2008 TECHNICAL SYMPOSIUMNew Packaging Technologies to Improve and Maintain Food Safety

September 18-19, 2008, TorontoSeptember 18 19, 2008, Toronto

Active/intelligent packaging : C t A li ti d I tiConcept, Applications and Innovations

Islem A. Yezza, Ph.DProject Manager

Tel: 514-255-4444 # 6288iyezza@cmaisonneuve.qc.ca

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What we will talk about today…

1. Introduction: outbreak, market, definitions, trends…

2. Active packaging in meat industry: concept, applicationsand innovations

3. Intelligent packaging in meat industry: concept,applications and innovations

4. Take home…

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Listeriosis crisis

The biggest recall in Canadian history:gg y220 Maple Leaf Foods products

Health crisis:Health crisis:13 deaths connected to the outbreak,another 6 deaths are under investigation3838 cases of listeriosis have beenconfirmed and 20 more are suspected

The expanded recall will cost thecompany an estimated $20 million inrefunds to consumers and in plant

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refunds to consumers and in plantcleanup

Factors limiting the case life of meat

Meat: one of the most perishable foods present in commerceMeat: one of the most perishable foods present in commerce

Meat: an ideal substratum for the growth of spoilagemicroorganisms (Pseudomonas Lactobacillus etc ) andmicroorganisms (Pseudomonas, Lactobacillus, etc.) andpotential pathogens (Escherichia coli, Salmonella spp.,Listeria, Bacillus cereus, etc.)

Susceptibility to degradative modification of microbiological and physical–chemical nature

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Problems associated with meat packaging

1. Meat oxidation

2. Moisture loss

3. Compartmentalised odour/flavour

4. Growth of spoilage bacteria4. Growth of spoilage bacteria

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Fonctions of packaging

Packaging should protect the product fromPackaging should protect the product fromcontamination and prevent it from spoilage, andat the same time it should:

Extend shelf life

Facilitate distribution and display

Provide the consumer with greater ease of use andProvide the consumer with greater ease of use andtime-saving convenience

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Communicate with the consumer as a marketing tool

Drivers in packaging innovation

The major driving forces :

The increase in consumer demand for ready-prepared foods

Th h i t il d di t ib ti ti i t d

j g

The change in retail and distribution practices associatedwith globalization

Stricter requirements regarding consumer health and safetyStricter requirements regarding consumer health and safety

Shelf-life extension

C t ffi iCost-efficiency

Environmental issue: Reduction, recycling, biodegradable...

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Request for fewer or no food additives/preservatives

Smart Packaging Market

In the USA, Japan and Australia, active and intelligentk i l d b i f ll li d t t d

A ti k i ill b th

packaging are already being successfully applied to extendshelf-life or to monitor food quality and safety

Active packaging will be worth anestimated $4.6 billion in 2008 andshould reach $6.4 billion by 2013y

Intelligent packaging will be a $1.4billion in 2008 increasing to $2 3billion in 2008, increasing to $2.3billion over the next 5 years, for aCAGR of 11.4%

8Source: BCC Research (January 2008)

Active Packaging

Concept Applications and InnovationsConcept, Applications and Innovations

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Active Packaging

AP: Packaging that changes the condition of the packedAP: Packaging that changes the condition of the packedfood to extend the shelf-life or to improve safety orsensory properties, while maintaining the quality

All AP technologies involve some physical, chemical, orbiological action for altering the interactions betweenth k th d t d th k h dthe package, the product, and the package headspaceto achieve certain desired outcome

AP t b l ifi d i tAP systems can be classified into:

Active scavenging systems (absorbers) Active releasing systems (emitters)

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Active releasing systems (emitters) Controlled release packaging (antimicrobials)

Active Packaging for Meat

1. Gas barrier and gas permeable films for MAP

2. Moisture control (drip absorbers)

3 Oxygen scavengers (in or on packaging)3. Oxygen scavengers (in or on packaging)

4. CO2 scavengers and emitters (in or on packaging)

5. Anti-microbial packaging (in and on the packaging)

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Moisture control

Lower the water activity of the product,thereby suppressing microbial growththereby suppressing microbial growth

Systems consist of a super absorbentl l t d b t t l fpolymer located between two layers of a

micro-porous or non-woven polymer

Enhanced product appearance andfreshness

Materials :Polyacrylates (sheets)Propylene glycol (film)

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Propylene glycol (film)Silica gel (sachet)Clays (sachet)

Compostable Absorbent Pads

Dri-FreshTM Resolve (Sirane): biodegradable,biocompostable absorbent meat pad completelyeliminates surface discolouration for red meats

Ideal for display counters or meat packs, these pads

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Ideal for display counters or meat packs, these padswill compost in less than 60 days

O2 Scavenging Technology

High levels of O2 present in foodpackages may facilitate microbialgrowth, off flavours and off odoursdevelopment, colour changes andp , gnutritional losses

O2 absorbing systems provide an alternative to vacuum andg y pgas flushing technologies as a means of improving productquality and shelf life

Existing oxygen scavenging technologies utilise one or moreof the following concepts: iron powder, ascorbic acid,photosensitive dye and enzymatic oxidation (e g glucose

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photosensitive dye and enzymatic oxidation (e.g. glucoseoxidase and alcohol oxidase)…

O2 Absorbers

O2 absorbers can prevent the growth of moulds, aerobicp g ,bacteria such as Pseudomonas and oxidative damage ofmuscle pigments and flavors to avoid discoloration

The majority of currently commercially available O2scavengers are based on the principle of iron oxidation

Applications in sliced cookedApplications in sliced cooked meats (e.g. ham) and prevent

discoloration in fresh beef

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Commercial Examples

1. Ageless® absorbers / Scavengers (Mitsubishi Gas Chemical Co.)g g ( )2. FreshPax® absorbers / Scavengers (MultisorbTechnologies Inc)3. Atco® absorbers / Scavengers (Emco Packaging Systems)4. O-Busters® absorbers / Scavengers (Dessicare Inc)

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UV light-activated oxygen scavenging polymer

UV light activated films composed of an O2 scavengerUV light activated films composed of an O2 scavengerlayer extruded into multilayer film (polyolefins likepolyethylene and polypropylene)

Purpose: Restricting light induced oxidation

Applications in dried or smoked ppmeat products, processed and

sliced meats

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Commercial example : Cryovac OS2000

Cryovac® OS2000™ polymer-based O2y p yscavenging film has been developed byCryovac

Based on the incorporation of an O2scavenging organic compound into a

l f l i l i t dpolymer for use as a layer in a laminatedpackaging film

Protects nutrients, color and flavor components in foodproducts while reducing or eliminating the formation of

id ti b d t

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oxidative by-products

CO2 generators

The function of CO2 with a packaging environment is top g gsuppress microbial growth

Since the permeability of CO2 is 3–5 times higher than thatof O2 in most plastic films, it must be continuouslyproduced to maintain the desired concentration within thepackagepackage

High CO2 levels (10–80%) are desirable for foods such asmeat and poultry in order to inhibit surface microbialp ygrowth and extend shelf life

Principle: Calcium, sodium or potassium hydroxide,

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calcium oxide and silica gel…

Commercial CO2 generators

1 Ageless (Mitsubishi Gas Chemical Co Japan)1. Ageless (Mitsubishi Gas Chemical Co., Japan)2. Freshilizer (Toppan Printing Co., Japan)3. FreshPax (Multisorb Technologies Inc., USA)3. FreshPax (Multisorb Technologies Inc., USA)4. Verifrais™ package, SARL Codimer (Paris, France)

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Antimicrobial packaging

Mi bi l t i ti d b t th dMicrobial contamination and subsequent growth reducesthe shelf life of foods and increases the risk of food borneillness

Antimicrobial packaging is a promising form of active foodpackaging in particular for meat productspackaging, in particular for meat products

Use of antimicrobial substances can control the microbiall ti d t t ifi i i t idpopulation and target specific microorganisms to provide

higher safety and quality products: significant impact onshelf-life extension

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Antimicrobial packaging

Approaches to antimicrobial packaging can be dividedinto 2 types:

1. Preservatives that are released slowly from thepackaged materials to the food surface

2 P ti th t fi l fi d d d t2. Preservatives that are firmly fixed and do notmigrate into the food products

To confer antimicrobial activity antimicrobial agents mayTo confer antimicrobial activity, antimicrobial agents maybe coated, incorporated, immobilised, or surface modifiedonto package materials

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Classes of antimicrobial compounds

Many classes of antimicrobial compounds have beenevaluated in film structures, both synthetic polymersand edible films:

Organic acids and their salts (sorbic acid,...)Miscellaneous compounds (triclosan,...)Bacteriocins (nisin )Bacteriocins (nisin,...)Enzymes, AllylisothiocyanateSpice and herb extracts

Commercial ExamplesAgION™(concentrate) AgION Technologies LLC

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AgION (concentrate), AgION Technologies LLCNisaplin®(extract) and Microgard™(film), Danisco

Antimicrobial against Listeria

1. The combination of a biopolymer (PLA) and natural bacteriocin (Nisin) haspotential for use in antimicrobial food packaging against Listeria, E. coliand Salmonella (Jin and Zhang, 2008. Journal of Food Science)

2 Films coated with pediocin (peptides) were shown to inhibit the growth of2. Films coated with pediocin (peptides) were shown to inhibit the growth ofListeria in the preservation of sliced ham (Food Control, 2008)

3 Cranberry and oregano extracts combined with lactic acid inhibit the3. Cranberry and oregano extracts combined with lactic acid inhibit thegrowth of L. monocytogenes in meat (Food Navigator, 2004)

4. Edible packaging, Chitosan at 1 and 2% solution in acetic acid wasp g gdemonstrated against Listeria in meat (Food Production Daily, 2004)

5. Oregano proved effective as an antimicrobial agent against L.t d t t t d lt (M t P 2003)

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monocytogenes on ready-to-eat meat and poultry (Meat Process, 2003)

Intelligent Packaging

Concept Applications and InnovationsConcept, Applications and Innovations

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IP: Track, Sense and Communicate

Intelligent packaging: systems that monitor the conditiong p g g yof the packaged food to give information about the qualityduring transport and distribution

IP is a packaging that has the ability to:1. Track the product2. Sense the environment inside or outside the packagep g3. Inform the manufacturer, retailer and consumer

IP Applications:1. Pack integrity2. Safety/quality indicators3 Traceability/anti-theft devices

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3. Traceability/anti theft devices4. Product authenticity

Intelligent Packaging

S I di t RFIDSensors Indicators RFID Tags

Gas sensors Integrityindicators

Fluorescence based oxygen Freshness

indicatorsbased o ygesensors indicators

Ti

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BiosensorsTime

TemperatureIndicators

Gas Sensors

The gas composition in the package headspace oftenThe gas composition in the package headspace oftenchanges as a result of the activity of the food product, thenature of the package, or the environmental conditions

Gas sensors are devices thatGas sensors are devices thatrespond reversibly and quantitativelyto the presence of a gaseous analyteby changing the physical parametersof the sensor and are monitored byan external device

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a e te a de ce

Bio-sensor: The Food Sentinel System™

FSS is a biosensor system capable ofcontinuous detection of pathogens infood packages

A specific-pathogen antibody isattached to a membrane-forming partof the barcode

The presence of contaminatingbacteria such as Salmonella sp., E.p ,coli and L. monocytogenes will causethe formation of a localized dark bar,rendering the barcode unreadable

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gupon scanning

Indicators

A substance that indicates theA substance that indicates thepresence or absence of anothersubstance or the degree of reactionbetween two or more substancesbetween two or more substancesby means of a characteristicchange, especially in colour

In contrast with sensors, indicatorsdo not comprise receptor anddo not comprise receptor andtransducer components andcommunicate information throughdirect visual change

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direct visual change

Leakage indicators

Most of leakage indicators assume a colour change as aresult of a chemical or enzymatic reaction

The most common redox dye used for leak indicators isThe most common redox dye used for leak indicators ismethylene blue

Leak indicator: Suitable for MAP

Based on oxygen sensitive dyeColor change from white to bluein the presence of a leakage

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p g

Oxygen indicator: Ageless Eye

Ageless Eye indicating tablets verify that all the oxygen h b b b d f khas been absorbed from your package

An oxygen indicator that is blue in normal atmospheres and pink when concentrations of O2 are below 1%

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and pink when concentrations of O2 are below 1%

Time Temperature Indicators (TTI)

Small tag or label used to show time temperature history toSmall tag or label used to show time-temperature history towhich a perishable product has been exposed

O ti f TTI i b d h i l h i lOperation of TTIs is based on mechanical, chemical,electrochemical, enzymatic or microbiological change, usuallyexpressed as a visible response in the form of a mechanicaldeformation, colour development or colour movement

The basic requirement of an effective TTI is to indicate clear,q ,continuous, irreversible reaction to changes in temperature

The cost of TTIs: $0 02 to $0 20 per unit

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The cost of TTIs: $0.02 to $0.20 per unit

Fresh-Check® : Show the freshness

A self-adhesive device that is specifically formulated tot h th h lf lif f th f d d t t hi h it i ffi dmatch the shelf life of the food products to which it is affixed

Darkens irreversibly: changes color to show the freshnessof the food productof the food product

LifeLinesFresh-Check: Based on polymerization reaction

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OnVu™ Time-Temperature Indicators

OnVu TTIs allow producers,retailers and consumers to check ata glance whether perishableproducts have been correctlyproducts have been correctlytransported and stored

Help to enhance consumer convenience and confidenceHelp to enhance consumer convenience and confidence,strengthen the reputation of brands using them and optimizeshelf life

OnVu TTI technology relies on theproperties of pigments that change colorover time and if temperatures fluctuate

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over time and if temperatures fluctuate

CheckPoint® labels: Enzymatic TTIs

Warn of any time-temperature conditionswhich could potentially represent abusiveconditions that might lead to growth ofpathogens like E. coli within the productpathogens like E. coli within the product

Based on a colour change induced by adrop in pH resulting from the controlleddrop in pH resulting from the controlledenzymatic hydrolysis of a lipid substrate

Hydrolysis of the substrate causes a drop in pHand a subsequent colour change in the pHindicator from dark green to bright yellow

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indicator from dark green to bright yellow

TRACEO : Microbial growth indicatorg

TRACEO® : Tracks breakage in the cold chain

TRACEO ® colours itself and turns opaque after a criticalaccumulation of cold chain disruptions or when the use by datep yis exceeded and that the product has been properly stored

TRACEO® once coloured avoids itsreading and allows an automatic andgsystematic control of the productswhich are not suitable for consumptionany more

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3M MonitorMark™: Monitor temperature exposure

3M™ MonitorMark™ TTI monitor product temperatureth h th ti l h iexposure through the entire supply chain

They provide a non-reversible record of temperatureexposure (not product quality)

Utilize a chemically activated, irreversibledye color change that occurs when themonitored environment reaches a specifiedthreshold temperature (+/-1°C).threshold temperature ( / 1 C).

The Monitor Mark monitors the approximateduration (hours or days depending on the

d l) th t th d t h b d

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model) that the product has been exposedto the threshold temperature

SensorQ™: Senses spoilage in fresh meat

Detects food-borne bacteriologicallevels right inside the package

SensorQ™ is made of food gradematerials and is economical:costing less than 1% of the totalvalue of the average package ofvalue of the average package ofmeat or poultry that it labels

When the inside of the quality “Q” on the label istangerine orange, the product is fresh. When thebacteria count in the package builds to a critical level,the orange turns to tan to indicate spoilage

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the orange turns to tan to indicate spoilage

Paksense: Temperature-monitoring labels

The PakSense Labels monitor theThe PakSense Labels monitor thetemperature and time of a perishableproduct throughout the distribution chain

Visual alerts indicate if the temperatureexcursions have occurred and the datacollected by the label can bedownloaded and graphed formanagement reporting and recordsmanagement reporting and records

The PakSense Labels enable better foodquality and safety decisions

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quality and safety decisions

TIMESTRIP : Expiry Date Indicators

TIMESTRIP® : single-use, disposable, smart-labels

A t ti ll it l d ti FAutomatically monitor lapsed time: From under 1 day to 6 months

W k b ill ti ll i ti t dWork by capillary action, allowing a tinted liquid to migrate through a micro-porous material at a consistent rate

Provides a simple and safe way of monitoring food freshness

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Tracking your meat with RFID

Radio Frequency Identification (RFID) offersq y ( )a number of potential benefits to the meatproduction, distribution and retail chain:traceability inventory managementtraceability, inventory management,labour saving costs, security andpromotion of quality and safety

Inside the RFID tag is a minuscule microchipconnected to a tiny antenna

A RFID tag may also be integrated with a TTIor a biosensor to carry time-temperature

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y phistory and microbiological data

RFID for meat authenticity and traceability

T k th ti d tiTrack the entire production process,from the time pigs arrive at theslaughterhouse until the prosciutto issent to warehouses and retail stores

Verify ham's authenticity

“ We want to protect the consumer so th t h k th t fthat each person knows the story of each ham through RFID, including when the pig was born and details

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about its life and death”

Take home…

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Take home…Think outside the box

Active and intelligent packaging are the results ofActive and intelligent packaging are the results of“thinking outside the box”

A bright f t re ma be anticipated for acti e andA bright future may be anticipated for active andintelligent packaging, as it fits perfectly with the foodsafety strategy, involving an improved level of food safetyand transparency to consumers

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Take home… Active Packaging

AP is useful for extending the shelf life of fresh, cookedand other meat productsand other meat products

Commercially, there is widespread use of oxygeni k d k d li d t d tscavengers in pre-packed cooked sliced meat products

Antimicrobial packaging is gaining interest fromp g g g gresearchers and industry due to its potential for providingquality and safety benefits

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Take home… Intelligent Packaging

IP can effectively provide solutions to current producer andconsumer problems: Track, Sense and Communicate

A variety of indicators are of interest to the meat packagingchain, such as TTI (breakage in the cold chain), freshnesschain, such as TTI (breakage in the cold chain), freshnessand leakage indicators and RFID tags

IP offers considerable potential as a marketing tool and theIP offers considerable potential as a marketing tool and theestablishment of brand differentiation for meat products

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Barriers to acceptance/adoption of smart packaging

For the future development in Canada some major factorsh t b id d

1. Cost effectiveness is dependent on the perceivedb fit d i d f h t

have to be considered:

benefits derived from such systems2. Some legal hurdles: Food safety/legislative regulations3. Reliability and effectivenessy4. Food producer, consumer and retail education/

acceptance/liability will be needed to enable anintroduction on a large scaleintroduction on a large scale

“Despite the hurdles that have to be overcome in the near future, AP and IP will be a technical tool in the market with a high potential, covering both

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g gmore transparent communication to consumers and the need for the retail

and food industry to better control the food production chain"

Questions

Islem A. Yezza, Ph.DProject Manager

Islem A. Yezza, Ph.DProject Manager

iyezza@cmaisonneuve.qc.caTel: 514-255-4444 # 6288Tel: 514-255-4444 # 6288

iyezza@cmaisonneuve.qc.ca

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