DEVELOPMENT OF A THERMOFORMABLE FIBRE-BASED TRAY … · Aqueous carnauba wax (Aquacer 2560, BYK...
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DEVELOPMENT OF A THERMOFORMABLE FIBRE-BASED TRAY FOR MEAT AND FISH PACKAGING October 12th, 2017 EMPACK, Mechelen Prof. dr. ir. Peter Ragaert Dr. Simbarashe Samapundo Dr. Kurt De Mey
Transcript of DEVELOPMENT OF A THERMOFORMABLE FIBRE-BASED TRAY … · Aqueous carnauba wax (Aquacer 2560, BYK...
DEVELOPMENT OF A
THERMOFORMABLE FIBRE-BASED TRAY
FOR MEAT AND FISH PACKAGING
October 12th, 2017
EMPACK, Mechelen
Prof. dr. ir. Peter Ragaert
Dr. Simbarashe Samapundo
Dr. Kurt De Mey
©Pack4Food, 2017
PACK4FOODCOLLABORATION PLATFORM INDUSTRY – RESEARCH INSTITUTES
INDUSTRY RESEARCH INSTITUTES
www.Pack4Food.be
You’re very welcome at booth KZ03
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PACK4FOODMANY INDUSTRIAL STAKEHOLDERS IN FOOD PACKAGING
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PACK4FOODTOPICS WITHIN PACK4FOOD
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PACK4FOODACTIVITIES WITHIN PACK4FOOD
RESEARCH
PUBLICATIONS
NETWORK
ADVICE
TRAINING
PROJECTS ON
DIFFERENT TOPICS
• OPTIMAL FOOD PACKAGING
CONCEPTS
• BIOBASED FOOD PACKAGING
• MIGRATION PROFILE OF FOOD
PACKAGING
• …
©Pack4Food, 2017
ACTIPOLYBACKGROUND
Source: World Economic Forum, Ellen MacArthur Foundation and McKinsey & Company, The New
Plastics Economy — Rethinking the future of plastics (2016,
http://www.ellenmacarthurfoundation.org/publications)
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• Bioplastics• Fibre-based (including cardboard, bagasse,…)
ACTIPOLY
► Alternatives for conventional crude-oil based food packaging?
BACKGROUND
Reduce
Renewable
Re-use
Recycle • Use recycled content• Use recyclable materials
• Trays with filling agents (e.g. CaCO3)• Foamed trays
• Re-use of PET-trays• Re-use of cardboard
Remove • Remove ‘unnecesarry’ packaging components
Redesign• Replace thick plastic jar in re-usable cardboard
box with plastic liner
STRATEGY
ACTIPOLY
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ACTIPOLY
► Mild preservation technology
► Less use of additives
► Reduction in fat, sugar and salt content
► Globalisation
BACKGROUND
► Mild preservation technology
► Less use of additives
► Reduction in fat, sugar and salt content
► Globalisation
Stability of food products?
• Mult i layer packaging
• Modi f ied atmosphere packaging (MAP)
• Act ive packaging: e .g. ant imicrobia l
packaging
STRATEGY
ACTIPOLY
©Pack4Food, 2017
Modified fibre, thermoformable
ACTIPOLYCOMBINING DIFFERENT STRATEGIES WITHIN FOOD PACKAGING INNOVATION
Coating: oxygen and water vapour barrier
Coating: antimicrobial activity
Topfoil: antimicrobial activity
©Pack4Food, 2017
ACTIPOLY
► Active polyvalent packaging based on environmentally friendly fibre materialwith thermo-formable properties to extend shelf-life of fresh food for thereduction of waste
► European collective research project with research institutes and companies
► May 2015 – October 2017
► €2.000.000
► 9 Flemish companies
THE PROJECT
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ACTIPOLYRESEARCH PARTNERS
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ACTIPOLYPARTICIPATING COMPANIES
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THE TRAY
► Cellulose ring opening
► Degree of Oxidation
BASE PAPER STRATEGIES
oxidation reduction
Cellulose
pulp
(NBSK)
Modified
Pulp I
Modified
Pulp II
Thermo-
plastic
Paper
Tray
Oxidation:
1,32 wt eq. NaIO4
4,74 wt eq. Isopropanol
75 wt eq. water
Room temperature
42h
Then filtration
washing 40 wt eq. water
Reduction:
0,06 wt eq. NaBH4
64 wt eq. water
Room temperature
4h
Then filtration and
washing 40 wt eq. water
Sheet forming:
Formulation: 100%
Modified Pulp II
250 g/m2
Thermoforming:
Thermoplastic paper is
heated to 80°C and
then formed
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THE TRAY
► Cellulose ring opening
BASE PAPER STRATEGIES
oxidation reduction
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THE TRAYMODIFIED FIBRE, THERMOFORMABLE
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THE COATING
► Requirements based on existing packaging materials of fresh food
OXYGEN AND WATER VAPOUR BARRIER
Peelman et al. (2014). Innovative Food Science and Emerging Technologies 26, 319-329
ProductConventional
packaging
Bio-based
packagingG/P ratio
Shelf life
(@4°C)MAP
Rumpsteak PP tray +
PET/CPP top film
PLA tray +
Natureflex
N913/PLA top film
0.3 – 0.4 8 days 60-65% O2
20-25% CO2
rest N2
Ham sausage APET/LDPE tray
+ PET/EVOH/PE
top film
PLA tray +
Natureflex
N913/PLA top film
0.56 29 days 20-40% CO2
rest N2
Filet de saxe PET/EVOH/PE
film
Natureflex
N931/N913
0.925 37 days 40-70% CO2
90% of pre-packaged fresh meat in self-service sector is MAP
©Pack4Food, 2017
THE COATING
► Requirements based on existing packaging materials of fresh food
OXYGEN AND WATER VAPOUR BARRIER
Tray OTR cm³/m²/d WVTR g/m²/d Thickness
PP 140-210 0.16-0.6 300-500 µm
PET/PE 20.6 4.0 200-400 (50)µm
PLA 46.8 3.8 200-300 µm
Foil OTR cm³/m²/d WVTR g/m²/d Thickness
PET/EVOH/PE <8.0 <3.5 12+40 µm
PET/CPP 3.0 3.0 12+50 µm
Cellulose/PLA 11 11.2 60 µm
Massey, L. K. 2013. Permeability Properties of Plastics and Elastomers, 2nd ed., PDL
Peelman et al., Innovative Food Science and Emerging Technologies 26 (2014) 319-329
©Pack4Food, 2017
THE COATING
► Barrier coating properties
OXYGEN AND WATER VAPOUR BARRIER
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THE COATING
► Development of antimicrobial coating formulation
► Concept
ANTIMICROBIAL ACTIVITY
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THE COATING
► Antimicrobial compounds
► Ɛ-polylysine
► Broad spectrum = fungi, G+ and G- bacteria, temp. stable, low dosage (ppm), pH 5-9, cold
water soluble, FDA approved, excellent film-forming properties, high quality coatings,
available on the market
► Chitosan
► Antibacterial, available on market
► Novasol DS12, DS44 & DC44
► Benzoic/sorbic acid solibilisates
► Novasol PSP
► Plant extracts, active toward G+ & G- bacteria & fungi, water and fat soluble
► Intended for use as protective coating
ANTIMICROBIAL ACTIVITY
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THE COATING
► Biopolimeric matrices
► Low viscosity for spray coating is key
► Methylcellulose (Methocel K99FG, Dow Chemicals Company)
► Methyl hydroxypropyl cellulose (Dow Chemicals Company)
► Carboxymethylcellulose (Walocel CRT15000PPA, Dow Chemicals Company)
► Aqueous carnauba wax (Aquacer 2560, BYK Additives and instruments)
► Chitosan (ChitoClear43010, Primex)
ANTIMICROBIAL ACTIVITY
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THE COATING
► Development of antimicrobial coating formulation
► Evaluation
ANTIMICROBIAL ACTIVITY
©Pack4Food, 2017
THE COATING
► BARRIER COATINGS
ANTIMICROBIAL ACTIVITY
NeocrylA-2092 -referenc
es
NeocrylA-2092 +2% PSP(fresh)
NeocrylA-2092 +
2%Polylisyn
e
Eurocryl2080 -
references
Eurocryl2080+
PSP(Fresh)
Eurocryl2080+
2%Polylisyn
e
EcroprintRA112 -referenc
es
EcroprintRA112 +2% PSP(fresh)
EcroprintRA112 +
2%Polylisyn
e
Ukaphob5100 -
references
Ukaphob5100 +2% PSP(fresh)
Ukaphob5100 +
2%Polylisyn
e
Topscreen 250 -
references
Topscreen 250 +2% PSP(Fresh)
Topscreen 250 +
2%Polylisyn
e
S.aureus 3,91E+06 2,84E+06 2,50E+01 2,59E+06 1,08E+00 1,08E+00 4,63E+06 8,33E+00 1,92E+02 3,56E+06 1,38E+04 6,90E+03 3,21E+06 3,67E+06 5,00E+01
E.coli 2,38E+07 6,75E+06 1,67E+01 2,84E+07 1,18E+07 1,25E+00 3,90E+07 3,00E+02 2,00E+02 4,85E+07 1,66E+07 2,38E+06 7,85E+07 4,34E+07 7,80E+05
1,00E+00
1,00E+01
1,00E+02
1,00E+03
1,00E+04
1,00E+05
1,00E+06
1,00E+07
1,00E+08
1,00E+09
► BARRIER COATINGS
©Pack4Food, 2017
Modified fibre, thermoformable
ACTIPOLYCOMBINING DIFFERENT STRATEGIES WITHIN FOOD PACKAGING INNOVATION
Coating: oxygen and water vapour barrier: Ecroprint RA112
• Good water and gas barrier
• Has minimal effect on antimicrobial activity of ε-polylysine
Coating: antimicrobial activity
• Methocel = methylcellulose is a good matrix
• - polylysine (2-5%): resistant to 120C
Topfoil: antimicrobial activity
©Pack4Food, 2017
THE TOP FOIL
► Tested Films
► PLA (polylactic acid)
► PBS (polybutylene succinate)
► PBAT Ecoflex (polybutylene adipate-co-terephtalate)
► Ecovio (Ecoflex/PLA blend)
► Tested Antimicrobials
► ZnO
► -polylysine
► Hop extract
ANTIMICROBIAL ACTIVITY
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THE TOP FOIL
► Requirements based on existing packaging materials of fresh food
Bio-film Thickness [µm]OTR [mlO2/m².d.bar] (23°C,
75% RH, 21% O2)
WVTR [g/m².d.bar]
(23°C, 85-100% RH)
Starch/cellophane 50.7 ± 1.0 2.7 ± 0.1 6.4 ± 0.2
Bio-PE/cellophane 65.4 ± 0.3 2.0 ± 0.1 0.2 ± 0.0
Cellophane/PLA 45.7 ± 0.1 2.6 ± 0.1 <0.1
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THE TOP FOIL
► Synthesis of ZnO-Ag thin film by magnetron sputtering
ANTIMICROBIAL ACTIVITY
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ACTIPOLYSTATUS
Modified fibre, thermoformable
Coating: oxygen and water vapour barrier
Coating: antimicrobial activity
Topfoil: antimicrobial activity
Material assessment and shelf-life studies
Compostability
Safety assessment
LCA
©Pack4Food, 2017
STATUS
► Beef stew packaged under high oxygen atmosphere
► Sugarcane tray (as simulant of cellulose tray) + Ecroprint + Methocell + Polylysine
► Only 17 sheets of cellulose tray could be produced; optimization steps further needed
► Sugarcane tray (bagasse): biobased and compostable (supplied by Be_NaturaL)
► Cellulose/bio-PE film (only performance of the tray towards food is tested)
► Supplied by Be_NaturaL
► Reference: PP-tray
SHELF-LIFE STUDIES RUNNING
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STATUS
► Testing based on EN 13432
COMPOSTABILITY TESTS RUNNING
Co
ated
tray
s
After two weeks After eight weeks After twelve weeks
Not available yet
©Pack4Food, 2017
ACKNOWLEDGEMENTSPROJECT PARTNERS
Papiertechnische Stiftung (coordinator)
www.ptspaper.com
CELABOR
www.celabor.be
The Association West Pomerian
Cluster “Green Chemistry”
www.zielonachemia.eu
MateriaNova
www.materianova.be
Pack4Food VZW
www.pack4food.be
Sirris
www.sirris.be
The West Pomeranian University
of Technology, Szczecin
www.zut.edu.pl
Leibniz Institute for Agricultural
Engineering
www.atb-potsdam.de
©Pack4Food, 2017
ACKNOWLEDGEMENTS
► All participating companies across Europe for their input, samples,…
► All involved national agencies for co-funding
► The CORNET-network
©Pack4Food, 2017
THANK YOU FOR YOUR ATTENTION
Pack4Food vzwCoupure Links 653
9000 GentBelgië
Tel: +32 (0)9 264 99 30 [email protected]
Pack4Food helps companies to improve
food packaging.
We bring together companies and research
institutes to achieve large and small
improvements in the packaging chain.
We initiate and coordinate research, build
a network and offer training and advice.
See you at booth KZ03!
