Written by As the name suggest, the flexible packaging involves the use of flexible or foldable material that can easily be deformed to assume different forms. Some of them are plastic wraps, bags, pouches, etc flexible packaging films, as are of immense use in food packing and also increase the shelf life of a number of products. Here are some of the main ways flexible packaging enhances product shelf life:Here are some of the main ways flexible packaging enhances product shelf life:
Barrier Properties
Another function that is critical in the use of flexible packaging films is the ability to offer a barrier function. Barrier properties mean the capacity of the film to block or to be an obstruction to matters such as moisture, oxygen, light, etc: Most flexible packaging structures will comprise multilayer barrier films. For example, a cereal packet might carry a laminated pouch that is made up of polyester, aluminum foil, and polyethylene. Polyethylene on its own offers the weight advantage while polyester brings in the mechanical strength. Aluminum foil can be said to act as a very good cover to the product in that it restricts light, moisture, and gaseous products from penetrating through the packaging material. The combined effect makes the preservation of crispiness and freshness of the cereals.
Moisture Barrier
Energy management films employ specific plastics or metallic foils that help to minimize the loss of moisture and condensation. Some of the products that need protection from moisture include food items such as crisps and snacks as the moisture makes them less attractive to customers due to change in texture. On the other hand moisture loss is a big problem since it results to dried and unappetizing fresh produce. An optimized moisture barrier is assumed to enhance product stability and in some instance, the shelf life is doubled. For instance, microwaveable popcorn bags retain moisture so that the popcorn does not dry out while in storage and release moisture to allow the popcorn to heat up while in the microwave.
Oxygen Barrier
Oxygen brings about oxidation reactions in foods which equals to accelerated spoilage. Flexible packaging contains metals, metallized films, specialized plastics and oxygen scavengers to form an oxygen barrier. This helps to retain the food’s colour, texture and nutrients in their natural state. **Vacuum pouches** and Modified Atmosphere Packaging are innovative technologies that vacuum the residual oxygen all the way to the last drop before heat sealing. Lesser oxygen inside provides shelf lives 3 to 5 time higher. The use of oxygen barrier films has seen the accommodation of processed meats, ready-to-eat meals, snacks, dried foods, and many others for exportation.
Light Barrier
They are responsible for the rancidity of fats and color pigments in foods and active pharmaceutical ingredients upon exposure to light particularly ultraviolet light. This is averted by flexible packaging since the packaging material contains aluminum foils, metallized or films with UV blocking elements. Through light barrier beer producers are able to filled photosensitive products such as milk, vegetable oil, and shampoos in transparent flexible pouches. It ensures that the contents are highly exposed to light but at the same time protecting the contents from undergoing chemical reactions by effect of light.
Lower Bioburden
With regard to microbial contamination, the form for this flexible packaging is less likely to be contaminated with microbes at first as compared to a rigid packaging. To begin with, flexible films undergo high speeds in their production processes. This transfers heat to melt and steri- lize the contact surfaces. Second, the vast majority of the films go through chemical sterilization and washing before being filled. Lastly, sealing itself generates temporary local pasteurization since the hot metal jaws used are hot to the touch. Therefore, moisture loss and oxygen concentrations remain as the critical factors and not the initial germ loading. The ability of flexible packaging to protect and preserve sterilized or hot filled food items makes it ideal.
Retort Pouch Technology
Flexible packaging structures for the new generation known as retort pouches enable heat sterilization in sealed food packs. This distinctiveness is a product stability combined with consumer accessibility. Some of the products that are heat sterilized in retort pouches are shelf stable foods such as soups, curry preparations, rice preparations, baby foods, seafood etc. It is sterilized using steam at 240 degree Fahrenheit enables killing of bacteria spores as well. The distribution and storage also occur without requiring cold chain facilities. High temperatures as a result of heat exposure affects aluminum foils for instance; they get damaged. And therefore, retort pouches have specific polyester films that provide oxygen and light barriers and mechanical resistance.
Modified Atmosphere Packaging (MAP)
It is an advanced technology that involves the replacement of the air contained in a pack with a protective gas before sealing. This reduces the likelihood of microbial growth and prevents chemical reactions from occurring in foods. Packing fresh meat in packs, it is said that it can contain as much as 70% of oxygen in order to maintain that bright red shine. To counteract this process, coffee packets and baked goods are preserved in an atmosphere with more than 70% nitrogen. MAP also helps in the extension of the distribution networks with packaging centers. The distribution of fresh produce or any perishable food item either for long-distance transport or for display purposes becomes possible. It increases shelf life by three hundred and ninety percent compared with conventional packing method. All in all, it minimizes the level of product returns and damages in the supply chain system.
Active & Intelligent Packaging
Other newer developments include flexible packagings with active absorbing systems and time-temperature suggesting mechanisms. Active packaging means that active agents are placed inside the thickness of packaging walls. For example – oxygen; moisture absorbers; ethanol emitters etc Intelligent packaging includes sensors that monitor the quality of the product in real time. It is therefore important to state that time-temperature indicators reveal integrated heat experience. These leak indicators help to identify when the packages are compromised. These smart flexible packaging systems offer far more vital information concerning the shelf life than simply expiry dates. It enhances the consumer’s safety when purchasing the product while minimizing on things that may be needlessly stored at very low temperatures to prevent spoilage.
As a summary of the above discussion, there can be no doubt that multi purpose flexible packaging films meet the barrier needs of all types of food and pharmaceutical products. This assures the product goes through less handling, is stored for longer while not being exposed to unfavorable conditions hence reducing wastage. Technological advancements enhance packaging equipment and supply products that are safer for consumers globally. Ongoing research in developing high-performance barrier layers is gradually addressing the issue of product shelf life.
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