February 2017- Tactical Packaging Challenges and Solutions for Fresh Seafood by Dr. Sand

Louisiana Food Processors' Conference
Tactical Packaging
Challenges & Solutions
for Seafood Dr Claire Sand
February, 2017
Tactical Packaging Challenges & Solutions for Seafood 1Dr Claire Sand Winter 2017

Packaging Challenges
MANUFACTURER
• Reduce contamination
during product fill
• Assess initial microbial
load
• Reduce initial microbial
load
• Enable HACCP, etc
• Address chilled worker
conditions
DISTRIBUTOR/
RETAILER
• Enable stock rotation
• Time &Temp monitoring
system
• Oxygen level monitoring
system
• Control temperature
• Reduce microbial load at
POS
CONSUMER
• Refrigerate to Freezer
• Heat/Cook in Package
• Enable safe package reuse
• Reduce consumer contamin
from repeat use
• Expand time for safe product
use
• Enable freezer storage

Challenges Isolated Into 4 Key Areas
Maintain Texture, Flavor, Color, and Nutrients
Ensure Low Microbial Growth
Add Value to Consumers
Add Value to Retailers

Available Packaging Solutions
MANUFACTURER
• Decrease filling time by reducing number
of packaging components
• Enable more rapid filling
• Rapid product sealing
• Use antimicrobial packaging
RETAILER/ CONSUMER
• Edible water vapor barrier
• Enable package sterilization
• Serving size separators within package
• Enhanced product interface
• Refine freezer storage options

Packaging solutions isolated into 4 key areas
Antimicrobial packaging
Communicate safety-intelligent packaging
Edible packaging
Value Chain needed to meet goals

Antimicrobial Packaging

Increasing Need for Antimicrobial
Packaging
Market need for Antimicrobial is increasing due to increase in:
1. Resistance of microbes to standard processing technologies
2. Food safety outbreaks
• Foodborne disease reaches 30% of the population
• Vibrio increased 115% since 2006
3. Need for controlled temperature conditions to inhibit microbial growth
4. Global food distribution in various stages of processing
5. Increase in consumer interest in fresh and multicomponent prepared meals
6. Inability of MAP/CAP technology to accommodate lack of controls in distribution,
processing, product
7. Growing urban population in need of food they can not produce
8. High potential for cross contamination
• Processing facilities often manufacturer more than one product
• Distribution systems between products are often linked

3 ways to convey Antimicrobial activity
from the package
within a structure
as a coating
through headspace

3 Ways to Convey Antimicrobial
Activity From the Package
• For coatings and degradable polymers that contain Antimicrobials, all the
Antimicrobial activity is imparted into food
• For Antimicrobials within polymers and in indirect contact with the food,
the final amount of Antimicrobials within the food is a function of the
ratio of Spolymer to Sfood

Antimicrobials
ORGANIC ACIDS
• Benzoic acid and
benzoates
• Sorbic acid and sorbates
• Acetic acid
• Propionic acids and
propionates
• Lysozyme
SOME OTHERS
• Chlorine dioxide
• Triclosan
• Silver zeolite, nitrate
• Bacteriophages
• Maillard reaction end
products
BACTERIOCINS
• Nisin
• Pediocin
POLYMERS
• Chitosan
NATURAL EXTRACTS
• Cinnamaldehyde
• Eugenol
• Allyl isothiocyanate
• Green tea extract
• Various extracts

Antimicrobial Options
Regulatory
• FDA
• Most are GRAS
• EU
• Defined
amounts
allowed

Antimicrobial Packaging Bases
• Base materials: cellulose and SPI, zein, WPI, LDPE, Cellophane, paper,
chitosan
• Format: coating/flexible; encapsulated within structures; coated on
substrates
• Constraints: seal area, migration rates are product dependent

Nisin
• Nisin in conjunction with:
• Lysozyme resulted in a reduction of E coli
• EDTA resulted in a reduction of Listeria and E Coli
• Grapeseed/Green tea extract resulted in a reduction of Listeria
• Chilled lobster (listeria), salmon (listeria)

Nisin - Regulatory
• EU
• E234 (EEC 1983); EU commission number 215-807-5
• Restrictions to cheese, eggs, puddings
• FDA GRAS status (1988)
• China
• GB2760-86 (1990)
• Canned food, plant protein, dairy, meat, prepared meat, cooked meat
beverages, condiments, cereals products, convenience rice products,
cooked seafood
• Global
• Harmonized System (HS) code 29419090
• Only bacteriocin approved by the World Health Organization (WHO, 1969)

Pediocin
• Shellfish
• Food safety: Listeria focused spectrum
• Food quality: S aureus and B cereus
• Lack of approval by EU and WHO/FAO limits research

Chitosan
• 3 log cycles decay are typical
• Chitosan Discrepancies in reported Antimicrobial activity are due to:
• Variability (in molecular weight and degree of polymerization)
associated with naturally derived products
• Reduces the motility of the chitosan and their interaction with microbes
due to required cross-linking and/or heat to form
• Abundance of research on combinations of chitosan and other antimicrobials
• Cinnamaldehyde (Enterobacteriaceae, L Sakei)
• Oregano (Listeria, E Coli)
• Silver ions (Listeria, E Coli)
• Nisin (E Coli, S, aureus, B cereus)
• Chitosan/vermiculite nanocomposites
• FDA approved

Lysozyme
• Tuna, sushi
• Regulatory
• Need for combining with EDTA or lactoferrin to inhibit E coli
increases regulatory issues and cost
• Lysozyme
• FDA GRAS
• EU number 1105
• Egg white derivation is potential allergen
• EDTA
• FDA GRAS
• EU number 385
• unprocessed shellfish, processed fish and shellfish

• Governed by CFR 21 and updated in the Federal Register
• How much of an Antimicrobials can be used is determined by the:
• Acceptable Daily Intake (ADI) of the Antimicrobials
• Estimated Daily Intake (EDI) if Antimicrobials
• Kinetics of direct and indirect contact
• Often maximum adsorption of Antimicrobials is assumed to allow for
temperature abuse and to account for uncontrollable factors
• If no data for a substance is present, research to determine the ADI must be
conducted
• So, most Antimicrobials research and development is done with approved
substances
Kinetics: Acceptable Limits of
Antimicrobial Use

Factors Effecting Efficacy of
Antimicrobials
1. FOOD PROCESSING
CONDITIONS
• Food pH, and stability after
pH changes
• Inactivation by food
enzymes
• Interaction with food
additives/ingredients
2. FOOD SHELF LIFE FACTORS
• Food storage temperature
• Limited stability during food
shelf life
3. MICROBIAL FACTORS
• Microbial load
• Microbial diversity and the
target bacteria
• Microbial interactions in
the food system
• Physiological stage
(growing, resting, starving
or viable)
4. BARRIERS
• Protection by physico-
chemical barriers
(microcolonies, biofilms,
slime)
• Barriers enrobing
Antimicrobials
5. DEVELOPMENT OF
RESISTANCE/ADAPTATION
• Predicted to be an issue of
concern

Recommendations -1
• Focus efforts on use of Antimicrobial coatings or within a degrading film to:
• Optimize required amount of Antimicrobial
• Blend antimicrobials
• Reuterin-Bacteriostatic activity against L monocytogenes, S aureus,
E coli in combination with nisin and lactoperoxidase
• HPP with nisin with lysozyme, lactoferricin, and a synthetic
lysozyme-derived peptide increases efficacy
• Unique bacteriocins can be generated by either mutating
bacteriocin-encoding genes or by fusing genes from different
bacterial species
• Mutating of ring A within nisin results in enhanced Antimicrobial
activity

Recommendations -1
• Nisin coated vs incorporated to the polymer matrix
0
1
2
3
4
5
6
7
0 2 4 6 8 10 12
Days of storage
logcfu/16cm2
MC
NI
NC
(Mangalassary & Cooksey, unpublished data)

Recommendations-2
• Ensure consistent amount of Antimicrobial
• Avoid reliance of multifaceted kinetics that prevent predictions
• Nisin from 2-layer ﬁlms (EC/HPMC) desorbed in 0 5 h
• Nisin from 2-layer ﬁlms (EC/HPMC/EC) desorbed in 20 h
• Controlled release of the Antimicrobial is necessary to extend the shelf
life
• Done with nanotechnology
• Rapid release causes fast antimicrobial “consumption” in a short
period of time
• Slow release may enable spoilage reactions on the food surface

Recommendations-2
• Natamycin migration from polyvinyldichloride lacquer coating
(Hanusova et al ,
2010)
(Hanusova et al , 2010)

Recommendations-2
Use nanocomposite films
• Antibacterial activity of gelatin based nanocomposite film against E coli
(b) and L monocytogenes (c)
(Kanmani & Rhim, 2014)

Antimicrobial Food Safety
Microbes
Food Quality
Microbes
Categories
Tested
Packaging
Materials
Tested
FDA EU FAO/WHO Manufacturers Economic Social Issues Technology Innovation Recommendation
Nisin Listeria (with
Lysozyme); E.
coli (with EDTA);
Salmonella
Not assessed Meat, cheese,
seafood,
perishable
processed food
Cellulose and
SPI, zein, WPI,
LDPE,
cellophane,
paper, chitosan
GRAS E234;
Restrictions to
cheese, eggs,
puddings
Approved Numerous Costs are not standard and
are based on desired result;
concern with resistance
promotoes use of other
bacteriocins in tandem
Increased resistance
possible; considered natural
Abundance of studies due to
nisin’s commercial availability
Use bacteriociins
synergistically;
bioengineering for increased
efficacy; refine coating
distribution
Pursue
Pediocin Listeria S. aureus and B.
cereus
Processed meat
(ham, bologna,
smoked fish)
WPI coated PP,
Cellulose
GRAS Not approved Minimal Concern with resistance
Limited studies Use bacteriociins
synergistically;
distribution
Lacticin Clostridia and
Listeria
S. aureus,
Bacillus,
Lactococcus,
Lactobacillus
Cottage cheese,
cheese, milk,
orange juice, egg,
water, ham,
turkey breast,
smoked salmon
Zein, WPI,
Paper board with
AP; PE,
Pectin/PLA
composite
Cellophane
GRAS Not approved Approved
by 50+
countries
Laboratories Concern with resistance
Limited understanding
beyond use as additive
Use bacteriociins
synergistically;
distribution
Pursue
Chitosan E. coli S. Aureus, P.
fragi, B. subtilis
Seafood PVA, PE, carrier
of other
antimicrobials
GRAS Not approved Multiple Innovations and use in water
quality and fuel cells may
lower prices or increase
demand to increase prices
Non-toxic, biodegradable,
and biocompatible
Abundance of research;
variability of results due to
natural origin
Combining with other
antimicrobials to increase
spectrum; identify optimum
molecular weight and
polymerization
Lysozyme Listeria; E.coli
(with lactoferrin
or EDTA)
S. Aureus, P.
fragi, B. subtilis,
L. plastarum
Tuna; sushi, raw
and processed
meat
Cellulose, paper,
zein, SPI,
PVOH, surface
immobilization
GRAS E1105;
approved for
cheese and
beer
Numerous
chemical
companies
Need to combine with
lactorferrin or EDTA to inhibit
E.coli
Considered natural Abundance of research;
variability of results due to
natural origin
To attain both Listeria and E.
coli inactivity, determine
optimum EDTA or lactoferrin
concentration
Pursue
Lactoperoxidase Listeria; E. coli Yeasts, Molds Salmon and
roasted turkey,
milk, cheese,
vegetables
•WPI, alginate GRAS No approved Recommen
ded when
adequate
cooling
unavailable
in dairy
Numerous
chemical
companies
Whey derivation lowers cost Advocacy by FAO has
increased awareness
Efficacy a function of LPS,
thiocyanate, and H2O2
Activation by H2O2 Pursue
Plant Extracts E. coli
(Oregano);
Listeria (Neem)
S. aureus
(Grapefruit seed,
green teat)
SPI, WPI,
chitosan, casein
GRAS Approved Approved Numerous Costly due to extraction Taste preferences inhibit use;
no labeling issues
Not applied beyond
laboratory stages
Natural/organic platform;
improving efficacy
Pursue as
natural/organic
platform
Metal ions E.coli , Listeria
(Titanium), Ziinc,
Silver, Copper);
Salmonella (Zinc
and nisin)
S. aureus Meat, sliced fruit,
eggs, orange juice
Glass, metal,
polymers,
chitosan, zein,
cellulose
Defined
amounts
Defined
amounts
Defined
amounts
Numerous Silver most costly Consumer familiarity;
Environmental and increased
resistance; Limit migration
into food is paramount
Nanoparticles most effectives
due to shigh surface area
Medical research applicable
to food packaging
Surface
Treatments
E. coli Antifungal Meat, produce Paperboard,
polymers
by-products
would need
approval
by-products
would need
approval
by-
products
would need
approval
Internal Variable resultant additives require
acceptance
Skill set within converters Adapt processes from
medical packaging; plasma
activation; GRAS by-products
Pursue to expand
core competency
Acids, Salts,
Anhydrides
Listeria and
E.coli (Sorbic
Acid); Listeria
(Lauric acid and
EDTA)
Yeasts, Molds Meat, produce Coatings on
various
substrates
Most are
GRAS
Defined
amounts
allowed
Defined
amounts
allowed
Numerous Variable Consumer familiarity Processes of inactivation are
well known
Refined efficacy Pursue
Chlorine Dioxide Listeria,
Salmonella
Not Evaluated Produce Known
permeability to
ClO2
Considered a
treatment
E926 under
consideration
Numerous Systems in place lowers cost Color issues; Connected to
household disinfectant
Technology well known Explore ability to recharge
system

Intelligent packaging

Difference Between Active and
Intelligent Packaging

Intelligent Packaging
• Focus on:
• TTI
• Degradation sensors
• No-Fraud assurance packaging
• Responsive packaging

TTIs
TTIs are a refined proven
technology
• Remain relevant since
temperature governs
reaction rates and controls
microbial growth

TTIs
• L5-8 Smart Seafood
• irreversible color
change from the
hydrolysis of
triglycerides
• CoolVu
• aluminum
layer thins
causing a
reaction
• FreshCode, Varcode
andTempix, Tempix
• fading barcodes
• FreshMeter
• turns from blue to
gray via
benzopyridine
photoactivation

Degradation Sensors
Degradation sensors are advancing rapidly
• Direct connection to food deterioration
• More sophisticated sensors that convert biochemical
signals to electrical responses that show remaining shelf
life from manufacturer to consumer

Degradation Sensors-
Mechanisms
• High surface to volume ratio of nanofibrous membranes and
electrospun sensors
• Based on surface enhanced Raman spectroscopy (SERS)
• Measures total volatile basic nitrogen (TVBN)
• Monitors cysteine loss via hydrogen sulfide
• Color change indicator that activates as microbial growth increases
• Advances in wireless nanosensor networks (WNSNs)
• Graphene printing and conductive polymers
• enables wireless communication between nanosystems
• Incorporate antibodies (for detection) within polymer films

Responsive Sensors
• Responsive sensors that detect then act to reduce deteriorative reactions
• Through the release of CO2, antioxidants or pH change agents
• Tremendous amount of IP in this area

Authenticity Sensors-Overt and Covert
Overt authenticity is refined and solutions exist and line is blended between
covert and overt
• Overt acts as deterrent and prevention
Older solutions
• Fiber tear
• TE bands
Current solutions
• Timestrip and Novas - time elapsed since opening
• RFID and NFC
• Alien Technology, CAENRFID, Convergence Systems
• authentiQ, Sicpa, and VerifyMe

Authenticity Sensors-Overt and Covert
Overt authenticity is refined and solutions exist and line is blended between
covert and overt
• Covert acts a detection
• Current solutions
• FluxSecure - glass coated metal thread embedded in packaging
• TruTag, Flint Group, Spectra Systems - silicon dioxide based tags
• SigNature - printing plant based DNA as barcodes, watermarks, microdots
• Genome Trakr - DNA based verification methods
• Alpvision - fingerprint within molded caps and bottles
• Unisecure - imperfection tracking with a 5-megapixel smart phone

Authenticity Sensors

Authenticity Sensors
Intelligent packaging expands brand image potential
Current solutions
• Thermochromatic inks change color and reveal images
when the product is at the proper temperature to eat or
drink
• NFC OpenSense package sensor is tapped with a
smartphone
• Polymark fluorescence based detection for sorting food-
contact PET

Intelligent Packaging Recommendations
• TTI continue to be the standard
• For optimum safety, focus on degradation sensors in 1-3 years
• Assess branding and authenticity link to balance costs
• For nutritional waste reduction and safety, focus on responsive sensors in
3-5 years

Edible Packaging

Edible Packaging
• Focus on
• Reduce and not replace synthetic packaging
• Freezer burn
• Decreasing water loss in fresh seafood
• Enhancing product offerings
• Cook in bag
• Shaped products
• Meal kits to align with what retailers are doing

The Need for Water Management
• Freezer burn
• Interfacial water freezes and thaws and ice crystals grow crushing
cells
• Increased degradation within cells before they burst
• Texture loss
• Water loss
• Loss from product
• Loss from package is ($$$) loss

Edible Packaging as a Water Vapor
Barrier
• Alternative to vacuum package
• Edible barriers are a robust solution
in consumer freezers
• Many options and can be linked to
antimicrobial barriers

Edible Packaging as a Water Vapor
Barrier
• Realistic assessment
• Lipids-wax, fatty acids, glycerides
• In a base-proteins, starches, or celluloses derivative
• Confused research
seafood

Edible Packaging to Enhance Product
Offerings - Cook in a Bag
Enable venting since product is better protected
1. Perforations
• (horizontal or in a “patch”) that are coated/laminated; but,
to allow air/steam to escape through holes
2 Laser scored
• top layer that is coated/laminated; but, to allow air/steam
to escape through laser cuts that expand when heated
• steam generated from within the package bursts through the
scoring and automatically ventilates the package
3 Channels that vent air/steam through fin seal area
• Consumer slit bag to vent before microwaving
4 Tray in colander

1. Perforations
• (horizontal or in a “patch”) that are coated/laminated;
but, to allow air/steam to escape through holes
2 Laser scored
• top layer that is coated/laminated; but, to allow
air/steam to escape through laser cuts that expand when
heated
• steam generated from within the package bursts through
the scoring and automatically ventilates the package
4 Tray in colander

1. Perforations
• (horizontal or in a “patch”) that are coated/laminated; but, to allow air/steam
to escape through holes
2 Laser scored
• top layer that is coated/laminated; but, to allow air/steam to escape through
laser cuts that expand when heated
• steam generated from within the package bursts through the scoring and
automatically ventilates the package
4 Tray in colander

1. Perforations
• (horizontal or in a “patch”) that are coated/laminated;
but, to allow air/steam to escape through holes
2. Laser scored
• top layer that is coated/laminated; but, to allow
air/steam to escape through laser cuts that expand
when heated
• steam generated from within the package bursts through
the scoring and automatically ventilates the package
4 Tray in colander

Offerings - Shapes
• Upscale frozen/fresh Surimi seafood
• Impart texture
• Lower fat content by reducing oil uptake
• Bite size
• Decrease product waste

Offerings – Meal Kits
• Keep water within separate foods
with reduced synthetic packaging

Offerings – Meal Kits
• Reduce retailer labor and provide improved food safety

Edible Moisture Barriers
Recommendations-1
• Assess viability

Edible Barriers Recommendations-2
• Water vapor barriers
• Apply research and test based on direction of prior work
• Develop proprietary solutions

Value Chain is Needed to
Meet Goals

Value Chain Actions
• Ensure Agility
• Build Trust
• Incent
• Develop with partners

Ensure Agility
• Ensure agility in meeting need for package change
• Because food industry processes are not aligned to implement packaging
solutions, agility to work a different way is needed
• Realign cost:benefit within value chain members
• Development time and costs shared within value chain
• Develop solutions jointly vs “serving up” solutions
• Employ startup (mentality/physically) without internal/external
barriers
• Gain tacit knowledge
• Identify core advisory team experts to guide team

Build Trust
Build Trust to increase shelf life:
• Trust to enable shifting the role to a packaging responsibility is needed
• Need to build trust that ___ can provide extra measure of food safety, or
key attribute
• Process transparency
• Align goal with food safety HACCP, FSMA, GFSI, etc processes
• Incorporate transparency to build tacit knowledge

Perform Stress Test
• To assess partner response
• To align to improve functionality
• Increased microbial load, product abused, seasonal variation in value
chain
• Explore viability of safety guarantee
• Need to be involved with integration into HACCP, FSMA, GFSI, etc
process and required post pack conditions

Incorporate Incentives
• Since food safety and reducing waste is normally the role of the food processor,
incentives to enable shifting the role to packaging is needed
• Need to provide incentives to work as a partner in food safety and waste reduction
• Assess motivation for CPG to work on ___
• Timing
• Reduce costs
• Chance to truly innovate
• Design reward system based on conversion process
• Connect with retailer on needs/signage
• Align rewards to conversion process
• Design reward system based ___ process efficacy
• Storage of ___ packaging material
• Packing of product with packaging material

Develop Core Competency with Partners
• Develop core competency with partners in the value chain
• Need to stretch value chain to incorporate more members
• Researchers in ____ arena jointly funded-consortiums, foundations,
universities
• Assess distribution controls
• Explore impact on retail if shelf life extended
• Make consumer connections
• Assess sustainability in holistic manner (reuse, regeneration,
recycling, reduce)
• Nutritional waste
• Package waste

Questions?
Dr Claire Sand
CEO, Packaging Technology & Research, LLC
Adjunct Professor, Michigan State University
Food science and packaging expertise:
• Coaching
• Consulting
• Technology
• Strategy
www.PackagingTechnologyandResearch com

February 2017- Tactical Packaging Challenges and Solutions for Fresh Seafood by Dr. Sand

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