. Pira, The Research Association for Packaging, Leatherhead, Surrey KT22 7RU, UK. Arve Iversen Project Leader, Norwegian Food Research Institute, PO Box 50, N-1432 Aas-NLH, Norway Loa Karjalainen Director, Association of Packaging Technology and Research, c/o Finnish Pulp and Paper Research Institute, Box 136, SF-OOlOl Helsinki, Finland. Kirsten Nielsen Manager, Packaging Materials Section, Danish Pack• aging, Distribution and Transport Research Institute, Meterbuen 15, DK-Skovlunde, Denmark. Frank Paine Secretary General, International Association of Packaging Research Institutes, Eyot Lodge, Petworth Road, Chiddingfold, Surrey, GU8 4UA, UK.