Article: PPS 16-5102
Permeation
Extending the shelf life of fresh pasta
Maintaining the quality of a food product, and
consequently its preservation, is based principally on
the inhibition or prevention of microbial growth. Food
can still be preserved by the addition of antimicrobial
substances that prevent or inhibit the development of
microorganisms; however, consumers are currently
demanding products that have better “in natura”
qualities.
Microbial growth is determined by the presence of
oxygen, favoring the growth of aerobic organisms and
consequently, the lack of oxygen will allow facultative
anaerobes to become dominant. (Cruz)1
Dr. Ron Thomas, Professor of Food, Nutrition, and
Packaging Sciences at Clemson University (South
Carolina, USA), states: “The overall issue is with
mold growth on fresh pastas. Dry pastas have low
water activity and are obviously shelf stable.
However, fresh pastas have a higher water activity
and will support microbial growth, mostly mold.
Thus, oxygen exclusion and high oxygen barrier is
needed. Also, MAP with high (50%) carbon dioxide
is used as a microbial inhibitor along with 50%
nitrogen. Oxygen scavengers also are used along
with high barrier films.”
As well as controlling oxygen permeation, the package
needs to provide physical protection, a moisture
barrier, and a barrier against odors and volatile
permeants. The packaging must also be able to
withstand high temperatures, which increase the
permeation rate through the barrier material.
06.16.15
The package development process
The following steps outline the recommended method
for determining the ideal packaging for fresh pasta or
any other product.
1. Identify product requirements
Not only does the maximum amount of allowable
product degradation need to be specified for the pasta
to still be sellable, identifying the contributors to this
degradation is a key part of developing a successful
package. While oxygen and water vapor permeation
are common, other factors such as carbon dioxide,
odors, and aromas must also be considered.
2. Identify candidate materials
Implementing a well-designed material testing
program will simplify the process of identifying the
optimal barrier material for this particular application.
Based on the results of barrier material analysis, final
package configurations can then be created that can be
tested to determine the barrier level of the package as
a whole.
During the development process, chemical as well as
physical protection must be considered. Microbiological
contamination, rancidity, loss of moisture, excessive
moisture, and off-flavor are just some examples of the
damage that can occur in fresh pasta when an
inappropriate barrier material is used. Permeation
testing is key in defining the appropriate packaging to
help minimize this damage.
Article # 16-5102 Extending the shelf life of fresh pasta
3. Determine the optimal packaging system
Product requirements and candidate materials are
then matched to either determine the shelf life obtainable
with a specific material, or to determine which material
will supply a specified shelf life. Storage or shelf life
studies are usually then conducted to confirm the
package performance.
Understanding the permeation rates of packaging
materials in the beginning of the package development
process helps to avoid both over- and under-packaging.
A lack of product knowledge will often lead a
manufacturer to use the strongest package available
within a given budget in order to prevent under-packaging,
which instead leads them to overpackage their product.
Over-packaging can be a significant waste of money
and material resources.
For more information, see our article entitled
“Permeation and its Impact on Packaging” or contact
your MOCON representative. Additional articles are
regularly published on our LinkedIn page.
1
Cruz, R S, Nilda de Fátina Ferreira Soares and Nélio José de Andrade.
“Evaluation of oxygen absorber on antimicrobial preservation of
lasagna-type fresh pasta under vacuum packed”. Ciênc. agrotec., Lavras,
v. .30, n.6.p.1135-1138, nov./dez, 2006.
http://www.scielo.br/pdf/cagro/v30n6/a15v30n6.pdf
Both scenarios can be costly, but can usually be
avoided with a proper testing protocol. Under-packaging
(inadequate barriers, improper thickness, etc.) allows
the transmission of some compounds at a rate that
will decrease the shelf life of the product. Repercussions
from under-packaging can range from product
complaints and returns, lost sales, voided warranties,
and even potential lawsuits or other legal action.
Furthermore, once a product is successful it is often
impossible to change the package design for fear of
losing market share.
Package design can also affect the environment.
Over-packaging can result in excessive material usage,
thus negatively impacting the environment, whereas
under-packaging creates product returns that result in
increased waste, both having a negative environmental
impact. By conducting analysis of the packaging prior
to launching the product, these financial and
environmental issues can be avoided.
Manufacturers can save a substantial amount of
money and increase the shelf life of their products
by understanding their products’ requirements and
taking the time to identify those barrier materials that
will most impact on shelf life at the beginning of the
package development process.
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