Active packages with garlic extracts: New opportunities for the industry

Ana Pascual Lizaga

AIMPLAS

apascual@aimplas.es

Contact with @aimplas

Index ◦ Brief summary of experience in active packaging

(AIMPLAS & DOMCA)

◦ PLA4FOOD project

◦ NATENVAS Project

◦ Conclusions

BRIEF SUMMARY OF EXPERIENCE IN ACTIVE PACKAGING:

AIMPLAS & DOMCA

AIMPLAS

- Plastics Technology Centre - Located in Valencia (Spain) - Focused in plastic research in the whole value chain

- Solutions to companies of the plastics industry: R&D projects, analysis and testing, technical assistance, competitive intelligence and training.

- AIMPLAS has developed a number of projects in active packaging in last years, with the objective to achieve mainly antimicrobial or antioxidant properties.

AIMPLAS

• Some active substances tested: - Oxygen Scavengers - Sepiolites - Natural extracts: Garlic, onion, grape, tomato, orange, mustard, clove - Essential oils: Cinnamon, oregan, thyme, garlic - Inorganic substances: Zinc oxides, silver-based compounds - Tocopherol, hydroxytysorol - Synthetic peptides

AIMPLAS

• Some types of packaging tested: - Films and sheets - Bottles - Trays

• Some polymeric substrates tested: - PLA, PP, PE, HIPS, PET - Multilayer coextruded structures: PA/PE, PP/EVOH/PP.

AIMPLAS

• Some types of foodstuff tested:

- Fruits: Fresh-cut (avocado, watermelon, apple, strawberries) - Vegetables: Lettuce, tomato, beet, artichoke, - Meat: Ham, pork - Dairy: Cheese (semi-cured, grated, fresh) - Fish: Swordfish, salmon, smoked salmon - Other: Sliced bread, olive oil.

AIMPLAS

- Methods of incorporation of active substances to plastic substrates:

Coating: Bath or dispersion

Incorporation to plastic matrix: Compound

FOOD

FOOD

DOMCA

- Spanish company specialized in the development and application of natural functional additives in the food industry.

- Tailor-made solutions developed in accordance with specific customer.

- Multidisciplinary team, trained in various areas of biotechnology, microbiology, organic chemistry and engineering.

DOMCA

- DOMCA has developed a number of natural antioxidants, antimicrobials and antifungals which present alternatives to commercially present synthetic products

Natural

products

with biological

attributes

Plants Micro-

organisms

Natural

preservatives for

the food industry Natural

antioxidants

Selective products

against food borne

pathogens

Edible coatings

Meat and dairy

products, fruits and

vegetables

SUMMARY OF EXPERIENCE IN ACTIVE PACKAGING: AIMPLAS & DOMCA

KNOW-HOW

- Properties of plastic

substrates

- Incorporation of

substances to plastic

matrices

- Intensive experience in

plastic manufacturing

processes

KNOW-HOW

- Properties of active

ingredients.

- Customized

development of active

ingredients and

extracts from natural

resources

DOMCA has developed new natural preservatives and antioxidants and their applications in the food industry.

PROALLIUM: Based on extracts from the plant family Alliaceae (garlic, onion, leek…). The active principles are organosulfur compounds with extremely high antibacterial and antifungal properties. Right now they are applied in:

– Sauces and convenience products

– Post-Harvest-Treatment

– Environmental Control of storage or food-processing facilities

SUMMARY OF EXPERIENCE IN ACTIVE PACKAGING: AIMPLAS & DOMCA

PLASTIC PROCESSING PROCEDURE

Active natural

additive Polymer

COMPOUNDING

PROCESS

Compound Masterbatch Polymer

MIXING

EXTRUSION /

INJECTION

SUMMARY OF EXPERIENCE IN ACTIVE PACKAGING: AIMPLAS & DOMCA

1. Typical low thermal resistance of natural additives.

2. Type of plastic material used for manufacturing packaging It will define

processing temperature.

3. Physical form of active additive Liquid or powder? Liquid form implies

lower shear.

4. Concentration of additive to be incorporated More % of additive in powder form increases viscosity More shear.

5. Correct dispersion of additives in polymeric matrices

6. Possible effects of additive in final packaging, mainly related to colour and transparency.

KEY POINTS FOR INCORPORATION OF NATURAL EXTRACTS TO PLASTIC

SUMMARY OF EXPERIENCE IN ACTIVE PACKAGING: AIMPLAS & DOMCA

AIMPLAS

PLA4FOOD

Active multilayer packaging based on improved performance PLA

formulations for 4th range food products

NATENVAS

Development of active packaging with antifungal properties for

packaging dairy and fresh-cut products

PLA4FOOD Project

Active multilayer packaging based on improved

performance PLA formulations for 4th range

food products

18

Financing: COMMISSION OF THE EUROPEAN COMMUNITIES FP7

Type: Research for SMEs: 10 partners (3 R&D centers + 6 SMEs + 1

Large company)

PLA4FOOD

Development of innovative active and biodegradable packaging to increase the shelf life of fresh-cut food products

- The new product will degrade in composting conditions (EN 13432).

ADDITIONAL OBJECTIVES

- To improve PLA flexibility, to enhance water barrier properties and processability using different additives.

- To achieve the best cost/benefit ratio and optimal performance of products using co-extrusion techniques. - The new package will provide protection against environmental agents and will improve quality, shelf-life, microbiological safety and nutritional values.

PLA4FOOD

20

PLA4FOOD

21

PLA4FOOD

22

PLA4FOOD

ACTIVE ADDITIVES - ANTIMICROBIALS

CLOVE

These antimicrobial compounds increased inhibitory effects against spoilage and pathogenic bacteria by maintaining effective concentrations of the active compounds on the food surfaces.

GARLIC MUSTARD

PLA4FOOD

ANTIMICROBIAL ACTIVITY

- Results of washing lettuce leaves with antimicrobials

The antimicrobials have excellent anti microbial activity in washing

■ Total Aerobic

bacteria

■ Lactic acid

bacteria

□ Coliforms

PLA4FOOD

ENCAPSULATION PROCESS: WHY?

To control the release kinetics of additives into a food product.

To protect natural additives from high process temperatures or adverse environmental conditions (light, oxygen, pH).

To overcome undesirable flavors from natural additives.

To reduce the volatility and reactivity of natural additives.

PLA4FOOD

CAPSULE FORMULATION

Microencapsulation effectiveness.

Thermal stability at process temp.

Release of the active additives.

Activity of the antimicrobials.

Capsule size, around 5μm (lower than film thickness)

Zeolite

microcapsules-

PLA4FOOD

Preparation of PLA compounds

COMPOUNDING OF PLA

PLA4FOOD

A- PLA + Plasticiser +

water scavenger

C- PLA + Plasticiser +

active additive

B- PLA + Plasticiser

CAST SHEET CO-EXTRUSION

PLA4FOOD

CAST CO-EXTRUSION PROCESS

PLA4FOOD

THERMOFORMING PROCESS

PLA4FOOD

Heating

Vacuum

Heating

Vacuum

BLOWN-FILM

CO-EXTRUSION

PROCESS

PLA4FOOD

VFFS

PROCESS

PLA4FOOD

PACKAGE PROPERTIES

PTSO Release to packaged food

PLA4FOOD

PACKAGE PROPERTIES

Days 0 5 10 15 20 Control tray 0 0 1 2 8 Active package tray 0 0 0 0 0

Nº of tomatoes infected with the mold Rhizopus per tray

PLA4FOOD

PACKAGE PROPERTIES

PLA4FOOD

• Active packaging did not show mold or bacteria growth while in the control tray, molds increased along the time. The new package effectively enlarge the shelf life of the fresh cut products.

• Comparison between multilayer structure developed and PLA commercial grade:

• Increase in flexibility (tensile strength reduced about 50 %,

elongation increased about 200 %) • Decrease in WVTR (6 %) • Other properties are maintained: OTR, haze, tear strength

• The package is compliant to food contact plastic legislation (Regulation 10/2011)

• New package developed is compostable according to standards EN 13432 and ISO 17088.

PACKAGE PROPERTIES

PLA4FOOD

NATENVAS Project

Active packaging with antifungal and

antioxidant effects for the packaging of dairy

and fresh-cut products.

38

Financing: CDTI (Spanish Centre for the Development of Industrial

Technology)

Partners: 8 (3 RTD centers + 5 companies)

NATENVAS

OBJECTIVE

Development of active packaging obtained by film extrusion,

incorporating natural additives intended to enlarge shelf life of fresh

fruits and dairy products (strawberries and fresh cheese).

NATENVAS

WP 1. Study and selection of natural additives with active properties. In vivo activity testing. Packaging requirements.

WP 2. Encapsulation and stabilization studies for natural additives. Study of compatibility of additives-polymers in processing.

WP 3. Study of kinetics of migration of active additives in monolayer films and sheets.

WP 4. Development of active packages compliant with mechanical and migration requirements for each case study.

W

P 6

. Eco

nom

ical, leggis

lative a

nd

environm

enta

l st

udie

s.

Dis

sem

ination o

f re

sults.

WP 5. Validation of developed active packages. Interaction food-package.

NATENVAS

NATENVAS

SELECTION OF ADDITIVES

• Determination of typical alterations in fresh cheese and strawberries

(microbiology)

• Usual shelf-life of selected foods:

STRAWBERRIES: 7 days

• Preliminary selection of natural additives by means of effectiveness studies on foods. Proposal of dosis.

Alliaceae extract DMC1

• 500-1000 ppm in package

NATENVAS

PACKAGE REQUIREMENTS FOR STRAWBERRIES

Main alterations in food Produced by microorganisms:

- Filamentous moulds Physico-chemical alterations: - Oxidation

Required protection Antifungal/Antioxidant

Suitable natural additives - Garlic extract: Broad spectrum and good antioxidant action: DMC 1

- Antimicrobial metabolite obtained from lactic fermentation: Peptide DMC 3

Preservation of packaged food Refrigeration

NATENVAS

PACKAGE REQUIREMENTS FOR STRAWBERRIES

Packaging method Filling tray + Horizontal Flow Wrapper (HFFS)

Type of package Semirigid tray + perforated PE Flow-pack

Packaging materials Tray: PP Flow-pack: perforated PE

Active layer material PE layer 35-60 microns (Film)

NATENVAS

ENCAPSULATION

% W

eig

ht

los

s

Temperature (ºC)

• Studies of thermal resistance of extracts with different encapsulation systems

NATENVAS

PROCESSING TRIALS

• Mixtures LDPE+ Encapsulated extracts in Brabender mixer (1 % w/w)

NATENVAS

PROCESSING TRIALS

• Obtention of PE sheets with 1 % garlic extract

A sheet with good transparency and dispersion of additive was achieved (hot plates compression moulding)

NATENVAS

PROCESSING TRIALS

• Compounding pilot plant trials

Extract Concentration (ppm)

Concentration (% w/w)

Observations

Garlic 20.000 2 Compound will be diluted to 50 % in film manufacturing (Active concentration in films: 1 % (w/w))

NATENVAS

PROCESSING TRIALS

• Blown-film extrusion pilot plant trials

Obtained films:

• 1 % (w/w) garlic extract

NATENVAS

PROCESSING TRIALS

• Blown-film extrusion industrial scale trials

Used equipment: Industrial extruder.

Obtained films:

• 1 % (w/w) garlic extract

NATENVAS

FILM CHARACTERIZATION

• Optical microscopy (homogeneity evaluation) • Haze, gloss • Tensile properties • Thermosealing performance

• Verification of compliance with Regulation 10/2011

NATENVAS

EFFECTIVITY STUDIES

• Delay in moulds growth compared to control film. • Good antifungal effect

Shelf- life studies:

NATENVAS

EFFECTIVITY STUDIES

Shelf- life studies:

Time (days) Control PE film without

additive PE film + 1% Garlic extract

Percentage of fruit covered with moulds

Time (days)

CONCLUSIONS

CONCLUSIONS

• Effective protection against degradation during processing

has been achieved in garlic extract incorporation to plastic matrices.

• Customizable formulation of extracts and stabilization techniques is possible in order to improve properties.

• Specifically for garlic extract, the main handicap to be overtaken are odour effects that can lead to organoleptic changes in some packaged foods.

Thank you

Contact us:

www.aimplas.es

info@aimplas.es

Tel. 96 136 60 40

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Twitter: @aimplas