Modern Processing, Packaging and Distribution Systems for Food

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1 Modern Processing, Packaging and Distribution Systems for Food

2 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 Published in the USA by avl an imprint of Van Nostrand Reinhold Company New York

3 Blackie and Son Limited Bishopbriggs, Glasgow G64 2NZ 7 Leicester Place, London WC2H 7BP Published in the USA and Canada by A VI, an imprint of Van Nostrand Reinhold Company Inc. 115 Fifth Avenue New York, New York Distributed in Canada by Macmillan of Canada Division of Canada Publishing Corporation 164 Commander Boulevard Agincourt, Ontario MIS 3C Blackie and Son Ltd First published 1987 Softcover reprint of the hardcover 1 sr 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 ISBN (ebook) DOl / For the USA and Canada Photosetting by Best-set Typesetter Ltd

4 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 thermoplastics, in conjunction with paper, metal foils, adhesives 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, modified atmosphere 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 food packaging. FAP

5 Contents 1 Retortable plastic packaging R.C. GRIFFIN The origin of retorting as a food process Traditional packaging Metal cans Glass jars Advantages and disadvantages Thermal processing Spoilage organisms Factors influencing growth Disadvantages of can and jar geometry The retort pouch Materials Pouch fabrication Filling, closing, and air evacuation Retorting Testing requirements Economics The market for the retort pouch The evolution of plastic retortable packages The foil laminated tray Rctortable plastic materials Retortable thermoformed plastic containers Rctortable pressure-formed plastic containers Retortable injection blow-moulded plastic containers Other candidates Summary 2 Aseptic packaging FRANK A. PAINE Introduction Heat processing Pasteurization New trends in retorting The basis of sterility calculations Product" sterilization Sterilization of the packaging Web sterilization Container sterilization Some fundamental aspects: reducing the bacterial load Maintaining sterile conditions during plant operation Presterilization of the packaging machinery The production (and protection) of satisfactory seals and closures Systems available and possible developments

6 viii CONTENTS 3 Modified atmosphere packaging RICHARD INNS Introduction and history Reasons for use of modified atmospher packaging Technical requirements Safety Applications Vegetables Meat packaging Poultry packaging Fish products Bakery products Other products Packaging materials Limitations of MAP Testing of modified atmosphere packs and further reading 4 Use of irradiation techniques in food packaging KIRSTEN NIELSEN Historical introduction The technology Techniques Low-dose gamma-irradiation Low-dose electron-beam irradiation Applications Inactivation of pathogens Disinfection of cereals and flour products Sterilization of packaging materials for the food industries Disinfection of herbs and spices Extending the life of perishable foods Inhibiting sprouting Decontamination of soils Sterilizing food for prolonged storage Legislation Standardization Effects on packaging 5 Shelf-life prediction DENNISJ. HINE Incentives for shelf-life prediction studies Factors in the shelf-life prediction process The mechanisms of deterioration Water vapour Oxidation Light Volatiles Temperature Basic shelf-life prediction data Th:! moisture absorption isotherm Oxygen absorption The storage climate Values for package permeability Water vapour Oxygcn

7 CONTENTS IX Vapour permeability Light transmission Shelf-life prediction techniques Deterioration by loss or gain of moisture Deterioration by oxygen absorption Deterioration by a number of causes Influence of package imperfections on shelf life Multiple package distribution In conclusion Cartons for liquids ARVE IVERSEN Introduction History and development Principles of production Converting Filling and sealing Materials Hygiene Mechanical strength Barrier coatings Seals Permeability to gases and water vapour Material compatibility Light Aseptic packaging of liquid foods Tetra Brik Aseptic Packaging material Quality control Distribution Resources and energy Marketing aspects and competition Packaging of carbonated beverages LOA KARJALAINEN Historical background Other developments Carbonated beverages and the environment Recycling of beverage packages Economics The impact of legislation Volume of beverage packaging systems Future trends or wishful thinking? Physical distribution today IV ANKA DIMITROV A Background and definitions The structure of physical distribution and the importance of packaging New aspects of physical distribution Costs of distribution

8 CONTENTS x 9 Packaging for consumer convenience INGRID FLORY Introduction Non-packaged foods Changing social and economic climate Lifestyles and food orientation Recent developments New plastic materials Nutritional supplement in Tetra Brik Aseptic School milk programmes Opening and rec\osing function Let Pak Cekacan Microwave cooking Microglas Future developments Index

9 List of contributors Ivanka Dimitrova Project Leader, The Swedish Packaging Research Institute, Torshamnsgatan 24, Box 9, S Spanga, Stockholm, Sweden. Ingrid Flory Roger Griffin Dennis Hine Richard Inns Arve Iversen Loa Karjalainen Kirsten Nielsen Consultant and Project Leader, c/o The Swedish Packaging Research Institute, Torhamnsgatan 24, Box 9, S-l63 93 Spanga, Stockholm, Sweden. Visiting Lecturer, School of Packaging, Michigan State University. East Lansing, Michigan , USA. Principal Consultant, Packaging Division, Pira, The Research Association for Packaging, Leatherhead, Surrey, KT22 7RU, UK. Director, Packaging Division. Pira, The Research Association for Packaging, Leatherhead, Surrey KT22 7RU, UK. Project Leader, Norwegian Food Research Institute, PO Box 50, N-1432 Aas-NLH, Norway Director, Association of Packaging Technology and Research, c/o Finnish Pulp and Paper Research Institute, Box 136, SF-OOlOl Helsinki, Finland. Manager, Packaging Materials Section, Danish Packaging, 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.

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