Sunday, 14 June 2015

Packaging of Convenience foods



What are convenience foods?

Convenience foods are used to shorten the time of meal preparation at home.  Some foods can be eaten immediately or after adding water, heating or thawing etc.

Convenience food, or tertiary processed food, is commercially prepared food designed for ease of consumption. Although restaurant meals meet this definition, the term is seldom applied to them. Convenience foods include prepared foods such as ready-to-eat foods, frozen foods such as TV dinners, shelf-stable products and prepared mixes such as cake mix.

Bread, cheese, salted food and other prepared foods have been sold for thousands of years. Other kinds were developed with improvements in food technology. Types of convenience foods can vary by country and geographic region. Some convenience foods have received criticism due to concerns about nutritional content and how its packaging may increase solid waste in landfills. Initiatives have occurred to reduce the unhealthy aspects of commercially produced food and fight childhood obesity.

Convenience food is commercially prepared for ease of consumption. Products designated as convenience food are often sold as hot, ready-to-eat dishes; as room-temperature, shelf-stable products; or as refrigerated or frozen food products that require minimal preparation (typically just heating) Convenience foods have also been described as foods that have been created to "make them more appealing to the consumer." Convenience foods and fast foods are similar, because the development of both occurred to save time in the preparation of food. Both typically cost more money and less time compared to home cooking from scratch.

Types of convenience foods:

Convenience foods can include products such as
Ø  Candy.
Ø  Beverages such as soft drinks, juices and milk.
Ø  Fast food.
Ø  Nuts, fruits and vegetables in fresh or preserved states.
Ø  Processed meats and cheeses.
Ø  Canned products such as soups and pasta dishes.
Ø  Frozen foods.
Ø  Chips and cookies.
Ø  Dehydrated foods etc.,





Candy Packaging:

Prior to the 1900s, candy was commonly sold unwrapped from carts in the street, where it was exposed to dirt and insects. By 1914 there were some machines to wrap gum and stick candies, but this was not the common practice. After the polio outbreak in 1916, unwrapped candies garnered widespread censure because of the dirt and germs. At the time, only upscale candy stores used glass jars. With advancements in technology wax paper was adopted, and foil and cellophane were imported from France by DuPont in 1925. Necco packagers were one of the first companies to package without human touch.
Packaging preserves aroma and flavor and eases shipping and dispensation. Wax paper seals against air, moisture, dust, and germs, while cellophane is valued by packagers for its transparency and resistance to grease, odors and moisture. In addition, it is often resealable. Polyethylene is another form of film sealed with heat, and this material is often used to make bags in bulk packaging. Saran wraps are also common. Aluminum foils wrap chocolate bars and prevent transfer of water vapor, while being lightweight, non-toxic and odor proof. Vegetable parchment lines boxes of high-quality confections like gourmet chocolates. Cardboard cartons are less common, though they offer many options concerning thickness and movement of water and oil.
Packages are often sealed with a starch-based adhesive derived from tapioca, potato, wheat, sago, or sweet potato. Occasionally, glues are made from the bones and skin of cattle and hogs for a stronger and more flexible product, but this is not as common because of the expense.

Beverages Packaging:

The packaging requirements for all types of beverages are:
• Absolutely leak-proof and prevent contamination
• Protect the contents against chemical deterioration
• No pick up of external flavours
• Be hygienic and safe
• Retain carbonation in the case of carbonated beverages
• Economical, easy to use and dispose
• Good aesthetic appearance

Beverages are classified into Alcoholic and Non-Alcoholic beverages.

Packaging Materials for Non-Alcoholic Beverages:

Key parameters to be considered when selecting a packaging system are:
• Process
• Distribution, shelf-life requirements, legislation
• Product composition and quality as produced and at full shelf-life
• Product protection required during storage, distribution and retail sale
• Pack size, printing options, display etc.
• Packing system concept, automation options, ability to integrate with existing and/or future systems
• Consumer appeal, image of product and packing

The different packaging materials used are:
• Glass Containers: The use of glass bottles for the packaging of fruit beverages was widespread although the hot-fill/hold/cool process had to be applied with care to avoid breakage of the containers. Glass is still the preferred packaging medium for high quality fruit beverages. However, over recent years, an increasing proportion is being packed aseptically, into cartons.

The improvements that have occurred in glass bottle packaging are:

• Light weight

• Surface coating to increase abrasion resistance

• Use of wide mouth containers fitted with easy-open-caps.

• Metal Containers: Tinplate cans made of low carbon mild steel of 99.75% purity, coated with tin with easy open ends are used. These tinplate containers are either 3 piece or 2 piece containers. They are lacquered internally to prevent corrosion.

• Plastic Containers: Fruit juices contain organic substances, which are sensitive to bacterial contamination. Packaging of such products is done through hot filling, to achieve extended shelf-life, PET bottles are usually used for hot filling applications. Special features are added to the containers through design and manufacturing process. The package is heat-set in order to improve the temperature resistance of the containers. PET resins with a higher Tg (glass transition) temperature and/or a faster rate of crystallisation are used. Normally hot-filled PET bottles are designed about 1.5 times heavier than cold-filled bottles. Reinforcing ribs and grooves are also provided along the circumference and base of the bottle. After filling and capping operations, the liquid continues to cool, which results in formation of vacuum. The bottle wall can deform under the influence of vacuum, and this problem is overcome by providing vacuum panels in the container side wall. Generally, lower levels of PET co-polymer are preferred and intrinsic viscosities of about 80 are acceptable. Flexible plastic packages offer economic savings over conventional glass and metal containers but they are permeable to oxygen. Therefore, it is critical to select a flexible package that minimizes the permeability to oxygen. Flexible laminated pouches like metalized polyester/polyester/ polyethylene are used for hot fill packaging method without retorting for acidic fruit juices. These are used either as flat pouches or stand-up pouches. However, the shelf-life of the product in these pouches is limited.

• Aseptic Packages: Ready to serve fruit beverages and fruit pulps / concentrates, packed in aseptic packages provide excellent protection for fruit juices / pulps. These aseptic packages are made by combining thermoplastic with paperboard and aluminium foil. Their multi-layered construction enables the carton to protect the contents from various factors responsible for spoilage. The aluminium foil layer is a strong barrier for O2 and light. The inner plastic layer made of polyethylene makes it possible to seal through the liquid. The outer paper layer provides stiffness making it possible for the cartons in a brick shape, thus, enabling maximum utilization of available storage and transportation space. Excellent graphics are possible leading to good display and shelf appeal and also providing information regarding the product. The aseptic process makes the product bacteria-free before being packaged. To provide convenient access to the contents, beverage cartons offer a variety of opening devices. A familiar opening feature of the pack is the drinking straw, which is attached to the package. Some recent trends are pull-tab opening, which can be readily detached from a pre-punched hole without compromising the package integrity. Also, custom designed caps and closures can be incorporated on beverage cartons for easier pouring and for enhancing the brand image. Also, the beverage cartons are now available in new prisma shape, which is comfortable to hold, and the unique shape offers maximum display effectiveness and high space efficiency. These packs are shelf-stable at room temperature and the shelf-life and nutrient composition of the fruit juice is influenced by the barrier properties of the tetrapak.

• Bag-in-Box System: It consists of a collapsible bag within a rigid container, a filling machine to introduce the liquid product into the bag and a dispenser to draw the product out.

Bag: The outer container can be a box, a crate or a drum. The bag actually consists of two bags. An inner bag contains the liquid and an outer bag provides the barrier properties. Both are heat-sealed at the edges. The tubular spout fitted to the bag aids in filling and dispensing of the product. As little as 3 litres or as much as 1000 litres, can be packed.

The bag is the “life” of the system. The bag itself consists of three components:
i. An inner layer
ii. An outer layer
iii. A spout
The function of the inner layer, the one in contact with the material being packed, is to provide the bag with seal integrity. The seals are to be strong enough to withstand constant mechanical and chemical “pressure” for at least twice the expected shelf-life of the product.
Generally, the inner layer is not designed for barrier unless the product needs extra barrier, which the outer layer cannot provide. Plastic films manufactured from high performance polyethylene, with excellent sealing and puncture properties are usually used as inner layer materials.
The function of the outer layer is to provide the bag with barrier commensurate with the expectation of the shelf-life of the product. In this respect, bag in box scores over other packaging forms, because unlike other packaging materials like jars and cans, the barrier property and hence the cost of this packaging form can be varied. The shelf-life expectations and storage condition play an important part in determining what the barrier requirements of the outer layer needs to be. The standard outside layer is a metalized film laminate, which under standard conditions has an OTR of 1cc/m2 / 24hrs. The spout and cap assembly are made of injection moulded plastics. The spout is provided with a flange, which is welded to the bag’s inner layer during bag’s manufacture. The spout and cap have two functions. They are used to fill the product in the bag and are also used to dispense the product from the pack. Several spout types are available ranging from a simple bung like configuration to ones, which can only be opened on the filling machine. The caps come with various tamper evident features as well.

Rigid Containers: The purpose of this container, is to hold the bag during storage, transportation and use. As is evident, the bag being made from flexible films, is incapable of being stored and transported by itself. Hence, each bag is individually stored into rigid outer container post filling. For packs of capacity below 50 litres, corrugated fibreboard cartons are generally used as the rigid containers. Beyond that plastics and metal drums are used. For very large bags, 1000 litres, + polygonal (6-8 faces) corrugated fibreboard containers made from 7 to 9 ply are used, though there are other alternatives as well.

Ex) Coffee
While developing packaging system for coffee the following are to be considered:
• Moisture vapour ingress
• Oxygen permeability
• CO2 and Volatile component egress
• Grease resistance
The packaging materials used are tinplate containers, composite containers, glass jars and flexible plastic pouches. The flexible laminates most widely used are 12μ PET / 2μ Al Foil /
70μ LDPE and MET PET / LDPE. Aluminium foil lined plastic pouches are most popular having 59% contribution in terms of volume.

Carbonated Drinks:
Carbonated drinks contain carbonated water, flavour, colour, sweeteners and preservatives.
CO2 gas from pure source is dissolved in water (amount varies with different types of beverages). A variety of ingredients like flavouring agents, colouring agents, preservatives, artificial sweeteners, antioxidants and foaming agents are then added.

Two major deteriorative changes that occur in carbonated drinks are the loss of carbonation and rancidification of essential flavouring oils. The first is largely a function of the effectiveness of the package in providing a barrier to gas permeation, while the latter can be prevented by the use of high quality flavourings and antioxidants, and de-aerating the mix prior to carbonation. Oxidative rancidity is reduced by the effectiveness of the package in providing a barrier to gas permeation.

Hence, the carbonated drink package requires a container that will hold pressure and not contribute off flavours. For many years virtually all carbonated soft drinks were packaged in glass bottles sealed with crown cork. In recent years, non-returnable glass bottles are giving way to refillable bottles. These have a foam plastic protective label of paper/poly or an all plastic shrink sleeve, as a safety measure to prevent flying of glass fragments in case of breakage of these containers. The crown closure has been replaced with a roll-on aluminium screw cap with tamper proof facility. Among the metal containers, the 3-piece tinplate containers have been used since long for the packaging of carbonated beverages. These are being replaced now by 2-piece aluminium cans. These cans retain the integrity of lacquer better than tin cans. Vinyl, epoxy and vinyl organosol coatings are used as lacquers for aluminium cans. Epoxy amine provides good adhesion, colour and flexibility to the can.
Among the plastic containers, PET bottles are the most preferred packaging material for packaging of soft drinks.

Soft drinks have a maximum permissible level of 20ppm for citrus flavoured beverages and
40ppm for cola drinks while the water loss is of the order of 1%. Also, the loss of CO2 through the wall must be allowed for. While increasing thickness will decrease the rate of CO2 permeation, the cost of the bottle, will also increase and so a compromise has to be made. Other problems to be considered in plastic containers are creep and elastic deformation. The polyethylene terephthalate (PET) bottle satisfies most of the requirements for packaging of carbonated soft drinks.

Improved blow moulding techniques and bi-axial stretching have made PET container to be pressurised due to its strength, dimensional stability and precision. Also, they have a glass like appearance, good transparency, lustre, chemical inertness and unbreakability.

The advantages of PET container are:
• Superior packaging to product ratio: PET container being 63% and 47% more energy efficient than glass bottles and aluminium cans respectively.
• PET bottles are 32% more energy efficient than glass bottles during delivery of 1000 gallons of soft drinks.
• Glass bottles and Aluminium-cans generate 230% and 175% times more atmospheric emissions compared to PET.
• PET bottles contribute 68% and 18% less solid waste by weight compared to glass and aluminium containers.
• 100 kg of oil is required to produce 1000 1-litre PET bottles as against 230 kg for 1000 equivalent glass bottles.
• PET bottles help in fuel saving due to their lower weight.

The resins used in PET bottles to pack carbonated drinks are of a very special quality. The PET bottles have to be extremely strong to contain the internal pressure of CO2 without distortion and expansion. This is obtained by using a resin, which has high intrinsic viscosity and lower co-polymer levels. Currently, more than 90% of PET is consumed in food packaging with beverages/drinks forming nearly 80%.


Packaging Materials for Alcoholic Beverages:
Alcoholic drinks originated through the action of yeast cells on sugar containing liquids. Alcoholic drinks are aromatic liquids with a specified alcohol content. Some kinds contain carbon dioxide, others a quantity of sugar. They are either fruit/sap based or grain based. They can either be non-distilled or distilled depending on the volume percentage of alcohol per litre. The border between the two kinds of drink is about 20%. The different types of alcoholic beverages are beer, wine, whiskey, brandy etc.

Non Distilled Alcoholic Beverages:

• Beer (Grain Based): Beer is made from grains and has low alcoholic content around 5% by volume. Barley is the chief grain, but rice and corn are also used. The grains are brewed and fermented and then carbonated with CO2 and flavoured with hops to give a bitter flavour. Owing to its low pH (about 4.0), microbial degradation is not usually a problem with beer, and the use of pasteurization and aseptic cold filtration excludes yeast. However, during storage beer can undergo irreversible changes leading to appearance of haze, development
of off-flavours and increased colour. The oxidation reaction gives beer a “card-board-like” flavour. Flavour loss is also accelerated in the presence of light and certain metal ions. The fermentation process consumes oxygen. Also, brewing reduces the level of oxygen in beer to 40-50 ppb prior to packaging. During the packaging process, atmospheric oxygen enters the package and the level of oxygen contamination reaches 250-500 ppb, which corresponds to 0.1-0.2 ml of oxygen per 335 ml bottle or can. This results in a shelf-life of beer of 80 to 120 days. The oxygen consumption of beer varies with the composition of the beer, its age, presence of reducing agents, temperature etc.
The traditional packaging media for beer is the glass bottle sealed with a crown closure.
Recent development is the use of PET bottles for packaging of beer. Types of PET beer bottles used are non-tunnel pasterurised, one way tunnel pasterurised and returnable / re-fillable bottles.

Beer needs high performance in both CO2 and O2 barrier compared to PET used in carbonated soft drinks (CSD) applications. The level required depends on the type of beer, container size, distribution channels and environmental conditions (storage time, temperature and humidity levels). Improvements in the barrier can be obtained via colourants, creating multi-layer bottles and scavengers. Protection from U. V. light is obtained by adding colourants or U. V. additives, during the injection moulding stage. Because of the varied requirements for beer, the resins chosen must provide an adequate barrier, UV protection and clarity. Beer bottles need strength in order to maintain the CO2 pressure over a wide range of temperatures. Intrinsic viscosities in the range of 0.8 to 0.84 are normally used.
Since the PET bottles are lighter, a truck can carry 60% more of the beverage and 80% less packaging–a fuel saving of 40% and less air pollution.

• Wine (Fruit/Sap based): Wine is a beverage resulting from the fermentation by yeasts of the juice of grapes with appropriate processing and additions. The major deteriorative reaction in wines is caused by oxidation, the oxygen gradually changing the wine character, leading to development of browning and undesirable flavours. The most common form of packaging used for wines is the glass bottle sealed with natural cork. Since wines are affected by sunlight, the bottles usually used are of coloured glass. Bottled wine is normally stored in the horizontal position so that the cork is kept moist, thereby providing a better barrier to the ingress of oxygen. The most significant change in the packaging of wine resulted from the development of the bag-in-box package: a flexible, collapsible, fully sealed bag made from one or more plies of synthetic films, a closure and a tubular spout through which the contents are filled and dispensed, and a rigid outer box or container. The bag is generally constructed from co-extruded film of EVA-BA-EVOH-BAEVA or LDPE-BA-EVOH-BA-LDPE. The features of the bag-in-box system of packaging have been explained earlier in the chapter.

The physical strength of the bag is of prime importance and must remain intact throughout distribution and subsequent storage. Under normal circumstances, the bags are subjected
to two forms of stress: hydraulic shock (normally caused by sudden acceleration / deacceleration of the pack) and flex crack. By using polymers, which have high flex resistance and improving the adhesion between the films, the strength of the bag can be increased.

One problem associated with the packaging of wine into bag-in-box system is the decrease
in shelf-life as compared to that obtained using traditional glass bottles. This is due to permeation of oxygen through the valve material of the tap. By improving the barrier properties of the bag and the design of the tap the problem can be solved. A special heatsealable membrane is partially attached to the gland during manufacture of the bag. After
filling but prior to insertion of the tap, this membrane is fully sealed to the gland and the
potential entry path is greatly reduced. As a result the bag is completely sealed and is totally independent of the tap until the membrane is broached when the pack is just opened
by the consumer.

Wines are also available in PET bottles and in stand-up pouches of metallised polyester laminates.

Distilled Alcoholic Beverages:

• Brandy and Whisky: These drinks are obtained by distillation of alcohol containing drinks. During distillation the aqueous part is separated from the alcohol. The distillates obtained are sold under several names like brandy, gin, whisky cognac, vodka, etc and have different alcohol percentage. Because of their high alcohol percentages, these liquors are mostly packed in glass bottles so that they can be kept for an infinite time after opening. The bottles are sealed to prevent alcohol from evaporating and to protect the contents of the bottles from dirt and dust.




Packaging system for fruits and vegetables:

Fruits:

Oranges:
Oranges are placed in moulded pulp trays with cavities for individual oranges. Each tray contains about 20/25/30 oranges depending upon the size. Four to five such trays are placed in a corrugated fibreboard box.

Custard Apples:
Custard apples are packed in 3-Ply CFB boxes of RSC type or EPS (Expanded Polystyrene) boxes. The capacity of the box is 3kg. The fruits are placed in one layer inside the box and depending upon the size the number of fruits vary.  The box is closed by application of pressure sensitive tape.

Lychee:
Lychees are graded, weighed and packed in plastic punnets of 250 grams capacity. 8 nos. of punnets are placed in a CFB box (One piece tray type) with ventilation holes. The capacity of the box is about 4kgs. Lychees are also packed in 3-Ply CFB boxes of RSC type of capacity 2 kg. These boxes are then put in cold storage till dispatch. From cold store to airport, the lychee boxes are transported in refrigerated van. For export the transportation is by air.


Vegetables:

Vegetables like green chillies, brinjal, papadi, kantola, tindola, bottle gourd are packed in 3-Ply or 5-Ply CFB boxes with ventilation holes depending upon the capacity. The capacity of box varies from 5kg to 7kg to 10 kg. Generally the box is lidded type (0306) but at times for some vegetables RSC (0201) box is also used. In case of green chillies the different varieties exported are G-4, Kiran and Jawla, while the different varieties of brinjal exported are black beauty, pink rawaya. In case of bottle gourds, they are wrapped in tissue paper and then placed in the CFB box. Tindola are also packed in woven sacks of the capacity of 5 kg to 7 kg.

Vegetables like arbi are packed in capacity of 5kg and yam are packed in  capacity of  10kg to 15kg in gunny bags.

Curry leaves are packed in plastic pouches of 30gm capacity with ventilation holes and then placed in 3-Ply CFB box. The capacity of the box is 3kg. In some cases loose curry leaves are packed in the same box. All the above vegetables are exported by air.

The different varieties of potatoes exported are Kuffri Bahar, Kuffri Locker and Kuffri Badshah. The potatoes are packed in Hessian bags (Jute bags) of the capacity of 25 kg. The bags used are generally hand stitched and the final stitching is done in such a manner that there is no space and scope for the movement of the product within the pack. Two corners of the open end of the bag when stitched are used as handles while loading and  unloading. The potatoes are exported by sea as containerized cargo in both general purpose as well as refer containers. For vegetables like brocolli, celery, Brussels sprout and cherry tomatoes, since the export is negligible, the current packages were not available.

Development of Packages Based on International Standards:

Consumer/bulk packages were developed based on International Standards, making reference to:
1. Manual on the packaging of fresh fruits and vegetables by International Trade Centre, UNCTAD/GATT (1988 edition)
2. Guide to food transport-fruits and vegetables. (Mercentla Publication 1989)

Recommendations are based on UN/ECE and OECD Standards, which are covered in the above publications.

While selecting the packaging materials and packages new type of packaging materials with ability to add value to the product and which is eco- friendly and economic were considered. Some of these are PET punnets with lid, EPS tray stretch wrapped, leno/raschel/net bags and moulded EPS box with lid.

Frozen Foods Packaging:

The prime purpose of packaging of these frozen foods is to keep food from drying out and to preserve nutritive value, flavor, texture and color. Labels on packages will say if the product is suitable for freezer storage.

A good packaging material should have the following characteristics:
·         Moisture/vapor-proof or at least moisture resistant.
·         Made of food grade material, i.e. designed to be used for food products.
·         Durable and leakproof.
·         Doesn’t become brittle and crack at low temperatures.
·         Resistant to oil, grease or water.
·         Protect foods from off flavors and odors.
·         Easy to fill and seal.
·         Easy to mark and store.

The packaging you select will depend on the type of food to be frozen, personal preference and availability. For satisfactory results, do not freeze fruits and vegetables in containers larger than one-half gallon. Packaging not sufficiently moisture/vapor-resistant for long-time freezer storage includes ordinary waxed paper and paper cartons from ice cream and milk.

Rigid Containers:

Rigid containers are made of plastic, glass, aluminum and heavily waxed cardboard and are suitable for all packs. These are often reusable. Straight or tapered sides on rigid containers make it much easier to remove frozen foods.

Glass jars used for freezing should be made for the purpose. Regular glass jars may not withstand the extremes in temperature. Do not use regular, narrow-mouth canning jars for freezing foods packed in liquid. Expansion of the liquid could cause the jar to break at the neck.

Cans, such as shortening and coffee cans, are good for packaging delicate foods. Line the can with a food-storage bag and seal the lid with freezer tape because they are not airtight.

Baking dishes can be used for freezing, heating and serving. Dishes may be covered with a heavy aluminum foil taped with freezer tape. To reuse the baking dish after the food is frozen, wrap the food in casserole- wrap fashion.

Ice cube trays are good for freezing foods in small amounts. Freeze food until firm and then transfer to freezer bags.

Flexible Bags or Wrapping:

Bags and sheets of moisture/vapor-resistant materials and heavy-duty foil are suitable for dry packed vegetables and fruits, meat, fish or poultry. Bags can also be used for liquid packs. Protective cardboard cartons may be used to protect bags and sheets from tearing and to make stacking easier. Laminated papers made of various combinations of paper, metal foil and/or cellophane are suitable for dry packed vegetables and fruits, meats, fish and poultry. Laminated papers are also used as protective overwrap.

Packaging, Sealing and Labeling:
·         Cool all foods and syrup before packing. This speeds up freezing and helps retain natural color, flavor and texture of food.
·         Pack foods in quantities that will be used at one time.
·         Most foods require head space between the packed food and the closure for expansion as the food freezes. Loose packing vegetables, such as asparagus and broccoli, bony pieces of meat, tray-packed foods and breads, do not need head space.
·         Pack foods tightly to cut down on the amount of air in the package.
·         Run a nonmetal utensil, such as a rubber scraper handle, around the inside of the container to eliminate air pockets.
·         When wrapping food, press out as much air as possible and mold the wrapping as close to the food as possible.
·         When packing food in bags, press the air from the bags. Beginning at the bottom of the bag, press firmly moving toward the top of the bag to prevent air from re-entering or force the air out by placing the filled bag in a bowl of cold water taking care that no water enters the bag. Seal either method by twisting and folding back the top of the bag and securing with string, good quality rubber band, strip of coated wire or other sealing device. Many bags may be heat sealed, and some have a tongue-in-groove seal built in.
·         Keep sealing edges free from moisture or food so they will make a good closure.
·         When using tape, it should be freezer tape, designed for use in the freezer. The adhesive remains effective at low temperature.
·         Label each package with name of product, date, amount and any added ingredients. Use freezer tape, freezer marking pens or crayons, or gummed labels made especially for freezer use.

Packaging of dried or de-hydrated foods:
Dried foods are susceptible to insect contamination and moisture reabsorption and must be properly packaged and stored immediately First, cool completely. Warm food causes sweating which could provide enough moisture for mold to grow. Pack foods into clean, dry insect-proof containers as tightly as possible without crushing.

Glass jars, metal cans or boxes with tight fitted lids or moisture-vapor resistant freezer cartons make good containers for storing dried foods. Heavy-duty plastic bags are acceptable, but are not insect and rodent proof. Plastic bags with a 3/8-inch seal are best to keep out moisture. Pack food in amounts that will be used in a recipe. Every time a package is re-opened, the food is exposed to air and moisture that lower the quality of the food.

Fruit that has been sulfured should not touch metal. Place the fruit in a plastic bag before storing it in a metal can. Sulfur fumes will react with the metal and cause color changes in the fruit.

Food irradiation



Food irradiation is one means of food preservation that may not be familiar to many, but it has been in development since the early decades of the twentieth century. If properly applied, irradiation can be an effective way to treat a variety of problems in our food supply, such as insect infestation of grains, sprouting of potatoes, rapid ripening of fruits and bacterial growth. However, it has not yet obtained a significant place in the U.S. food industry. This apparent hesitancy is caused in part by very vocal and active opponents who provide inaccurate information to instill fear about food safety into the public's minds. Many factors of economic feasibility seem to hinge on food industry as well as consumer acceptance, and in turn, have hindered the potential for widespread commercial success of food irradiation.

Radiation is not a modern, man-made creation. We get natural radiation from the sun and other natural components of our environment such as gases and deposits of uranium ore in rock structures. In the 1890s, radioactive substances and X-rays were discovered. Intense research about the biological effects of these radiations began immediately and beneficial uses of these substances were soon found. The biggest contribution of man's use of radiation has been in the medical field -- medical and dental X-rays, detection and treatment of diseases, sterilization of medical equipment, medical devices, pharmaceutical products, and home products, and production of sterilized food for special hospital diets. It is also interesting to note that for many years precious stones have been irradiated to increase their brilliance, as with diamonds, or to change their appearance, as with topaz, in which irradiation produces a smoky-like appearance in the crystal.

Despite these known benefits of irradiation and the technologies to control its use, consumer acceptance and concern for nuclear issues have hindered the potential for widespread commercial success in this country. However, more than 30 countries have approved and are using food irradiation technologies to ensure food safety. Countries utilizing food irradiation for various purposes include Japan, China, the Soviet Union, the Netherlands and France. In the U.S., irradiated foods have been used by astronauts, the military and hospital patients, but the adoption of the technology for other purposes has been slow despite approvals from the Food and Drug Administration (FDA). For example, the process to control trichinosis in pork, approved in 1985, is still not used. With the recent approval of irradiation for controlling bacteria on red meats, attention was again focused on food irradiation. The U.S. may be the closest it has ever been to seeing irradiation accepted for more widespread use, due to recent outbreaks from E. ColiO157:H7.

History of the Irradiation Preservation of Food
Early in the 1920s, a French scientist discovered that irradiation could be used to preserve food. This technology was not adopted in the U.S. until World War II. At this time there was a need to feed millions of men and women in uniform. The U.S. Army sponsored a series of experiments with fruits, vegetables, dairy products, fish and meats. In 1963, the U.S. saw its first approval of food irradiation when FDA approved its use to control insects in wheat and wheat flour. In 1964, additional approval was given to inhibit the development of sprouts in white potatoes.

In 1983, approval was granted to kill insects and control microorganisms in a specific list of herbs, spices and vegetable seasonings. (The approved list of food products has been increased with later changes.) Then, in 1985, treatment of pork to control trichinosis was added to the list of approvals. In the same year, approval was granted to control insects and microorganisms in dry enzyme preparations used in fermentation-type processes. In 1986, approval was granted to control insects and inhibit growth and ripening in such foods as fruits, vegetables and grains.

Approval was granted in May, 1990, for irradiation of packaged fresh or frozen uncooked poultry. FDA supports it as an effective control of microorganisms responsible for a major portion of foodborne illness, including Salmonella, Yersinia, and Campylobacter. This approval was the first approved process to "pasteurize" solid foods, such as poultry. The process reduces but does not eliminate all bacteria. Therefore, processed poultry are safe longer than unprocessed poultry, but still require refrigeration.

The latest approval for irradiation in the U.S. was granted in December 1997, for red meat. A maximum dose of 4.5 KGy was approved for uncooked, chilled red meat and meat product, and 7.0 KGy for frozen red meat and products. These approvals are for the purpose of controlling microorganisms, including pathogens such as E. Coli 0157:H7. Just as with irradiated poultry, irradiated red meats still require refrigeration or freezing. Higher doses that sterilize frozen and packaged meats were approved in 1995 for use by NASA only. Legislation to allow the irradiation of seafood is being developed.

What is "Irradiation?"
Just a mention of the word irradiation usually sparks strong objections, usually based on misunderstanding of the process involved and its effects on foods. Very simply, food irradiation is a process of exposing foods, either prepackaged or in bulk, to very high-energy, invisible lightwaves (radiation). The process controls the amount of radiation the food absorbs.

Food irradiation is a means of preservation; it is used to extend product shelf life. The radiation energy used is able to cause changes in molecules, such as breaking chemical bonds. At small irradiation doses, properties of the food, such as sprouting and ripening can be modified (usually inhibited). Higher doses can alter molecules in microorganisms so they can no longer cause spoilage or human illness. The microorganisms may be killed or genetically altered so they can't reproduce. It takes lower doses to damage microorganisms and insects than to alter enough molecules in the food to damage it.

For those who want to know more about the radiation that is used and its relationship to other types of energy, it is necessary to look at the electromagnetic spectrum. Food irradiation uses gamma rays, X-rays or electron beams that are part of the invisible lightwaves range of the electromagnetic spectrum. Ultraviolet light (radiation) is also in the invisible range of the spectrum, although the waves of ultraviolet light are not as short as those of X-rays and gamma rays. The shorter the wavelength, the greater the amount of energy per unit.

High energy radiation can break molecules into smaller fragments that may be either electrically charged (ions) or neutral. The electrically charged ions are radioactive. Ultraviolet, X-ray and gamma radiation can break stronger bonds than visible light and even expel electrons from atoms. This is why they may also be called ionizing radiation or ionizing energy.

Other types of radiant energy with longer wavelengths and less energy per unit are infrared and microwave radiation. Thus, conventional cooking methods such as broiling and baking also use radiant energy, but in the infrared range. Cooking with microwaves is accomplished by microwave radiation, energy of yet another wavelength. Microwave radiation is also used to detect speeding cars, to send television and telephone communications, to treat muscle soreness, to dry and cure plywood and to raise bread and doughnuts.




 Sources of Radiation (Ionizing Energy)
There are three types of energy that can be used for irradiation of food: X-rays, electron beams and gamma rays. Machines called "electron accelerators" are used to produce beams of electrons to which food can be exposed. If the electrons from the accelerator are stopped by a metal target (such as tungsten foil) first, X-rays are produced and the food is exposed to X-rays. The amount of energy produced by electron beams can be adjusted.
Gamma rays are produced by radioactive substances (called radioisotopes) that continuously emit the high energy gamma rays. The approved sources of gamma rays for food irradiation are cobalt- 60 (the most common) and cesium-137.

Doses and Effects of Radiation
In food irradiation, the radiation "dose" that a food receives should not be confused with something added to the food. The "dose" for food irradiation is the amount of radiation absorbed by the food and it is not the same as the level of energy transmitted from the radiation sources. The dose is controlled by the intensity of radiation and the length of time the food is exposed.

Terms used to describe this "dose" or amount of absorbed radiation, are unfamiliar and confusing to most people. In the past, the term used was rad, short for "radiation absorbed dose," which is 100 ergs absorbed by 1 gram of matter. The rad has been replaced by the gray (Gy). One gray is equal to 100 rads or 0.00024 Calorie (i.e., diet calorie) per kilogram of food. (0.00024 Calorie per kilogram equals 0.0001 Calorie per pound.) The FDA's regulations describe radiation levels in terms of the kilogray (kGy), equal to 1000 Gy.
The dose (number of kGy) permitted varies according to the type of food and the desired action. Treatment levels have been approved by FDA as follows:
  1. "Low" doses - (up to 1 kGy) designed to
    1. control insects in grains
    2. inhibit sprouting in white potatoes
    3. control trichinae in pork
    4. inhibit decay and control insects in fruits and vegetables
  2. "Medium" doses - (1-10 kGy) designed to
    1. control SalmonellaShigellaCampylobacterYersinia and E. Coli in meat, poultry and fish
    2. delay mold growth on strawberries and other fruits
  3. "High" doses - (greater than 10 kGy) designed to
    1. kill microorganisms and insects in spices
    2. commercially sterilize foods, destroying all microorganisms of public health concern (e.g., to sterilize food to the same degree as if they were thermally sterilized (canned); however, no commercial applications of this dosage have been approved by FDA for use in the U.S. with the exception of some special hospital diets for immune-deficient patients.)
When radiation energy is absorbed by food, it causes a variety of chemical and physical reactions. The amount of energy the food absorbs is controlled so the changes produced have desirable food preservation effects while maintaining the safety, quality, and wholesomeness of the food. The food itself does not become radioactive.
Perishable foods treated with all but high doses, however, must still be refrigerated. Refrigerated storage life is extended, but the need for cold storage is not replaced by irradiation. Microorganisms are destroyed by radiation more easily than enzymes which lead to food deterioration (color, flavor and texture changes, for example). Many enzymes survive the current levels of radiation processing, although refrigeration can slow down many enzymatic changes. In addition, not all microorganisms are destroyed. The process does not protect the food against reinfestation or contamination. Therefore, irradiated perishable foods are still considered perishable.

Facilities
Facilities for irradiating food are similar to those in operation for sterilizing medical equipment and do not resemble nuclear reactors in any way. There are no explosives or materials that could cause widespread dissemination of radioactive material. Facilities using cobalt do not use materials from nuclear defense industries. Facilities used, however, must comply with plant and worker safety requirements of the Nuclear Regulatory Commission and the Occupational Safety and Health Administration.

 

At an irradiation facility, the radiation source (usually the cobalt-60) is contained in slender pencil- like stainless steel casing about 18 inches long by 3/8 inch diameter. The casings, in turn, are contained in a lead-lined chamber. Packaged food travels in pallets on a conveyor between 6-1/2 foot thick concrete walls into and through a chamber where it is exposed to the radiation source (gamma rays if cobalt-60 is used). Pallets may be turned to allow uniform exposure over the route. Radiation dosage is controlled by a computerized rate of passage (conveyor speed) through the chamber.

As of June 1989, there were three facilities in the U.S. which irradiated food on a commercial scale. Those in operation have been facilities for sterilizing medical and other supplies, and who sometimes divert to irradiate bulk loads of spices. One hospital in Seattle is approved for irradiating special diets for immune-deficient patients mentioned previously.

Adoption of the Technology
Although some food radiation treatments have been approved in the U.S. since 1963, there has been only infrequent use in test markets other than use on spices. The food industry is slow to invest in this technology because of uncertainty over the public acceptance of food. In 1986, 2 metric tons of mangoes irradiated in Puerto Rico were test marketed in Miami, FL. In 1987, irradiated Hawaiian papaya were tested in Anaheim and Irvine, CA. These test market studies as well as others in France, Argentina and South Africa indicated good consumer acceptance and willingness to buy.

Worldwide, over 30 countries approve some form of irradiation and many groups of consumers readily accept these products. As of 1986, Japan irradiated over 10,000 pounds of potatoes annually. The Netherlands irradiated 2 tons of food daily, and Belgium irradiated 1 ton daily. South Africa routinely irradiates mangoes, papaya, and other vegetables. Canada has a facility dedicated to irradiating potatoes.

Labeling of Irradiated Foods
 

Because the beneficial effects of irradiating foods are not discernable to consumers, labeling has been considered essential if consumers are to be adequately informed. After much debate, the FDA approved initial labeling requirements in April, 1986. The regulations required that all produce be labeled at the packing/wholesale and retail levels. Suggested wording and an international symbol (logo) were provided.

At the retail level, the label was required to bear the symbol plus one of these statements: "treated with radiation" or "treated by irradiation." In addition, the manufacturer was allowed to add a phrase which truthfully described the primary purpose of the treatment, such as "treated with radiation to control spoilage." For unpackaged fruits and vegetables, labels could be on each piece, on the shipping container placed in prominent consumer view, or on a sign near the commodities identifying the use of the treatment.

For irradiated foods sold at the wholesale level, the logo and the wording were still required. In addition, however, they were to be accompanied by the caution "do not irradiate again." Irradiated spices sold in the U.S. do not need to carry the logo if they are in packaged foods where they constitute one small ingredient. Most packaged spices in stores are usually treated by chemical fumigation, not by irradiation. New legislation in November 1997 (The FDA Modernization Act of 1997, Public Law 105-115) contained food provisions that direct FDA to review its labeling rule for irradiated foods. The agency was told to revise the rule so the disclosure statement is not more prominent than the declaration of ingredients. The ruling does not, however, exclude making a disclosure of irradiation through use of the radura.

Safety of Irradiated Foods
Irradiated food does not become radioactive. At the radiation energy levels used in food processing, only chemical changes are possible, not nuclear changes that would make the food itself radioactive. Over 35 years of research suggest that the chemical by-products of radiation ("radiolytic products") are mostly the same as by-products of conventional cooking or other preservation methods. Animal feeding studies show no toxic, teratogenic or mutagenic effects from irradiated foods. In addition, irradiation leaves no chemical residues in food.

In 1981, the Food and Agricultural Organization (FAO) of the United Nations, the International Atomic Energy Agency (IAEA), and the World Health Organization concluded that "any food irradiated up to an average dose of 1 Mrad or less is wholesome for humans and therefore should be approved without further testing" (WHO, 1981 in IFT, 1987). (A Mrad equals 10 kGy.) Also in 1981, the U.S. FDA concluded that food irradiated with up to 1 kGy is "wholesome and safe for human consumption, even where the food that is irradiated may constitute a substantial portion of the diet," and that food "compromising no more than 0.01% of the daily diet [ex., spices] and irradiated at 50 kGy or less also can be considered safe for human consumption" (FDA, 1981).

Before approving low dose irradiation of foods, the FDA reviewed over 400 toxicity studies, which included animal feeding studies. The U.S. Army Medical Department fed irradiated foods to 41 human volunteers in 15-day tests in 1955-58 and showed no unfavorable effects. More recently, in 1986, the People's Republic of China reported on eight experiments with 439 human volunteers. Their diets included 60% of ingredients irradiated at levels from 0.1-8 kGy. During and after these trials, there were no significant differences in the clinical, physiological and biochemical evaluations between the subjects receiving the irradiated foods and those receiving comparable food without such processing.

Changes in Irradiated Food
Food irradiation is sometimes called a "cold" process; it achieves its effect with little rise in the temperature of the food. There is little if any change in the physical appearance of irradiated foods as they do not undergo the changes in texture and/or color as foods preserved by heat pasteurization, canning or freezing. Food remains close to its original state. Problems that have occurred are some off-flavors in meat and excess tissue softening that has been documented in fresh peaches and nectarines.

As with all preservation or cooking methods, some chemical changes occur in irradiated food. When high energy particles strike matter, electrons are lost from atoms and ions are formed. Newly formed radiolytic products may then interact to create new compounds in the food that were not present before treatment, a few of which could produce off- flavors. (In meat, this can be partly controlled by maintaining low product temperatures during the irradiation process.) The most common chemical reaction during food irradiation is the conversion of water to hydrogen peroxide. Reactions like these occur in all types of food preservation, and those few reactions unique to irradiation are not harmful.

The FDA concluded that "very few of these radiolytic products are unique to irradiated foods; approximately 90% of the radiolytic products...are known to be natural components of food" (FDA, 1986). Some of these are fatty acids just like those that result from the breakdown of triglycerides, amino acids that make up proteins, and compounds (hydrocarbons) commonly found in the waxy coverings of fruits like apples, pears and berries. Others are fatty compounds just like those found from cooking meat by common methods such as grilling. The other 10% of radiolytic compounds are chemically very similar to natural components in food. The chemistry of irradiation is very predictable and the products of an individual component such as proteins are not affected by the type of food or other food components present. Radiolytic products have been critically tested for toxicity and no evidence of hazard has been found.

Radiation does not impair activity of certain nutrients, but overall nutrient retention in irradiated foods is similar to retention with other preservation methods. Vitamin C (ascorbic acid) reduction has been reported, but it is attributed to a shift from ascorbic acid to dehydroascorbic acid, a change that is mostly insignificant from a nutritional standpoint. Tocopherol, which have Vitamin E activity, appear to be very sensitive to irradiation in the presence of oxygen. Vitamin K seems relatively stable. These adverse effects of irradiation on vitamins can be reduced by excluding oxygen and light, keeping the food at a low temperature, and using the lowest dose need for treating (processing) food.

Consumer Acceptance
Studies on consumer acceptance have been done with a few irradiated products. Bruhn, Schutz and Sommer (1986) examined change in consumer attitudes toward food irradiation as the result of opportunities to read about and discuss the technology. They found that consumers in general showed a higher level of concern for preservatives and sprays than for food irradiation. "Alternative" consumers who were a vocal segment of ecologically sensitive consumers, were more skeptical about the safety and advantages of the process. They also were initially more aware of food irradiation and their concern increased after educational efforts. After educational efforts, conventional consumers adopted a minor concerned attitude toward irradiation, but a discussion leader knowledgeable in food irradiation reduced concerns of conventional consumers compared with the impact of a non-expert leader. These researchers concluded that the attitudes of conventional consumers can be positively influenced by an educational effort and the influence is most effective when the consumer can interact with someone knowledgeable about irradiation.
Wiese Research Associates (1984) found that less than 25% of a national telephone sample were aware of food irradiation technologies. Among those aware, 75% were concerned, but in general, consumers were more concerned about chemical sprays and preservatives than irradiation. Those with fewer concerns had more formal education and higher levels of awareness.

A market survey of the effects of irradiation on demand for papaya in California in the 1960s suggested that demand would be reduced by 23% if the fruit were treated with irradiation (Huang, et.al., 1987). Acceptance of irradiated produce is quite high in South Africa. Reportedly, 90% of consumers reacted positively to its introduction in the late 1970s. However, the test marketing was accompanied by an extensive educational campaign that involved mass media and supportive consumer organizations (Bruhn, et.al., 1986). A 1992 study revealed that consumers were willing to pay up to $0.81 more per meal to eliminate risk of foodborne illness. This is 10 times more expensive than the actual cost of irradiating food (Olson, 1997).

Even though some test marketing has shown some hope for consumer acceptance, irradiated foods have caused picketing and violent protests in the past. Consumer studies seem to suggest that people are more interested in the safety and wholesomeness of the foods rather than benefits of the process for any specific foods. These and other findings also seem to indicate that as knowledge and awareness of the technologies increase, so might its acceptance. History indicates that consumer acceptance will continue to influence the extent to which irradiation gets adopted as an alternative food processing technology.

Summary
There is no doubt that food irradiation involves many complex issues. If properly applied, irradiation can be an effective method of reducing organisms which cause food spoilage and human illness. Some benefits of food irradiation include:
Reduction of postharvest losses (less foodwaste);
Reduction of chemical residues in foods (could replace fumigants and other pesticides)
Reduction of risks of foodborne illness from bacteria (Salmonella, Campylobacter and Shigella)
Reduction of the risk of trichinosis from pork;
More appealing "fresh" characteristics for foods because it is a relatively "cold" process and foods closely resemble those in their fresh state.
The potential benefits of food irradiation may come closer to realization now that regulatory barriers are beginning to be removed, interest in alternatives to pesticides is high and some studies are demonstrating consumer acceptance of products. See Table 1 for clearances as of August, 1988, for use of ionizing energy on foods in the United States.

Table 1. Summary of Approved Food Irradiation Processes
Date
Food/Product
Dose (kGy)*
Purpose

1963
Wheat and wheat flour
0.2 - 0.5
Disinfestation of insects
1964, 1965
White potatoes
0.05 - 0.15
Inhibit sprouting (and extend shelf life)
1983
Spices and dry vegetable seasonings (38 commodities)
30 maximum
Disinfestation of insects and decontamination
1985
Pork (carcasses or fresh, non-heat processed cuts)
0.3 - 1.0
Control of Trichinella spiralis
1985, 1986
Dry or dehydrated enzymes
10 maximum
Control of insects and/or microorganisms
1986
Fruit
1 maximum
Delay of maturation (ripening) and disinfestation
1986
Fresh vegetables
1 maximum
Disinfestation of insects
1986
Herbs
30 maximum
Control of microorganisms (decontamination)
1986
Spices
30 maximum
Control of microorganisms
1986
Vegetable seasonings
30 maximum
Control of microorganisms
1990
Poultry, fresh or frozen
3 maximum
Control of microorganisms (includingSalmonella)
1995
Meat, frozen and packaged
(solely for use in NASA)
44 minimum
Sterilization (destruction of microorganisms)
1995
Animal feed and pet food
2 - 25
Control of Salmonella
1997
Red meat, uncooked, chilled
Red meat, frozen
4.5 maximum
7.0 maximum
Control of microorganisms