Principles and Applications of Modified Atmosphere Packaging of Foods

293 Pages·1998·6.85 MB·English

by  B. A. Blakistone (auth.), B. A. Blakistone (eds.)

Principles and Applications of Moditied
Atmosphere Packaging of Foods
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Principles and Applications
of Modified Atmosphere
Packaging of Foods
Second Edition
Edited by
B.A. BLAKISTONE
Senior Scientist
Food Chemistry and Packaging Department
National Food Processors Association
Washington DC
USA
Springer Science+Business Media, LLC
First edition 1993
Second edition 1998
© 1998 Springer Science+Business Media New York
Originally published by Thomson Science in 1998.
Softcover reprint of the hardcover 1s t edition 1998
Typeset in 1O/12pt Times by Cambrian Typesetters, Frimley, Surrey
Thomson Science is a division of International Thomson Publishing I(j)p·
ISBN 978-1-4757-6254-9 ISBN 978-1-4757-6252-5 (eBook)
DOI 10.1007/978-1-4757-6252-5
All rights reserved. No part of this publication may be reproduced, stored in a
retrieval system or transmitted in any form or by any means, electronic,
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The publisher makes no representation, express or implied, with regard to
the accuracy of the information contained in this book and cannot accept any
legal responsibility or liability for any errors or omissions that may be made.
A catalogue record for this book is available from the British Library
Library of Congress Catalog Card Number: 97-76967
@l Printed on permanent acid-free text paper, manufactured in accordance
with ANSIINISO Z39.48-1992 (Permanence of Paper).
Contents
Contributors xi
Preface xiii
1 Introduction 1
B.A. BLAKISTONE
1.1 Definitions, terminology and abbreviations 1
1.1.1 Modified atmosphere packaging (MAP) 1
1.1.2 Controlled atmosphere packaging (CAP) 1
1.1.3 Gas packaging 2
1.1.4 Vacuum packaging (VP) 2
1.1.5 Gas cocktail 2
1.1.6 Controlled atmosphere storage (CAS) 2
1.1.7 Hypobaric storage 3
1.2 Methods of atmosphere modification in packaged foods 3
1.2.1 Vacuum packaging 3
1.2.2 Gas packaging 3
1.3 Gases used in MAP 7
1.3.1 Oxygen 7
1.3.2 Carbon dioxide 8
1.3.3 Nitrogen 8
1.3.4 Carbon monoxide 8
1.3.5 Sulphur dioxide 9
1.4 Microbiology of MAP 9
1.4.1 Effects of spoilage microorganisms 9
1.4.2 Effects on pathogenic microorganisms 11
1.4.3 Storage temperatures 12
References 13
2 Markets for MAP foods 14
A.L. BRODY
2.1 Introduction 14
2.2 History of CAP, MAP and vacuum packaging 15
2.2.1 Tectrol 15
2.2.2 Transfresh 16
2.2.3 Cryovac 16
2.2.4 Processed meats 17
2.2.5 Bakery goods 17
2.2.6 Retail red me at 17
2.2.7 Sous-vide 18
2.2.8 Pasta 18
2.2.9 Microwave pasteurization 19
2.3 Europe 19
2.3.1 Uni ted Kingdom 20
VI CONTENTS
2.3.2 France 21
2.3.3 Germany 23
2.3.4 Italy 23
2.3.5 Other countries 24
2.3.6 Fresh meats 24
2.4 USA and Canada 25
2.4.1 Red meat 25
2.4.2 Pork 29
2.4.3 Poultry 29
2.4.4 Fish 30
2.4.5 Fruit and vegetables 30
2.4.6 Soft bakery goods 32
2.4.7 Prepared foods 34
2.4.8 Delicatessen salads 36
2.5 Contemporary issues in MAP technologies 36
2.6 Conclusion 37
Further reading 38
3 MAP machinery 39
M.J. HASTINGS
3.1 Historical development 39
3.2 Gases 39
3.3 Packaging material 41
3.4 Packaging machines 41
3.5 Chamber machines 41
3.5.1 Thermoforming system 41
3.5.2 Pre-formed container machines 45
3.6 Flexible form-fill-seal machine systems 48
3.6.1 Horizontal form-fill-seal machines systems 48
3.6.2 Inverted horizontal form-fill-seal machine systems 53
3.6.3 Vertical form-fill-seal systems 55
3.7 Fail-safe assurance 56
3.8 Automatie product feeding systems 58
3.9 Conclusion 59
Appendix 3.A Packaging systems for MAP 61
4 Packaging materials for MAP of foods 63
1. GREENGRASS
4.1 Introduction 63
4.2 Plastic films commonly used in MAP 67
4.2.1 Polyolefins 67
4.2.2 Vinyl polymers 71
4.2.3 Styrene polymers 73
4.2.4 Polyamides 73
4.2.5 Polyesters - polyethylene terephthalate (PET) 74
4.2.6 Otherfilms 74
4.3 Combination of films 75
4.3.1 Laminates, coextrusions and extrusion coating 75
4.3.2 Specifications 80
4.4 Typical specifications for MAP use 81
4.4.1 Horizontal and vertical form-fill-seal systems 83
4.4.2 Bulk gas packaging 84
4.4.3 Microwavable packs 85
4.4.4 Technical problems 85
4.4.5 Testing MAP packs 86
CONTENTS vii
4.5 Seal system and quality 87
4.5.1 Peelable seals 89
4.5.2 Antifog (AF) properties 90
4.5.3 Printing and labelling 91
4.5.4 Supplier/packer relations 93
4.6 Legislation and the environment 93
References 96
Appendix 4.A Film calculations 96
Appendix 4.8 Antifogging properties 98
Appendix 4.C Recommended storage conditions for MAP materials 99
Appendix 4.D Draft specification for MAP reels 99
Addendum to chapter: Specification development 101
5 Quality assurance of MAP products 102
I. ALU and L.M. WEDDIG
5.1 Introduction 102
5.2 Safety and quality of MAP foods 102
5.3 Application of HACCP to MAP foods 103
5.3.1 Revisions to HACCP Guidelines see page xiv
5.4 Total quality management and quality of MAP foods 110
5.5 Combining hazard analysis with both critical control point and total
quality control 111
5.6 International Organization for Standardization and ISO 9000 se ries
as a quality management tool 111
5.7 Inspection and testing methods 114
5.7.1 Film faults 114
5.7.2 Headspace gas analysis 114
5.7.3 Seal strength 114
5.7.4 Temperature checks 119
5.8 Regulatory aspects of MAP foods 121
5.8.1 HACCP 121
5.8.2 Labeling 121
5.9 Summary 123
References 123
6 Fresh-cut produce 125
E.H. GARRETI
6.1 Introduction 125
6.2 Product respiration and MAP 126
6.3 Quality maintenance 128
6.4 Safety of MAP produce 129
6.5 Packaging materials 130
6.6 Future industry needs 131
References 133
7 Bakery products 135
D.A.L. SEILER
7.1 Introduction 135
7.1.1 Types of wrapper 135
7.1.2 Reasons for improving shelf-life 135
7.2 Factors governing shelf life 136
7.2.1 Microbiological spoilage 137
viii CONTENTS
7.2.2 Staling 140
7.2.3 Moisture loss or gain 140
7.3 Methods of extending mould-free shelf-life 141
7.3.1 Hygiene considerations 141
7.3.2 Preventive measures 141
7.3.3 Destructive measures 142
7.3.4 Measures involving growth inhibition 143
7.4 MAP 145
7.4.1 Gas packaging 146
7.4.2 Oxygen scavengers 151
7.4.3 Ethanol 152
7.4.4 MAP methods and materials 153
7.5 Conclusions 155
References 156
8 Dairy foods, multi-component products, dried foods and
beverages 158
P.J. SUBRAMANIAM
8.1 Dairy products 158
8.1.1 Cheeses 158
8.1.2 Hard cheeses 159
8.1.3 Mould-ripened and soft cheeses 165
8.1.4 U nripened cheeses 167
8.1.5 Yoghurt 169
8.1.6 Milk 169
8.1.7 Milk powders 171
8.2 Coffee 171
8.2.1 Whole be ans 171
8.2.2 Ground coffee 172
8.2.3 Instant coffee 174
8.3 Tea 174
8.4 Snacks 175
8.4.1 Nuts 175
8.4.2 Crisps and other snacks 176
8.5 De\icatessen/multi-component products 178
8.5.1 Sandwiches 181
8.5.2 Dressed salads 182
8.5.3 Breaded and batter-coated products 183
8.5.4 Pastry-based products 184
8.5.5 Safety concerns 185
8.6 Fruit juices and other beverages 185
8.7 Use ofMAP in combination with other processes 188
References 190
9 Fish and shellfish 194
H.K. DAVIS
9.1 Introduction 194
9.2 Spoilage of fish 196
9.2.1 Effects of temperature on fish spoilage 199
9.2.2 Measurement of spoilage 199
9.2.3 Hazards associated with stored fish 202
9.3 Gaseous preservatives used in modified atmosphere storage offish 202
9.3.1 Properties of the principal components 202
9.3.2 Proportions of gases recommended for use in MAP 204
9.3.3 Vacuum packaging 205
CONTENTS lX
9.4 Changes occurring during storage of fish products in MAP 206
9.4.1 Composition of the headspace gas mixtures 206
9.4.2 Effect of MAP on the pH of fish products 207
9.4.3 Bacteriological changes 207
9.4.4 Effects of MAP on microbiological hazards 213
9.4.5 Sensory properties 216
9.4.6 Reference materials 220
9.4.7 Effects oftemperature rises on MAP products 221
9.4.8 MAP and chemical indices offish spoilage 221
9.4.9 Fish products in bulk MAP 222
9.4.10 Residual effects 224
9.5 Adjuvant treatments 224
9.5.1 Chemical additives 224
9.5.2 Physical treatments 226
9.6 Conclusion 227
References 228
10 Meats and pouItry 240
B.A. BLAKISTONE
10.1 Introduction 240
10.2 Microbiology of red meats 241
10.2.1 Microbiology of red meat 241
10.2.2 Colourofred me at 243
10.3 Packaging of meats and poultry 245
10.4 Vacuum packaging 246
10.5 Gas atmospheres 250
10.6 MAP storage of poultry 253
10.7 Meat products 258
10.7.1 Important considerations 258
10.7.2 Cured colour stability 261
10.7.3 Water activity, pH and microbial spoilage 262
10.8 Effects of MAP on selected me at products 264
10.8.1 Bacon 267
10.8.2 Beef jerky 268
10.8.3 Cooked beefroasts 268
10.8.4 Ground beef patties 270
10.8.5 British fresh sausages 270
10.8.6 Cooked meat loaves 272
10.8.7 Frankfurters 272
10.8.8 Harn 273
10.8.9 Meat pies 275
10.8.10 Pastrami 276
10.8.11 Wieners in natural casings 276
10.8.12 Poultry products 276
10.8.13 Cook-{:hill systems 277
10.8.14 Sous-vide cook-{:hill system 278
10.9 Safety aspects of MAP 278
10.10 The future 281
References 283
Index 291