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

©Pack4Food, 2017

PACK4FOODMANY INDUSTRIAL STAKEHOLDERS IN FOOD PACKAGING

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PACK4FOODTOPICS WITHIN PACK4FOOD

©Pack4Food, 2017

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)

©Pack4Food, 2017

• 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

©Pack4Food, 2017

THE TRAY

► Cellulose ring opening

BASE PAPER STRATEGIES

oxidation reduction

©Pack4Food, 2017

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

©Pack4Food, 2017

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

©Pack4Food, 2017

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

©Pack4Food, 2017

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

©Pack4Food, 2017

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

©Pack4Food, 2017

THE TOP FOIL

► Synthesis of ZnO-Ag thin film by magnetron sputtering

ANTIMICROBIAL ACTIVITY

©Pack4Food, 2017

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

©Pack4Food, 2017

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 peter.ragaert@Pack4Food.be

simbarashe.samapundo@Pack4Food.bewww.Pack4Food.be

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!