Towards innovative packaging materials and technologies Center of Bioimmobilisation

and Innovative Packaging Materials CBIMO

Center of Bioimmobilisation and Innovative Packaging Materials

Faculty of Food Sciences and Fisheries

Szczecin, 24-25 October, 2011

The West Pomeranian University of Technology officially was created on 1 January 2009. Bringing a new university into existence by joining two universities (Agricultural Academy in Szczecin and Szczecin University of Technology), besides enriching its teaching programme with new fields of study and specializations, creates a possibility of further, faster progress of new technologies in technical and natural sciences. The West Pomeranian University of Technology (WPUT) has a chance to make use of an effect of synergy which originated from joining two well-known universities. Around 13 000 full-time and extramural students study in numerous facilities under the tutelage of over 1 100 academic teachers (including almost 280 professors and assistant professors). There are ten faculties at WPUT specializing in 44 fields of study: Faculty of Biotechnology and Animal Husbandry Faculty of Civil Engineering and Architecture Faculty of Economics Faculty of Electrical Engineering Faculty of Computer Science and Information Technology Faculty of Mechanical Engineering and Mechatronics Faculty of Environmental Engineering and Agriculture Faculty of Food Sciences and Fisheries Faculty of Maritime Technology Faculty of Chemical Engineering

New fields are constantly created as the answer to changing economic conditions and needs of the labour market.. The creation of the West Pomeranian University of Technology consolidated research teams dealing with: engineering, environmental protection, renewable energy, bio- and nanotechnologies, polymers, economics and industry and agriculture technologies. WPUT has powers to confer the PhD degree in 17 specializations and the degree of assistant professor in 9 fields.

FOOD TECHNOLOGY 1. Department of Food Technology 2. Department of Meat Technology 3. Department of Dairy Technology and Food Storage 4. Department of Applied Microbiology and Biotechnology 5. Department of Food Process Engineering 6. Department of Physiology of Human Nutrition 7. Department of Fundamentals of Human Nutrition 8. Department of Commodity Science and Food Quality Assessment 9. Department of Toxicology 10. Center of Bioimmobilisation and Innovative Packaging Materials

FISHERIES 11. Department of Anatomy, Hydrobiology and Fish Biotechnology, 12. Department of Hydrosphere Ecology and Environmental Protection 13. Department of Water Sozology 14. Department of Fish Systematics 15. Department of Fisheries Technology 16. Department of Sustainable Development of Aquaculture 17. Department of Aquaculture 18. Department of Physiology and Pathology of Fish

Faculty of Food Sciences and Fisheries

Numbers: Established: 1951 Students: 962 Academic Teachers: 98

ul. Klemensa Janickiego 35, 71-270 Szczecin www.cbimo.zut.edu.pl, e-mial: cbimo@zut.edu.pl

CBIMO structure and international collaboration

Najwa!niejsze kierunki aktywno"ci Centrum CBIMO Scientific activities of CBIMO

nano- micro- macro-

1 mm

Immobilisation of living cells and microorganisms

Immobilisation of bioactive

substances

Biodegradable packaging materials

Novel Packaging methods and technologies

Biommobilisation

CBIMO

Main research topics and technologies

Innovative Packaging Materials

Innovative packaging of all sizes:

Main research areas: -  biodegradable food-packaging materials (plastics and cellulose based) -  properties of food-packaging materials (mechanical, gas-barrier, food contact ) -  immobilisation and microencapsulation of bioactive substances and food-additives,

CBIMO expertise: -  innovative biodegradable food packaging materials (cellulose, starch, PLA and

other biopolymer based) -  characterization of food packaging materials (mechanical properties, oxygen,

water vapor transmission rate and biodegradability) -  food and packaging interactions (long shelf-life studies - changes of texture and

chemical composition during storage, antimicrobial surfaces), -  various packaging techniques (MAP, bioactive packaging etc.) -  novel microencapsulation systems based on natural and modified polymers, -  immobilization of bioactive substances and living cells (DNA, enzymes,

animal&plant cells and bacteria, food-bioactive substances, taste and smell masking),

-  biotechnological applications of immobilized microorganisms in various processes,

Center of Bioimmobilisation and Innovative Packaging Materials Director: Prof. Artur Bartkowiak, e-mail: artur.bartkowiak@zut.edu.pl

Najwa!niejsze kierunki aktywno"ci Centrum CBIMO Scientific projects of CBIMO (October 2011) Projects funded under EU Funds: 1. POIG.01.03.01-32-193/09-00„Health promoting food additives containing immobilized unsaturated fatty acids and probiotic bacteria obtained by spray drying” (2010-2013) 2. POIG.01.01.02-00-074/09 "Biotechnological conversion of glycerol to polyols and dicarboxylic acids" (2010-2014) 3. POIG.04.01.00-14-084/09 "The application of polymeric materials on the surface layers of cardboard as a barrier to water vapor, water and fat " (2010-2011) 4. FP7-NMP-2007-SMALL - 7PR UE FLEXPAKRENEW "Design and development of an innovative ecoefficent low-substrate flexible paper packaging from renewable resources to replace petroleum based barrier films" (2008-2011) 5. COST FPS1003 Action "Impact of renewable materials in packaging for sustainability - development of renewable fibre and bio-based materials for new packaging applications" (2010-2013)

Projects funded by Polish Ministry of Science and Higher Education: 1. N305 1517 33 "Development a green method of surface water treatment from petroleum compounds using immobilized, environmental bacterial strains" (2007-2010) 2. N312 199135 "The application of bioimmobilisation process in technology for obtaining cyclodextrins from potato starch” (2008-2010) 3. N312 427937 „The processes of nano- emulsion and microencapsulation as a method of immobilization of functional food additives" (2009-2011) 4. N312 439937 „Continuous production of selelcted bacteriocins using the waste products of food industry" 2009-2011) 5. N312 334439 "Innovative methods for obtaining a composite film of poly(lactic acid) for food packaging with improved barrier properties" (2010-2012) 6. N508 592139 "Hydrofobisation of starch using fatty acids in the direction of receipt of the substrates for modifying cellulose packaging for food" (2010-2012

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Biodegradable packaging materials – CBIMO in EU projects surface modification and multilayer cellulose based materials

Paper board of grammage 200-300 g/m2 Paper of grammage 60-90 g/m2

35 partners from 13 EU countries – (2004-2008) 10 partners from 6 EU countries – (2008-2011)

classical ideal

CBIMO new concept

water vapor heat

Backed foams based on mixture of waste materials containing proteins, cellulose and starch as inner layer of food packages S. Lisiecki, A. Bartkowiak (e-mail: slisiecki@zut.edu.pl)

New concept of backed foams based on mixture of pure proteins, cellulose and starch + other substances – PL patent application (ZUT, 2009)

Projekty pt. „Transfer oraz podnoszenie stanu wiedzy w zakresie bada! materia"ów opakowaniowych i opakowa! do ryb i przetworów rybnych“ oraz „Proekologiczne opakowania celulozowe do transportu i sprzeda#y $wie#ych ryb oraz gotowych produktów rybnych” wspó"finansowane przez Uni% Europejsk& z Instrumentu Finansowego Wspierania Rybo"ówstwa w ramach Sektorowego Programu Operacyjnego Rybo"ówstwo i Przetwórstwo Ryb 2004 – 2006

Biodegradable packagings – collaboration with domestic converters

PLA films and composite packagings Paperboard packagings – inner surface modified with biopolymeric dispersions – grease and water barrier

Inner – coated surface Inner – coated surface

Paperboard tray Container „snack-food” outer part outer part

Boxes with laminated interior

Laminated tray Wrap film

Metalized bag Transparent bag

Biodegradable polymers – advantages and shortcomings

Shortcomings:

- high cost

-  low temperature of flow and high glass transition

-  high durability and low elongation index

-  poor gas barrier properties

-  some other technological problems during converting

Advantages:

- maintain the environmental CO2 constant

- biodegradability

-  possible formation of films and rigid containers

-  good printability

-  high gloss and add esthetic values

-  possible formation of multilayer films

Modification of PLA gas barrier properties Typical methods of film gas barrier modification: 1.  Multilayer films 2.  Surface coating 3.  Additional modifiers - fillers with good barrier properties (natural clays etc.)

PE EVOH PE

PLA biopolymer plast. PLA

High/medium-barrier O2 (CBIMO - 200x better OTR than for PLA)

Synthetic (now)

Biodegradable (now/future)

PLA PA

PA PE

Medium/low-barrier O2

1.  Multilayer films

2. Contionious production of bacteriocine solution using flow bioreactor

This work is supported by Polish Ministry of Science and Higher Education - contract 1517/B/P01/2009/33 (2009-2011)

1. Selection of microorganism and immobilisation systems

E. durans (ENTEROCINE) Lb. d. lactis (LACTICINE) Lc. lactis (NISIN)

REFERENCE STRAIN Bacillus subtilis

Bacteriocins as biosafe alternative for antymicrobial packaging materials K. Sobecka, A. Bartkowiak (e-mail: ksobecka@zut.edu.pl)

Surface coating containing bacteriocines

3. Bioactive coatings of food packaging materials

Coated paper

Uncoated paper

Base paper or paperboard

Modern infrastructure From July 2011 we are located in the new building of Center of Bioimmobilisation and Innovative Packaging Materials (more than 2000 m2)

created 2008 (2 UNIV + 2 IND) Large infrastructure project 2009-2011

(EU SF 2007-2013) 4.5 mEuro

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20 mm Twin Screw Extruder with Water Bath and Pelletizer

Chill Roll - Attachment type LCR 300-HD (for casting of 1-5 layer films or lamination of film/paper materials)

Film blowing LF400-CO-EX with 5-layers co-ex film blowing pancake type of die

and with central control panel

Zwick/Roell Z 2.5 - Universal testing machine (Zwick/Roell, G)

HSE-3 HEAT SEALER (RDM, UK) 4500SL - leakage and seal strength (Lippke, D)

Thermo-Mechanical and packaging process characterization

DMA Q800 – TA Instruments (USA) UV 5000-EC – DYMAX (USA)

2x OX-TRAN 2/20 ML i 2/10 Permatran 3/33/20 ML

Modified atmosphere O2, CO2, N2 – MAP packaging and monitoring + PackCheck (Moccon, USA)

MAP food packaging / gas barrier properties

Climate chambers for conditioning BINDER KBF115 (D)

Lab Spray Dryer BUCHI B-290 ADVANCED

Var J1 (Nisco, CH) – fluidized capsule generator

Var V1 (Nisco, CH) – electrostatic capsule generator

Mastersizer 2000 – size analyzer Malvern (UK)

Various microencapsulation techniques

Var D Generation II (Nisco, CH) – electromagnetically driven generator

Pilot Spray Dryer Anhydro MicraSpray 150

Chemical modification of biopolymers, purification and characterization including emulsion based methods

US generators (400 and 1000W) with flow cells - Hielscher (D)

IKA® magic LAB®

Ultrafiltration systems Labscale TFF "Pelicon TFF”

HPLC-GPC "Smartline” (Knauer, G)

Chemical characterization by various spectroscopic method

FTIR spectrometer + microscope Spectrum 100 + Spectrum Spotlight 300 PerkinElmer (USA)

Raman spectrometer – chemical scan of surfaces RamanStation 400 – PerkinElmer (USA)

CBIMO as a partner: interdisciplinary + creative + operative + …………

Modern infrastructure

created 2008 (2 UNIV + 2 IND) Large infrastructure project 2009-2011

(EU SF 2007-2013) 4.5 mEuro

CBiIMO

IP – 6FP SUSTAINPACK

COST FP1003

SP – 7FP FLEXPAKRENEW

Applied oriented projects Interdisciplinary group

Expertise in novel techniques and methods -  innovative packaging – biodegradable packaging materials, bioactive packaging, MAP food packaging / gas barrier properties

- biopolymers – biosynthesis, chemical modification, purification and application,

-  characterization of materials (surface and interfacial, emulsion, mechanical, biodegradation);

-  various microencapsulation techniques – food additives, bioprocessing including food waste conversion)

Center of Bioimmobilisation and Innovative Packaging Materials CBIMO Faculty of Food Sciences and Fisheries

West Pomeranian University of Technology, Szczecin

ul. Klemensa Janickiego 35 71-270 Szczecin, Poland

ph. (48)91+4496592 ph/fax. (48)91+4496590

http://www.cbimo.zut.edu.pl