Product Quality

Factors affecting product quality and shelf life

For many foods, the product shelf life is limited by specific or key attributes that can be predicted
at the time of product development. This is either on the basis of experience with similar
products or observations of them, or from a consideration of the make-up of the product
(intrinsic factors),the environment that it will encounter during its life (extrinsic factors)and the
shelf life limiting processes that this combination of intrinsic and extrinsic factors is likely to
result in.
Intrinsic factors are the properties resulting from the make-up of the final product and include the
following:
water activity (aw) (available water)
pH/total acidity; type of acid
natural microflora and surviving microbiological counts in final product
availability of oxygen
redox potential (Eh)
natural biochemistry/chemistry of the product
added preservatives (e.g. salt, spices, antioxidants)
product formulation
packaging interactions (e.g. tin pickup, migration).
Selection of raw materials is important for controlling intrinsic factors, since subsequent
processing can rarely compensate for poor-quality raw materials..Extrinsic factors are a result of
the environment that the product encounters during life and include the following:
timetemperature profile during processing
temperature control during storage and distribution
relative humidity (RH) during storage and distribution
exposure to light (UV and IR) during storage and distribution
composition of gas atmosphere within packaging
consumer handling.
Food-packaging interactions influencing quality and safety.
Interactions between foods and packaging can be detrimental to quality and/or safety. Changes in
product flavor due to aroma sorption and the transfer of undesirable flavours from packaging to
foods are important mechanisms of deterioration when foods are packaged in polymer-based

materials. Careful consideration must be given to those factors affecting such interactions when
selecting packaging materials in order to maximize product quality, safety, and shelf-life while
minimizing undesirable changes. Product considerations include sensitivity to flavor and related
deteriorations, color changes, vitamin loss, microbial activity, and amount of flavor available.
Storage considerations include temperature, time, and processing method. Polymer
considerations include type of polymer and processing method, volume or mass of polymer to
product ratio Methodology to determine the extent of such interactions must be developed.
Direct interactions between food and packaging are not necessarily detrimental. The same
principles governing undesirable interactions can be used to affect desirable outcomes. Examples
include films which directly intercept or absorb oxygen, inhibit microorganisms, remove
undesirable flavors by sorption, or indicate safety and product shelf-life.

Food Quality
Food quality is the quality characteristics of food that is acceptable to consumers. This includes
external factors as appearance (size, shape, color, gloss, and consistency), texture, and flavor;
factors such as federal grade standards (e.g. of eggs) and internal (chemical, physical,
microbial).Food quality is an important food manufacturing requirement, because food
consumers are susceptible to any form of contamination that may occur during the
manufacturing process. Many consumers also rely on manufacturing and processing standards,
particularly to know what ingredients are present, due to dietary, nutritional requirements
(kosher, halal, vegetarian), or medical conditions (e.g., diabetes, or allergies).Besides ingredient
quality, there are also sanitation requirements. It is important to ensure that the food processing
environment is as clean as possible in order to produce the safest possible food for the consumer.
A recent example of poor sanitation recently has been the 2006 North American E. coli
outbreak involving spinach, an outbreak that is still under investigation after new information has
come to light regarding the involvement of Cambodian nationals. Food quality also deals with
product traceability, (e.g., of ingredient, and packaging suppliers), should a recall of the product
be required. It also deals with labeling issues to ensure there is correct ingredient and nutritional
information. There are many existing international quality institutes testing food products in
order to indicate to all consumers which are higher quality products. Founded in 1961
in Brussels, The international quality institute. Monde Selection is the oldest one in evaluating
food quality. During the degustation, the products must meet the following selection criteria,
required by the Institute: sensory analysis, bacteriological and chemical analysis, the nutrition
and health claims, and the utilization notice. In short, the judgments are based on the following
areas: taste, health, convenience, labeling, packaging, environmental friendliness and innovation.

Example:

Shelf Life
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 (unfit for use), or just no longer on a supermarket shelf. It applies
to cosmetics, foods and beverages, medical devices, medicines, explosives, pharmaceutical
drugs, chemicals, car tires, 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. Barrier packaging can often help control or extend shelf life. When moisture content is a
mechanism for product degradation, packaging with a low moisture vapor transmission rate and
the use of desiccants help keep the moisture in the package within acceptable limits.
When oxidation is the primary concern, packaging with a low oxygen transmission rate and the
use of oxygen absorbers can help extend the shelf life. Produce and other products with
respiration often require packaging with controlled barrier properties. The use of a modified
atmosphere in the package can extend the shelf life for some products. Some active packaging is
also available with antibacterial properties.
Food shelf life and its importance for consumers. Food manufacturers are responsible for
determining the shelf life and for labeling their products accordingly. This includes the storage
conditions required to achieve that shelf life, for example refrigerate once opened. A foods
shelf life is typically determined during its development. Initially, the manufacturer determines
its characteristics (intrinsic and extrinsic), which affect its safety and/or quality. These
characteristics include the ingredients used, the production process and the type of packaging, for
example vacuum-packed or in a modified atmosphere, used to extend the products shelf life and
the storage conditions where the product will be sold. The manufacturer may also conduct other
studies such as sampling and microbiological analysis if deemed necessary. Shelf life
determination is an integral part of manufacturers food safety management systems. The
manufacturer evaluates the shelf life as a part of the regular audit of these systems. This is
especially important when products, production sites or machinery are modified.
The four factors that affect food storage shelf life
Factor 1: Temperature
if you are planning on storing your food in a warm environment, it will only last a fraction of the
time it would last if stored in a cool, dry place. You can expect good storage life if your storage
temperature is at 60F or below. Optimum storage temperature is at 40F or less. It is important
you also find a place where the temperature remains constant. Frequent temperature changes

shorten storage life. If you dont have a cool place for your food storage, plan on rotating your
storage quickly enough to prevent food loss.
Factor 2: Moisture
Foods with excess moisture can spoil in their containers. This is an important consideration when
packing food with dry ice as moisture condenses and freezes on the outer surface of the dry ice.
For long-term storage, grains should have moisture content of 10% or less. It is difficult to
accurately measure this without special equipment. It is also important to know that you can not
dehydrate foods at home that reach these levels. Food that is dried to a moisture level of 10%
moisture crisply snap when bent.
Factor 3: Atmosphere
Foods packed in air dont store as well as in oxygen-free gasses. This is because air contains
oxygen, which oxidizes many of the compounds in food. Bacteria, one of several agents that
makes food go rancid, also needs oxygen to grow. Food storage companies have a couple of
different processes for removing oxygen:
Displacing oxygen: This is done by purging out all the air in the product with an inert

gas. Nitrogen is almost always used because it is the most inert gas known. People doing
their own packing occasionally use dry ice which gives off carbon dioxide gas, and
probably works just about as well.
Absorbing oxygen: Air contains about 78% nitrogen and 21% oxygen, leaving about 1%
for the other gasses. Oxygen absorber packets leave about 99% pure nitrogen in a partial
vacuum. If oxygen absorber packets are used, care must be taken to use a storage
container that can stand some vacuum.

Factor 4: Container
to get the best storage life out of your product it must have a hermetic (air tight) seal. Containers
that do this well are:
Sealable food storage buckets
Sealable food quality metal (lined) or plastic drums

Active Packaging
The terms are closely related. Active packaging usually means having active functions beyond
the inert passive containment and protection of the product. 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.
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 actively 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 and drugs.

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. 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. VCI create a neutral environment in the packaging. It works on the
principle of difference in vapor pressure and causes reaction with Metals and Nonmetals and also
with Moisture to render it active to corrosion. There are different forms of VCI's available like
Papers, Plastics, HDPE Papers, Oils, Foams, Chips, Aluminum Barrier Foils, Bubble, Emitters
etc. that can prevent corrosion at many stages.
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. 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

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 "actively" 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. Thermochromics 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.
Controlling package temperatures
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 actively 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. Self are available for several products.
Dispensing
Some packages have closures or other dispensing systems that actively 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 twopart 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 super hydrophobic surfaces is
useful but can be further improved by using new lubricant-impregnated surfaces.
RFID
Radio-frequency identification chips are becoming more common as 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.

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 (on the product or on the package) is used to help counter
shoplifting.
Microwave packaging
Metallized films are used as a subsector for cooking in microwave ovens. These increase the
heating capacity and help make foods crisp and brown. Plastic microwavable 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.
Example:

Intelligent Packaging/Smart Packaging

Smartness in packaging is a broad term that covers a number of functionalities, depending on
the product being packaged, including food, beverage, pharmaceutical, household products etc.
Examples of current and future functional smartness would be in packages that

Retain integrity and actively prevent food spoilage (shelf-life)

Enhance product attributes (e.g. look, taste, flavor, aroma etc.)

Respond actively to changes in product or package environment

Communicate product information, product history or condition to user

Assist with opening and indicate seal Integrity

Confirm product authenticity, and act to counter theft.

Active

Oxygen scavenging

Anti-microbial

Light protection (photochromic)

Time-temperature history
Microbial growth indicators

Heating/cooling

Odour and flavor absorbing/releasing

Ethylene scavenging

Intelligent

Physical shock indicators

Leakage, microbial spoilage indicating

Moisture absorbing
Difference between smart and active packaging

How Intelligent Packaging Works

In intelligent packaging, the package function switches on and off in response to changing
external/internal conditions, and can include a communication to the customer or end user as to
the status of the product. A simple definition of intelligent packaging is packaging which senses
and informs, and nowhere does this generate a more potent vision than within the smart home of
the future.

Intelligent Packaging for Fresh Fruit and Vegetables

Fresh-cut produce continues to be one of the fastest growing segments of food retailing and
while conventional film packaging is suitable for lettuce and prepared salads, it cannot cope with
the high respiration rates of pre-cut vegetables and fruit, leading to early product deterioration. In
the USA, novel breathable polymer films are already in commercial use for fresh-cut vegetables
and fruit. Landec Corporation supplies Intellipac packaging films that are acrylic side-chain
crystallisable polymers tailored to change phase reversibly at various temperatures from 0-68C.
As the side-chain components melt, gas permeation increases dramatically, and by further
tailoring the package and materials of construction, it is possible to fine tune the carbon dioxide
to oxygen permeation ratios for particular products. The final package is smart because it
automatically regulates oxygen ingress and carbon dioxide egress by transpiration according to
the prevailing temperature. In this way, an optimum atmosphere is maintained around the
product during storage and distribution, extending freshness and allowing shipping of higher
quality products to the consumer.
Self-Heating and Self-Chilling Packaging
Improved convenience is a value-added function that customers are likely to pay extra for as
lifestyles change. Self-heating packages, for soup and coffee, for example, and self-cooling
containers for beer and soft drinks have been under active development for more than a decade,
but have yet to achieve commercial status. However, Crown Cork & Seal is pioneering the
development of a self-chilling beverage can in conjunction with Tempra Technologies and
development is nearing completion. The Crown/Tempra technology uses the latent heat of
evaporating water to produce the cooling effect. The water is bound in a gel layer coating a
separate container within the beverage can, and is in close thermal contact with the beverage.
The consumer twists the base of the can to open a valve, exposing the water to the desiccant held
in a separate, evacuated external chamber This initiates evaporation of the water at room
temperature. The unit has been designed to meet a target specification set by major beverage
customers cooling 300ml of beverage in a 355ml can by 16.7C in three minutes. This
performance level has been achieved in laboratory tests and working samples are currently
undergoing focus group trials with customers.

Thermochromics Labelling
Give a self-heating or self-cooling container a sensor to tell the consumer it is at the correct
temperature and the package becomes smart (such packaging is currently under development).
The most common use a thermochromics ink dot to indicate the product is at the correct serving
temperature following refrigeration or microwave heating. Plastic containers of pouring syrup for
pancakes can be purchased in the USA that are labelled with a thermochromics ink dot to
indicate that the syrup is at the right temperature following microwave heating. Similar examples
can be found on supermarket shelves with beer bottle labels that incorporate thermochromicsbased designs to inform the consumer when a refrigerated beer is cold enough to drink.
Smart Packaging Concepts for Pharmaceuticals
Smart packaging concepts that improve case of use could include dial-a-dose smart caps and
closures that allow the safe dispensing of exact controlled quantities of product, e.g.
pharmaceuticals, cleaning materials, and other potentially hazardous materials. Already a
prescription drug bottle with bottle cap alarm is available - it beeps to alert users when it is time
to take the medication, and it displays how many times the bottle has been opened and the
intervals between openings. The bottle can be connected via a modem to the healthcare center for
the automatic transmission of drug usage and, if necessary, provide feedback to the patient if not
in compliance. Eventually, programmed skin patches using smart gels that rely on changes in
skin properties to trigger drug delivery could replace conventional pill-taking medication.

Intelligent Tamper-Proof Packaging

Knowing whether a package has been tampered with is equally important to consumers. Tamper
evidence technologies that cannot easily be replicated, e.g. based on optically variable films or
gas sensing dyes, involving irreversible color changes, will become more widespread and costeffective for disposable packaging of commodity items. Piezoelectric polymeric materials might

be incorporated into package construction so that the package changes color at a certain stress
threshold. In this way, a 'self-bruising' closure on a bottle or jar might indicate that attempts had
been made to open it.
The Future for Packaging
The vision of the future of packaging, according to the recently published Foresight report
Materials: Shaping Our Society, is one in which the package will increasingly operate as a
smart system incorporating both smart and conventional materials, adding value and benefits
across the packaging supply chain. For smart materials to be adopted in packaging, they need to
be inexpensive relative to the value of the product, reliable, accurate, reproducible in their range
of operation, and environmentally benign and food contact safe.
Example:

Modified Atmospheric Packaging (MAP)

Modified Atmosphere Packaging (MAP) is a technique used for prolonging the shelf-life of fresh
or minimally processed foods. In this preservation technique the air surrounding the food in the
package is changed to another composition. This way the initial fresh state of the product may be
prolonged. It is the shelf-life of perishable products like meat, fish, fruits and vegetables that will
be prolonged with MAP since it slows the natural deterioration of the product. MAP is used with

various types of products. The mixture of gases in the package depends on the type of product,
packaging materials and storage temperature. Meat, fish and cheese are non-respiring products
needing very low gas permeability films and so-called high barrier films are used. The initial
flushed gas-mixture will be maintained inside the MA package. Conversely, fruits and vegetables
are respiring products where the interaction of the packaging material with the product is
important and so low barrier or so-called high permeability films are used for these. So long as
the permeability (for O2 and CO2) of the packaging film is adapted to the product's level of
respiration, an equilibrium modified atmosphere will be established in the package and the shelflife of the product will increase.
The three major commodity types are fruits and vegetables, meat and meat products, and
seafood. Many products such as red meat, seafood, minimally processed fruits and vegetables,
pasta, cheese, bakery goods, poultry, cooked and cured meats, ready meals and dried foods are
packaged under MA. It has been estimated that 25-40% of all fresh produce harvested will not
reach the consumers table, due to spoilage and mishandling that occurs during distribution.
Packaging Films
When selecting packaging films (web substrates) for EMAP of fruits and vegetables the main
characteristics to consider are gas permeability, water vapor transmission rate, mechanical
properties, transparency, type of package and sealing reliability. Traditionally used packaging
films like LDPE (low-density polyethylene), PVC (polyvinyl chloride), EVA(ethylene-vinyl
acetate) and OPP (oriented polypropylene) are not permeable enough for highly respiring
products like fresh-cut produce, mushrooms and broccoli. As fruits and vegetables are respiring
products, there is a need to transmit gases through the film. Films designed with these properties
are called permeable films. Other films, called barrier films, are designed to prevent the
exchange of gases and are mainly used with non-respiring products like meat and fish. EMAP
films developed to control the humidity level as well as the gas composition in the sealed
package are beneficial for the prolonged storage of fresh fruits, vegetables and herbs that are
sensitive to moisture.

Examples:

SUBJECT NAME:
APPLIED PACKAGING
COURSE CODE:
DJP6073
NAME:
SATISHWARA RAO A/L NARASIMMANAIDU
MATRIX NUMBER:
08DMP14F1022
CLASS:
DMP5B
LECTURERS NAME:
PUAN NOORHAZNIDA BINTI BAKAR
SESSION:
JUNE 2016