Packaging is the science, art and technology of enclosing or protecting products for
distribution, storage, sale and use. Packaging also refers to the process of design, evaluation,
and production of packages.
OBJECTIVES
Packaging have several objectives:
• Physical protection - The objects enclosed in the package may require protection from,
among other things, shock, vibration, compression, temperature, etc.
• Barrier protection - A barrier from oxygen, water vapor, dust, etc., is often required.
Package permeability is a critical factor in design. Some packages contain desiccants or
Oxygen absorbers to help extend shelf life. Modified atmospheres or controlled atmospheres
are also maintained in some food packages. Keeping the contents clean, fresh and safe for the
intended shelf life is a primary function.
• Containment or agglomeration - Small objects are typically grouped together in one
package for reasons of efficiency. For example, a single box of 1000 pencils requires less
physical handling than 1000 single pencils. Liquids, powders, and flowables need
containment.
• Information transmission - Information on how to use, transport, recycle, or dispose of the
package or product is often given on the package or label. With pharmaceutical, food,
medical, and chemical products, some types of information are required by legislation.
• Marketing - The packaging and labels can be used by marketers to encourage potential
buyers to purchase the product. Package design has been an important and constantly
evolving phenomenon for dozens of years. Marketing communications and graphic design are
applied to the surface of the package and (in many cases) the point of sale display.
• Security - Packaging can play an important role in reducing the security risks of shipment.
Packages can be made with improved tamper resistance to deter tampering and also can have
tamper-evident features to help indicate tampering. Packages can be engineered to help
reduce the risks of package pilferage: Some package constructions are more resistant to
pilferage and some have pilfer indicating seals. Packages may include authentication seals to
help indicate that the package and contents are not counterfeit. Packages also can include
anti-theft devices, such as dye-packs, Radio Frequency Identification (RFID) tags, or
electronic article surveillance tags, that can be activated or detected by devices at exit points
and require specialized tools to deactivate. Using packaging in this way is a means of loss
prevention.
• Convenience - Packages can have features which add convenience in distribution, handling,
display, sale, opening, reclosing, use and reuse.
• Portion control - Single serving or single dosage packaging has a precise amount of
contents to control usage. Bulk commodities (such as salt) can be divided into packages that
are a more suitable size for individual households. It is also aids the control of inventory:
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selling sealed one-liter-bottles of milk, rather than having people bring their own bottles to
fill themselves.
TYPES OF PACKAGING
1. Vacuum Packaging – Removes air to extend shelf life and prevent microbial growth.
1. Modified Atmosphere Packaging (MAP) – Alters the gas composition inside the
package to slow down spoilage.
2. Aseptic Packaging – Sterile packaging to maintain product freshness without
preservatives.
3. Canning – Heat-sterilized packaging to prevent bacterial contamination.
4. Shrink Wrapping – Uses heat to tightly wrap products for protection and stability.
ADVANCED & SMART PACKAGING TECHNOLOGIES
6. Active Packaging – Includes oxygen scavengers, moisture regulators, or
antimicrobial agents to enhance food safety.
7. Intelligent Packaging – Uses indicators (e.g., time-temperature sensors, freshness
sensors) to monitor food quality.
8. Edible Packaging – Biodegradable and safe to consume, often made from starch,
protein, or alginate.
9. Biodegradable Packaging – Uses compostable materials like plant fibers, PLA, or
seaweed.
10. Nanotechnology-based Packaging – Incorporates nanoparticles for improved barrier
properties, antimicrobial effects, and extended shelf life.
PROTECTIVE & CONVENIENCE PACKAGING
11. Retort Packaging – Flexible, heat-resistant pouches for ready-to-eat foods.
12. Skin Packaging – Film tightly adheres to the product, offering visibility and
protection.
13. Blister Packaging – Common for pharmaceuticals and small food items like gum or
chocolates.
14. Clamshell Packaging – Hinged plastic or paper-based containers for fresh produce
and bakery items.
15. Foil Packaging – Provides excellent barrier properties against moisture, oxygen, and
light.
SUSTAINABLE & ECO-FRIENDLY PACKAGING
16. Recyclable Packaging – Designed to be processed and reused (e.g., PET bottles,
cardboard).
17. Compostable Packaging – Breaks down into organic matter under composting
conditions.
18. Paper-based Packaging – Used as an alternative to plastics for environmental
benefits.
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19. Plant-based Packaging – Made from cornstarch, mushrooms, or other biodegradable
sources.
20. Water-soluble Packaging – Dissolves in water, used for instant food and detergent
pods.
SPECIALIZED PACKAGING TECHNOLOGIES
21. HPP (High-Pressure Processing) Packaging – Uses high pressure instead of heat
for sterilization.
22. Cold Chain Packaging – Maintains low temperatures for perishable goods (e.g.,
insulated boxes, gel packs).
23. Tamper-evident Packaging – Has seals or indicators that show if a product has been
opened.
24. Self-heating or Self-cooling Packaging – Uses chemical reactions to warm or cool
food on demand.
25. Microwaveable Packaging – Designed for direct heating in a microwave without
releasing harmful substances.
ESSENTIAL QUALITIES OF FOOD PACKAGING MATERIALS
A. Barrier Properties
• Oxygen Barrier – Prevents oxidation & microbial growth
– Materials: Aluminum foil, PET, EVOH (Ethylene Vinyl Alcohol),
Polyamide (Nylon)
• Moisture Barrier – Prevents dehydration & mold growth
– Materials: Polyethylene (PE), Polypropylene (PP), PVDC-coated films
• Light Barrier – Protects vitamins, flavors & colors
– Materials: Amber glass, UV-coated plastics, Aluminum laminates
B. Mechanical Strength & Durability
• Packaging must withstand handling, stacking, and transportation stress.
• Rigid vs. Flexible Packaging:
– Rigid (Glass, Metal, Hard Plastics): Suitable for delicate foods & liquids.
– Flexible (Pouches, Plastic Wraps): Lightweight, reduces waste, cost-
effective.
C. Chemical Resistance
• Prevents reaction with acidic, oily, or alkaline foods.
• Example: Glass and High-Density Polyethylene (HDPE) are chemically inert.
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D. Thermal Stability
• Must tolerate freezing, microwaving, pasteurization, or sterilization.
• Example: Retort pouches and heat-resistant plastics like Polypropylene (PP) are
used in high-heat applications.
E. Sustainability & Environmental Impact
• Recyclable Packaging: PET bottles, glass containers.
• Compostable Packaging: Biopolymers (PLA), starch-based films.
• Edible Packaging: Seaweed films, protein-based coatings.
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TYPES OF PACKAGING MATERIAL
GLASS
It is the preferred packaging material. It is also used in pharmaceutical industry
because it possesses superior protective qualities. Glass containers are readily
available in a variety of sizes and shapes. It is an amorphous, hard, brittle,
transparent or translucent .having no definite melting point obtained by fusing a
mixture of a number of metallic silicates or borates of sodium, potassium,
calcium and lead.
PROPERTIES OF GLASS
Transparency – Allows easy visibility of the product inside.
Chemical Inertness – Does not react with food or beverages, ensuring product
safety.
Barrier Properties – Provides an excellent barrier against gases, moisture, and
contaminants.
Recyclability – 100% recyclable without loss of quality.
Non-Porous & Non-Permeable – Prevents absorption of flavors, odors, and
microorganisms.
Heat Resistance – Can withstand high temperatures during sterilization and
pasteurization.
Rigid & Fragile – Offers structural integrity but is prone to breakage.
Heavyweight – Compared to other packaging materials, glass is relatively
heavy.
METHOD OF MANUFACTURING
The manufacturing process of glass
Consists of four major operations:
(1) Melting
(2) Shaping
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(3) Annealing
(4) Finishing
1. Melting. The ingredients called batch materials are mixed in the appropriate
proportion and heated to fusion in a furnace. Many designs of glass furnace are
in use. The two most commonly used furnaces are: (i) Pot furnace and (ii) Tank
furnace.
2. Shaping - The plastic glass formed in the furnace is next shaped or formed
into the desired articles. It is accomplished by blowing from mouth or by means
of a machine. Glass blowing is a skillful art. The blowing of a glass into bottle
is done as illustrated. It is elongated under its weight when hung downwards.
The elongated lump is introduced into a mould and is inflated by blowing air
into it from the mouth. On cooling, the bottle is taken out by removing the two-
halves of the mould.
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3. Annealing It is a process of cooling slowly the newly shaped articles. If they
are cooled quickly they become brittle on account of the high internal strain.
Annealing is done in a tunnel like oven called lehr. which is 50 to 60 feet long.
At one end the temperature is a little below the softening point of glass, i.e.,
500-600°C and it gradually falls along the length of the oven. At the other end
the temperature is almost the same as the room temperature. Immediately after
shaping, the articles are introduced into the lehr at the hotter end and travel
towards the cooler end by means of a moving belt. It takes a few hours for the
articles to move along through the tunnel. Some high quality glasses require
long annealing.
4. Finishing. The articles obtained from the lehr are subjected to a number of
operations such as cleaning, polishing, rounding edges, etc., for bringing them
to a useable form.
TYPES OF GLASS USED IN FOOD PACKAGING
Soda-lime glass: This is the most common type of glass used in food
packaging. It is made from silica sand, soda ash, and limestone. It is
strong and durable, and it is resistant to heat and chemicals. However, it
is not as resistant to impact as some other types of glass.
Borosilicate glass: This type of glass is also known as Pyrex. It is made
from silica sand and boron oxide. It is more resistant to heat and thermal
shock than soda-lime glass. It is also more resistant to chemicals.
However, it is more expensive than soda-lime glass
Lead crystal glass: This type of glass is made from silica sand, lead
oxide, and potassium oxide. It is known for its brilliance and clarity.
However, it is more expensive than soda-lime glass and borosilicate
glass. It is also not as resistant to heat as these other types of glass.
Chemicals added to glass:
Soda ash (sodium carbonate): This is used to lower the melting point of
the glass.
Limestone (calcium carbonate): This is used to stabilize the glass and
make it more resistant to water.
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Boron oxide: This is used to make the glass more resistant to heat and
thermal shock.
Lead oxide: This is used to make the glass more brilliant and clear.
Potassium oxide: This is used to make the glass more resistant to
chemicals.
Other chemicals that may be added to glass include:
- Alumina: This is used to make the glass more durable.
- Magnesia: This is used to make the glass more resistant to heat and
chemicals.
- Barium oxide: This is used to increase the refractive index of the glass.
- Antimony oxide: This is used to make the glass more resistant to
weathering.
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PACKAGING MATERIAL
PAPER- Paper, a versatile and widely available material, has been used for food packaging
for centuries. Its biodegradability and renewability make it an attractive option in an era of
increasing environmental awareness. However, its properties and limitations must be
carefully considered for safe and effective food packaging.
I. Properties of Paper Relevant to Food Packaging:
Porosity:
o Paper is inherently porous, allowing for gas exchange. This can be beneficial
for some foods (e.g., bread) but detrimental to others (e.g., foods requiring
moisture barriers).
Tensile Strength and Tear Resistance:
o Varies depending on paper type. Kraft paper is strong, while thinner papers are
more fragile.
Moisture Sensitivity:
o Paper absorbs moisture, leading to weakening and potential microbial growth.
o Moisture barriers (coatings, laminations) are often necessary.
Grease Resistance:
o Untreated paper is permeable to oils and fats.
o Grease-resistant papers are treated with chemicals or coatings.
Printability:
o Paper is easily printable, allowing for branding and labeling.
Biodegradability and Compostability:
o Paper is biodegradable and compostable, making it an environmentally
friendly option.
Recyclability:
o Paper is widely recyclable, contributing to a circular economy.
II. Types of Paper Used in Food Packaging:
Kraft Paper:
o Strong, unbleached paper used for bags, sacks, and wrapping.
Paperboard/Cardboard:
o Thicker, rigid material used for boxes, cartons, and trays.
Greaseproof Paper:
o Treated paper with a barrier to oils and fats.
o Used for wrapping greasy foods (e.g., pastries).
Waxed Paper:
o Paper coated with wax for moisture resistance.
o Used for wrapping sandwiches, candies, etc.
Laminated Paper:
o Paper combined with other materials (e.g., plastic, aluminum foil) for
enhanced barrier properties.
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Paper Production Processes
Kraft Process - The kraft process, also known as kraft pulping or sulfate process, is the
dominant method for producing paper.
Raw Material: Wood chips are used as the primary raw material.
Chemical Treatment: Wood chips are treated with a hot mixture of water, sodium hydroxide
(NaOH), and sodium sulfide (Na2S), known as white liquor.
Pulping: The chemical treatment breaks the bonds linking lignin, hemicellulose, and
cellulose.
Recovery: The process uses a recovery boiler to recycle inorganic pulping chemicals, making
it a nearly closed-cycle process.
Strength: The resulting kraft paper is known for its strength, which is reflected in the process
name (Kraft means "strength" in German).
Sulphite Process
The sulphite process is an alternative chemical pulping method.
Chemical Treatment: Wood is pulped using SO2 adsorbed in a base solution.
Pulp Characteristics: Sulphite pulping produces a weaker paper compared to kraft pulping,
but the pulp is less colored.
Applications: The resulting pulp is more suitable for printing, often requiring little bleaching
Paperboard Types
White Board:
o A type of paperboard with a bleached or coated white surface on one or both
sides.
o Provides a clean, bright appearance, ideal for printing and graphics.
o Often used for packaging where visual appeal is crucial, such as retail boxes,
display packaging, and food packaging.
o Can be coated or uncoated, affecting its printability and barrier properties.
Linerboard:
o A strong, kraft paper-based material used as the facing (outer layer) of
corrugated fiberboard.
o Provides structural integrity and a smooth surface for printing.
o Available in various grades, depending on strength and weight requirements.
o Key characteristics include burst strength and tear resistance.
Foodboard:
o Specifically designed for direct contact with food products.
o Must meet stringent food safety regulations.
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o Often coated with barrier materials (e.g., polyethylene, wax) to provide
moisture and grease resistance.
o Used for food containers, trays, and packaging that prevents contamination.
Cartonboard (Folding Boxboard):
o A stiff, multi-layered paperboard used for folding cartons.
o Offers good printability and folding properties.
o Available in various grades, depending on thickness, strength, and coating.
o Commonly used for cereal boxes, frozen food packaging, and beverage
cartons.
Cardboard:
o This term is often used generically, but it can be ambiguous. It can refer to:
Thin, single-layer paperboard.
Thicker paperboard used for boxes and packaging.
It is very often used as a general term for corrugated fiberboard.
o To reduce confusion, it's best to use more specific terms like cartonboard or
corrugated fiberboard.
Corrugated Fiberboard:
o A structural material made by gluing a corrugated (fluted) medium between
two linerboards.
o Provides exceptional strength and cushioning properties.
o Used for shipping containers, boxes, and protective packaging.
o Available in various flute sizes (A, B, C, E, F), each offering different strength
and cushioning characteristics.
o The flutes provide resistance to bending and compression.
o It is very recyclable.
CFB
Corrugated Fiberboard (CFB) is a widely used packaging material known for its strength,
versatility, and cost-effectiveness. It consists of a fluted (corrugated) medium sandwiched
between two linerboards, providing structural integrity and cushioning properties.
Structure and Properties of CFB:
Components:
o Linerboard: The flat outer layers, providing a smooth surface for printing and
structural support.
o Corrugated Medium (Fluting): The inner, wavy layer that provides strength
and cushioning.
o Adhesive: Used to bond the linerboard and fluting together.
Flute Types:
o A-Flute: Provides excellent cushioning and stacking strength.
o B-Flute: Offers good crush resistance and printability.
o C-Flute: A balance of stacking strength and crush resistance, widely used.
o E-Flute: Thin and lightweight, suitable for retail packaging.
o F-Flute: Very thin, used for high-quality printing and packaging.
Properties:
o Strength: Provides excellent structural support and stacking ability.
o Cushioning: Protects contents from impact and vibration.
o Lightweight: Reduces shipping costs.
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o Cost-Effective: Relatively inexpensive compared to other packaging
materials.
o Printability: Allows for branding and labeling.
o Recyclability: Highly recyclable and made from renewable resources.
o Biodegradability: Biodegradable under certain conditions.
II. Manufacturing Process:
Corrugating:
o The corrugated medium is formed by passing it through heated fluting rolls.
Combining:
o The fluted medium is glued to the linerboards.
Cutting and Scoring:
o The combined board is cut and scored to create the desired box shapes.
Printing and Finishing:
o The boxes are printed and may undergo additional finishing processes.
III. Applications of CFB:
Shipping Cartons:
o Used for transporting a wide range of goods.
Retail Packaging:
o Used for consumer
products, including
food, electronics,
and household
items.
Point-of-Purchase (POP)
Displays:
o Used for promotional displays in retail stores.
Moving Boxes:
o Used for packing and transporting household items.
Food Packaging:
o Used for produce, baked goods, and other food items.
Industrial Packaging:
o Used for heavy-duty packaging
of industrial products.
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TYPES OF PACKAGING MATERIAL
PLASTIC
Introduction Plastics are defined as ‘organic macromolecular compounds
(polymers) obtained from molecules of lower molecular weight (monomers) by
polymerization through polycondensation polyaddition The most widely
used plastic today, polyethylene, was invented in 1933 – it was used in
packaging from the late 1940s onwards
MANUFACTURING OF PLASTICS
• Plastics are made by condensation polymerization (polycondensation) or
addition polymerization (polyaddition) of monomer units
• In polycondensation, the polymer chain grows by condensation reactions
between molecules and is accompanied by formation of low molecular weight
byproducts such as water and methanol
• Polycondensation involves monomers with at least two functional groups such
as alcohol, amine, or carboxylic groups
• In polyaddition, polymer chains grow by addition reactions, in which two or
more molecules combine to form a larger molecule without liberation of by-
products
• Polyaddition involves unsaturated monomers; double or triple bonds are
broken to link monomer chains
Feature Thermoset Thermoplastic
Behavior upon Undergoes irreversible Softens upon heating, hardens
heating chemical change upon cooling (reversible)
(curing)
Molecular structure Cross-linked polymer Linear or branched polymer
chains chains
Melting/Remolding Cannot be melted or Can be melted and remolded
remolded
Strength Generally stronger and Generally less strong and more
more rigid flexible
Impact resistance Can be brittle, lower Generally higher impact
impact resistance resistance
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Chemical resistance Generally good Variable chemical resistance
chemical resistance
Temperature Generally higher Lower temperature resistance
resistance temperature resistance
Recyclability Difficult or impossible Generally recyclable
to recycle
Examples Epoxy, polyurethane, Polyethylene (PE),
vulcanized rubber, polypropylene (PP),
bakelite polystyrene (PS), polyvinyl
chloride (PVC)
Applications Adhesives, coatings, Packaging, toys, pipes,
electrical insulation, automotive parts
composites
Processing Often involves curing Often involves melt processing
(heat and/or pressure) (injection molding, extrusion,
etc.)
IMPORTANT PLASTICS :-
polyethylene (PE)
• polypropylene (PP)
• polyesters (PET, PEN, PC) (note: PET is referred to as PETE in some
markets)
• ionomers
• ethylene vinyl acetate (EVA)
• polyamides (PA)
• polyvinyl chloride (PVC)
• polyvinylidene chloride (PVdC)
• polystyrene (PS)
• styrene butadiene (SB)
• acrylonitrile butadiene styrene (ABS)
• ethylene vinyl alcohol (EVOH)
• polymethyl pentene (TPX)
• high nitrile polymers (HNP)
• fluoropolymers (PCTFE/PTFE)
• cellulose-based materials
• polyvinyl acetate (PVA)
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Polyethylene Terephthalate (PET or PETE) (#1):
Characteristics:
o Clear, strong, and lightweight.
o Good barrier against gases and moisture.
o Recyclable.
Applications:
o Beverage bottles (water, soda, juice).
o Food jars and containers.
o Salad dressing and cooking oil bottles.
Considerations:
o Generally considered safe, but prolonged exposure to high
temperatures may cause leaching of chemicals.
High-Density Polyethylene (HDPE) (#2):
Characteristics:
o Rigid, strong, and resistant to chemicals.
o Good moisture barrier.
o Recyclable.
Applications:
o Milk jugs, juice bottles.
o Yogurt and margarine tubs.
o Grocery bags.
Considerations:
o Considered a relatively safe plastic choice.
Polyvinyl Chloride (PVC) (#3):
Characteristics:
o Flexible or rigid, depending on additives.
o Good chemical resistance.
Applications:
o Cling wrap.
o Some food trays.
Considerations:
o Contains phthalates, which can leach and pose health risks.
o Recycling is challenging.
Low-Density Polyethylene (LDPE) (#4):
Characteristics:
o Flexible, soft, and transparent.
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o Good moisture barrier.
Applications:
o Squeeze bottles.
o Plastic films and bags.
o Food storage containers.
Considerations:
o Considered relatively safe.
Polypropylene (PP) (#5):
Characteristics:
o Rigid, strong, and heat-resistant.
o Good chemical resistance.
Applications:
o Yogurt and ice cream containers.
o Microwaveable food containers.
o Bottle caps.
Considerations:
o Considered a relatively safe plastic choice.
Polystyrene (PS) (#6):
Characteristics:
o Rigid or foamed (Styrofoam).
o Lightweight and inexpensive.
Applications:
o Disposable cups and plates.
o Takeout containers.
Considerations:
o Can leach styrene, a potential health hazard.
o Difficult to recycle.
Other (Including Polycarbonate) (#7):
Characteristics:
o This category includes various plastics, some of which may contain
bisphenol A (BPA).
Applications:
o Water cooler jugs.
o Some reusable food containers.
Considerations:
o BPA has been linked to potential health risks.
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LAMINATED FILMS
Laminates are the combination of two or more layers of packaging films. They
are used when required properties are not achieved in single packaging material.
Laminates are used for:
1. Good water vapour barrier properties
2. Good gas barrier properties
3. Good grease resistance
4. Heat sealing facility
5. To provide strength to the base film
6. To improve toughness
7. To improve tear resistance
8. To improve abrasion resistance
9. To improve machinability
10. To improve printability
METHODS TO LAMINATE MATERIALS
1. Adhesive Lamination: The webs are bonded by means of a suitable
adhesive which may be (i) Aqueous, (ii) Lacquer or (iii) Hot melt. The
adhesive is applied to the web which is subsequently brought in to contact
with another by passing through two rollers.
Aqueous adhesives: Dextrin, Starch, Casein, Sodium silicate
Lacquers: Polymethanes, urea formaldehyde, nylons, vinyls.
Hot melts: Wax and wax blends.
2. Extrusion Lamination: A thermoplastic web is directly extruded on to a
suitable substrate web. Extrusion coating could also be achieved. It is a
cheap process. A thermal extrusion or co-extrusion can be used.
3. Direct Heat Lamination: A thermoplastic web maybe bonded to a second
one by heat and pressure without the use of an adhesive
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TETRA PACK
1. Polyethylene – Contributes 15% of the total packaging; it protects from
outside moisture.
2. Paper – Contributes 80% of the total packaging for providing stability,
strength and smoothness to the printing surface.
3. Polyethylene – Polyethylene acts as an adhesive layer between other layers.
4. Aluminum foil – Contributes 5% of the total packaging. It forms a barrier
against light and oxygen, eliminating the need for refrigeration and preventing
spoilage without using preservatives.
5. Polyethylene – Acts as an adhesion layer.
6. Polyethylene – Seals the Liquid from inside.
COMPOSITE CONTAINERS
Recently due to development of laminates with metalized films which are
having similar properties of a metal container with less cost, the use of metal
containers is decreasing.
Therefore, cans made from a combination of paperboard, foil, and plastic are
now used in place of metal cans.
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Kraft paper is the main component in the can body. The inside of the can is
plastic (low-density polyethylene, polypropylene, or ionomer) often backed by
foil for added barrier properties. End closures can be made of metal, plastic,
paper, or a combination of these materials.
Composite cans are manufactured by a spin convolute wound method, with
spiral cans dominating the market due to their superior barrier characteristics.
Composite cans are widely used to package shortening, powdered and
dehydrated baby foods, aseptically packaged single-strength fruit juices, and
frozen dough.
RETORT POUCHES
Retort is a cooking process that uses heat and pressure to cook food in its sealed
package. Retort Pouches conditions are quite demanding with temperatures
typically ranging from 120°C to 130°C.
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ACTIVE PACKAGING
Definition: Packaging that enhances the shelf life and safety of food products
by interacting with the contents, typically through the use of additives that
actively modify the package environment.
Historical Development:
The term "active packaging" was popularized in the late 1980s,
particularly through Dr. Theodore Labuza's work.
Notable early patents date back to the 1930s with various methods for
oxygen removal (e.g., use of iron, zinc, and manganese powders).
Examples -
1. Oxygen Absorbers:
Function: Removes oxygen from the package atmosphere, reducing
oxidation and spoilage.
Applications: Commonly used in vacuum-sealed meats, baked goods,
and dried fruits.
Example: Sachets containing iron powder or other chemical agents that
absorb oxygen.
2. Moisture Absorbers:
Function: Reduces humidity inside the package, preventing mold growth
and spoilage.
Applications: Used in products like dried fruits, cereals, and
pharmaceuticals.
Example: Silica gel packets or zeolite-based materials.
3. Ethylene Absorbers:
Function: Absorbs ethylene gas, which is produced by ripening fruits and
vegetables to slow down ripening.
Applications: Extends the shelf life of fresh produce, particularly in
supply chains.
Example: Potassium permanganate or activated carbon sachets.
4. Carbon Dioxide Emitters:
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Function: Produce carbon dioxide within the package environment to
inhibit microbial growth.
Applications: Often used in modified atmosphere packaging (MAP) for
perishables.
Example: Certain chemical systems that release CO₂ upon activation.
5. Antimicrobial Packaging:
Function: Incorporates substances that inhibit or kill spoilage-causing
microorganisms.
Applications: Suitable for meat, dairy, and ready-to-eat meals.
Example: Films or coatings infused with natural or synthetic
antimicrobial agents like silver or organic acids.
6. Smart Films:
Function: Selectively permeable films that adjust permeability based on
the surrounding environment.
Applications: Used in MAP where gas concentrations fluctuate.
Example: Films made of a combination of polymers, such as HDPE and
PET, engineered to allow CO₂ to escape while blocking O₂.
INTELLIGENT PACKAGING:
Definition: Packaging systems that provide information about the
condition of the product, often incorporating technology that can monitor
time and temperature or detect spoilage.
Functions:
Time-Temperature Indicators (TTIs) that display product freshness.
Sensors to detect gas composition changes within the packaging.
EXAMPLES-
1. Time-Temperature Indicators (TTIs):
Function: Provides visual indications of temperature exposure and time, informing
consumers about product quality.
Applications: Used in refrigerated and chilled food products.
Example: Labels that change color after a certain time at temperature, indicating
potential spoilage.
2. Gas Concentration Indicators:
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Function: Monitors and signals changes in gas composition (e.g., O₂ and CO₂ levels)
in the package.
Applications: Useful for fresh produce and packaged meats to maintain optimal
atmospheric conditions.
Example: Colorimetric sensors that change color based on gas levels.
3. Tamper-Evident Technologies:
Function: Indicators that change appearance if a package has been opened or
tampered with.
Applications: Common in pharmaceuticals, food, and beverages to enhance
consumer confidence.
Example: Labels or seals that reveal a color change or message when broken.
4. Smart Labels:
Function: Incorporate RFID or NFC technology to allow for tracking and interaction
with smartphones.
Applications: Enhances inventory management in retail and supply chain.
Example: QR codes or tags that provide detailed product information or freshness
alerts when scanned.
5. Interactive Packaging:
Function: Engages consumers through games or contests using augmented reality
(AR) or QR codes.
Applications: Marketing and brand engagement, particularly in the food and
beverage sectors.
Example: Labels that lead users to online experiences when scanned.
FSSAI ACT Series Food Safety Officer Mahapack
VACUUM PACKAGING
Vacuum packing is a method of packaging that removes air from the package
prior to sealing. This method involves (manually or automatically) placing
items in a plastic film package, removing air from inside, and sealing the
package. The intent of vacuum packing is usually to remove oxygen from the
container to extend the shelf life of foods and, with flexible package forms, to
reduce the volume of the contents and package.
Vacuum packing reduces atmospheric oxygen, limiting the growth of aerobic
bacteria or fungi, and preventing the evaporation of volatile components. It is
also commonly used to store dry foods over a long period of time, such as
cereals, nuts, cured meats, cheese, smoked fish, coffee, and potato chips. On a
more short term basis, vacuum packing can also be used to store fresh foods,
such as vegetables, meats, and liquids, because it inhibits bacterial growth.
TYPES OF VACUUM PACKAGING MACHINES
External sealers
Single Vacuum Chamber Machines
Double Vacuum Chamber Machines
Rotary belt type vacuum sealer (Rolling vacuum sealer)
Automatic Belt Vacuum Chamber Machines
Thermoforming Vacuum Packaging Machines
1. Single Vacuum Chamber Machines Single chamber sealers require the
entire product to be placed within the machine. Like external sealers, a
plastic bag is typically used for packaging. Once the product is placed in
the machine, the lid is closed and air is
removed. Then, there is a heat seal inside
the chamber that will seal the bag, after
sealing the bag the chamber is refilled
with air by the automatic opening of a
vent to the outside. This oncoming
pressure squeezes all remaining air in the
bag. The lid is then opened and the
product removed.
2. Double chamber sealers are typically
used for medium-volume packaging, and
also have the capability to vacuum seal
FSSAI ACT Series Food Safety Officer Mahapack
liquids. The lid generally
swings from one side to
another, increasing production
speed over a single chamber
model. Double chamber
vacuum packaging machines
generally have either spring-
weighted lids or fully
automatic lids.
3. AUTOMATIC BELT
VACUUM CHAMBER MACHINES - The product travels on the
conveyor belt and automatically positioned in the machine, the lid is
closed and the air gets removed and finally sealed. The chamber is
refilled with air by the automatic opening of a vent to the outside
Suitable for packaging of large items.
FSSAI ACT Series Food Safety Officer Mahapack
TESTING OF PACKAGING MATERIALS
NEED FOR TESTING PACKAGING MATERIAL
1. Comparison with competitive packaging material, e.g. to compare offers.
2. Comparison of the current supply of material with the quality of that
offered for the first time; also regular checking of uniformity in new
supplies of packaging materials.
3. Quality checks during the production of packaging materials.
4. Evaluation of the suitability of a packaging material for a certain specific
purpose, for instance protection against mechanical or climatic hazards.
IMPORTANT ORGANIZATIONS
1. ASTM - American Society of Testing and Materials Standards
2. TAPPI - Technical Association for the Pulp and Paper Industry (USA)
Standards
3. BIS - Bureau of Indian Standards
4. ISO/R - International Standards Recommendations BS - British Standards
5. FEFCO - Federation Europeanne des Fabricants de Carton Ondule Test
Methods
6. PIFA - Packaging and Industrial Films Association Standards
7. ABA - American Box Board Association
8. BPBMA - British Paper and Board Manufacturers' Association
9. NFPA - National Flexible Packaging Association
SAMPLING
Sample Size: Factors influencing sample size include the desired confidence
level, acceptable quality level (AQL), and the variability of the material.
SAMPLING METHOD:
• Random sampling: Each unit in the batch has an equal chance of being
selected.
• Stratified sampling: The batch is divided into subgroups (strata), and
samples are selected from each stratum.
FSSAI ACT Series Food Safety Officer Mahapack
• Systematic sampling: Samples are selected at regular intervals.
• Judgment sampling: Samples are selected based on expert judgment (use
with caution).
CONDITIONING OF TEST SPECIMENS
The process of exposing the test specimen to a standard condition is
known as “conditioning of test specimens”.
As per Indian Standards IS : 1060 (Part – I) 1966, a standard atmospheric
conditions of 27°C ± 1°C and 65% ± 2% relative humidity is maintained
to expose the samples for to 24 hours prior to conduct the tests.
FSSAI ACT Series Food Safety Officer Mahapack
TESTING OF PACKAGING MATERIALS
NEED FOR TESTING PACKAGING MATERIAL
1. Comparison with competitive packaging material, e.g. to compare offers.
2. Comparison of the current supply of material with the quality of that
offered for the first time; also regular checking of uniformity in new
supplies of packaging materials.
3. Quality checks during the production of packaging materials.
4. Evaluation of the suitability of a packaging material for a certain specific
purpose, for instance protection against mechanical or climatic hazards.
IMPORTANT ORGANIZATIONS
1. ASTM - American Society of Testing and Materials Standards
2. TAPPI - Technical Association for the Pulp and Paper Industry (USA)
Standards
3. BIS - Bureau of Indian Standards
4. ISO/R - International Standards Recommendations BS - British Standards
5. FEFCO - Federation Europeanne des Fabricants de Carton Ondule Test
Methods
6. PIFA - Packaging and Industrial Films Association Standards
7. ABA - American Box Board Association
8. BPBMA - British Paper and Board Manufacturers' Association
9. NFPA - National Flexible Packaging Association
SAMPLING
Sample Size: Factors influencing sample size include the desired confidence
level, acceptable quality level (AQL), and the variability of the material.
SAMPLING METHOD:
• Random sampling: Each unit in the batch has an equal chance of being
selected.
• Stratified sampling: The batch is divided into subgroups (strata), and
samples are selected from each stratum.
FSSAI ACT Series Food Safety Officer Mahapack
• Systematic sampling: Samples are selected at regular intervals.
• Judgment sampling: Samples are selected based on expert judgment (use
with caution).
CONDITIONING OF TEST SPECIMENS
The process of exposing the test specimen to a standard condition is
known as “conditioning of test specimens”.
As per Indian Standards IS : 1060 (Part – I) 1966, a standard atmospheric
conditions of 27°C ± 1°C and 65% ± 2% relative humidity is maintained
to expose the samples for to 24 hours prior to conduct the tests.
FSSAI ACT Series Food Safety Officer Mahapack
PACKAGING MATERIAL EVALUATION
Packaging material evaluation is crucial to ensure that the packaging adequately protects the
product during storage, transportation, and handling.
Tensile Strength:
o This test measures the maximum stress a material can withstand while being
stretched or pulled before breaking.
o It indicates the material's resistance to tearing and stretching forces.
o Important for evaluating the packaging's ability to maintain integrity under
tension.
Burst Test:
o The burst test determines the material's resistance to rupture when pressure is
applied to one of its sides.
o It's particularly relevant for evaluating materials used for bags, pouches, and
cartons that may experience internal pressure.
Grammage:
o Grammage refers to the mass per unit area of a material, usually expressed in
grams per square meter (g/m²).
o It's a fundamental property that affects the material's stiffness, thickness, and
strength.
o Used for quality control and material specification.
Tear Resistance:
o This test measures the material's ability to resist tearing after an initial cut or
puncture.
o It's critical for assessing the packaging's durability during handling and
transportation.
Cobb Test:
o The Cobb test determines the amount of water absorbed by a material
(especially paper and cardboard) in a specific time under standard conditions.
o It's important for evaluating the material's water resistance, which can affect
its strength and integrity.
Coefficient of Friction (COF):
o COF measures the resistance to sliding between two surfaces.
o Static COF refers to the force required to start moving, and kinetic COF is the
force required to maintain movement.
o Important for packaging line efficiency (smooth running) and pallet stability.
Dart Impact Test:
o This test measures the material's resistance to impact by dropping a dart from
a specified height.
o It assesses the material's toughness and ability to withstand sudden forces,
crucial for preventing punctures and damage during handling.
Pin Hole Test:
o This test detects the presence of small holes or imperfections in the material.
o Pinholes can compromise the barrier properties of packaging, leading to
spoilage or contamination.
Water Vapor Transmission Rate (WVTR):
o WVTR measures the rate at which water vapor passes through a material.
o It's critical for packaging that needs to protect products from moisture gain or
loss.
FSSAI ACT Series Food Safety Officer Mahapack
Oxygen Transmission Rate (OTR):
o OTR measures the rate at which oxygen passes through a material.
o Important for packaging food and other oxygen-sensitive products, as oxygen
can cause spoilage and degradation.
Gas Transmission Rate (GTR):
o GTR is a general term that measures the rate at which any gas (including CO2,
nitrogen, etc.) passes through a material.
o Relevant for modified atmosphere packaging (MAP) and other applications
where gas barrier properties are crucial.
Peeling Test:
o This test measures the force required to separate two layers of a laminated
material or to open a sealed package.
o It's important for evaluating the seal strength and openability of packaging.
Dye Penetration Test:
o This test uses a dye to detect defects, cracks, or incomplete seals in packaging.
o It helps visualize potential leakage points and assess the integrity of seals.
Accelerated Aging Test:
o These tests simulate the effects of long-term storage and environmental
conditions (temperature, humidity) on packaging materials over a short period.
o They help predict the shelf life and durability of packaging.
Opacity Test:
o Opacity measures a material's ability to block light.
o It's important for packaging products that are sensitive to light exposure, as
light can cause degradation and quality loss.
FSSAI ACT Series Food Safety Officer Mahapack
RECENT TRENDS AND DEVELOPMENTS IN FOOD
PACKAGING
Technological Innovations:
o Internet of Packaging (IoP): This involves using technologies like RFID,
NFC, and QR codes to improve supply chain tracking and reduce fraud.
QR Codes & Barcodes: These provide product details, traceability,
and ways for consumers to interact with the product.
RFID (Radio Frequency Identification): This technology helps track
inventory and reduce food waste by monitoring shelf life.
NFC (Near Field Communication): Enables smartphone
authentication and enhances consumer interaction.
Smart Sensors: These sensors can detect temperature, humidity, and
contamination.
Blockchain Technology: Used to ensure transparency and traceability
throughout the food supply chain.
o AI Integration: Artificial intelligence is being used to:
Optimize packaging design and improve efficiency.
Enhance consumer engagement.
Predict shelf-life, optimize storage conditions, and detect spoilage
using machine learning.
AI-enabled quality inspection systems detect defects, contamination,
and inconsistencies in packaging.
AI-driven robotic systems are used to improve packaging efficiency
and reduce human intervention.
AI analyzes consumer preferences to create personalized packaging.
AI optimizes inventory management and reduces food wastage through
predictive analytics for demand forecasting.
Convenience and Portability:
o Flexible Packaging: Stand-up pouches and resealable bags are used to reduce
material usage and offer convenience.
o Easy-to-Open and Resealable Packaging: Consumers prefer packaging that
is easy to open and resealable to maintain freshness.
Food Storage Principles:
o Storage is essential for preserving goods from production to consumption.
o The goal of storage is to maintain the quality of agricultural materials and
prevent deterioration.
Factors Affecting Food Storage:
o Humidity can decrease the shelf life of food.
o Optimal relative humidity for storing fresh fruits and vegetables is 90%.
o Temperature is a critical factor; the ideal range for storing most perishable
foods in a refrigerator is 0°C to 5°C, and for dry storage of food products is
10°C to 21°C.
o Light exposure can lead to oxidation and nutrient loss, hence food is stored in
the dark during preservation.
Storage Methods and Technologies:
o Canning is a common method for preserving vegetables.
o Controlled atmosphere storage is used for fruits and vegetables to reduce the
ripening process.
FSSAI ACT Series Food Safety Officer Mahapack
o Airtight containers are ideal for long-term storage of dry foods at room
temperature.
o Osmotic dehydration, involving the addition of salt or sugar, inhibits microbial
growth.
o Modern grain storage methods include metal silos and the use of
dehumidifiers to reduce moisture content and CO2 or nitrogen-based
controlled atmosphere storage to prevent insect infestation without chemical
fumigants.
o Hermetic storage bags create an airtight environment to prevent pest
infestation.
o Ozone treatment is used in food storage facilities as a natural fumigant.
Challenges in Food Storage:
o Plastic packaging can have the disadvantage of not allowing proper
ventilation.
o Freezer burn in frozen foods is primarily caused by moisture loss.
o Cross-contamination, the transfer of harmful bacteria from one food to
another, is a risk, especially when storing raw meat above ready-to-eat foods.
o Improperly stored grains are susceptible to mycotoxin contamination, often
associated with Aspergillus flavus.
Traditional Storage Methods:
o Traditional grain storage structures in rural areas often use mud and bamboo.
o Earthen pits are used for storing root vegetables.
o Traditional storage structures are sometimes treated with cow dung and clay to
prevent insect infestation.
o Gunny bags are traditionally used for storing pulses in India.
II. Multiple-Choice Questions (MCQs)
1. What is a key benefit of using IoP in food packaging?
o a) Reduces the cost of packaging materials
o b) Enhances supply chain traceability
o c) Simplifies the packaging design process
o d) Increases the oxygen content within the package
o Answer: b) Enhances supply chain traceability
2. Which technology is used to authenticate products and enhance consumer interaction
via smartphones?
o a) RFID
o b) NFC
o c) QR codes
o d) Blockchain
o Answer: b) NFC
3. AI is being used in food packaging for which of the following?
o a) To increase the size of packaging
o b) To predict shelf-life
o c) To add artificial flavors
o d) To slow down the production process
o Answer: b) To predict shelf-life
4. What type of packaging offers convenience and sustainability by reducing material
usage?
o a) Glass jars
FSSAI ACT Series Food Safety Officer Mahapack
o b) Cardboard boxes
o c) Flexible packaging
o d) Metal cans
o Answer: c) Flexible packaging
5. What is a consumer preference in modern food packaging?
o a) Difficult-to-open packaging
o b) Large, bulky packaging
o c) Easy-to-open and resealable packaging
o d) Opaque packaging
o Answer: c) Easy-to-open and resealable packaging
6. What is the primary function of food storage?
o a) To change the nutritional content of food
o b) To extend shelf life
o c) To make food easier to cook
o d) To alter the color of food
o Answer: b) To extend shelf life
7. What is the ideal temperature range for storing most perishable foods in a
refrigerator?
o a) -10°C to 0°C
o b) 0°C to 5°C
o c) 5°C to 10°C
o d) 10°C to 15°C
o Answer: b) 0°C to 5°C
8. High humidity generally has what effect on the shelf life of food?
o a) Increases it
o b) Decreases it
o c) No effect
o d) Depends on the food type
o Answer: b) Decreases it
9. What is the most common cause of freezer burn?
o a) Bacterial contamination
o b) Excessive freezing temperature
o c) Moisture loss
o d) Improper packaging color
o Answer: c) Moisture loss
10. What is the optimal relative humidity for storing fresh fruits and vegetables?
o a) 20%
o b) 50%
o c) 80%
o d) 90%
o Answer: d) 90%
11. Why is controlled atmosphere storage used for fruits and vegetables?
o a) To increase oxygen content
o b) To reduce the ripening process
o c) To increase moisture content
o d) To kill bacteria
o Answer: b) To reduce the ripening process
12. Which type of food is best suited for long-term storage in airtight containers at room
temperature?
o a) Meat
FSSAI ACT Series Food Safety Officer Mahapack
o b) Fresh vegetables
o c) Dried beans
o d) Dairy products
o Answer: c) Dried beans
13. Which preservation method uses salt or sugar to inhibit microbial growth?
o a) Drying
o b) Canning
o c) Osmotic dehydration
o d) Freezing
o Answer: c) Osmotic dehydration
14. Why is food often stored in the dark?
o a) To prevent oxidation
o b) To maintain texture
o c) To prevent mold growth
o d) To avoid increasing caloric value
o Answer: a) To prevent oxidation
15. What is the ideal temperature range for dry storage of food products?
o a) -10°C to 0°C
o b) 0°C to 5°C
o c) 10°C to 21°C
o d) 30°C to 40°C
o Answer: c) 10°C to 21°C
16. Which of the following food items should be stored in dry storage?
o a) Fresh vegetables
o b) Frozen meats
o c) Canned goods
o d) Dairy products
o Answer: c) Canned goods
17. What type of container is ideal for storing dry grains?
o a) Open baskets
o b) Airtight metal or plastic containers
o c) Cloth bags
o d) Cardboard boxes
o Answer: b) Airtight metal or plastic containers
18. What is cross-contamination in food storage?
o a) Mixing different spices
o b) Transfer of harmful bacteria from one food to another
o c) Blending food flavors
o d) Proper labeling
o Answer: b) Transfer of harmful bacteria from one food to another
19. Which of the following is a common cause of cross-contamination?
o a) Storing raw meat below ready-to-eat foods
o b) Using color-coded storage bins
o c) Storing dry and wet foods separately
o d) Keeping food in sealed containers
o Answer: a) Storing raw meat below ready-to-eat foods
20. What is a traditional storage structure used for storing grains?
o a) Plastic drums
o b) Underground pits
o c) Refrigerated silos
FSSAI ACT Series Food Safety Officer Mahapack
o d) Vacuum-sealed bags
o Answer: b) Underground pits
21. What material is traditionally used in grain storage structures in rural areas?
o a) Concrete
o b) Plastic
o c) Mud and bamboo
o d) Stainless steel
o Answer: c) Mud and bamboo
22. Which traditional method is used for storing root vegetables?
o a) Earthen pits
o b) Metal containers
o c) Refrigerators
o d) Drying cabinets
o Answer: a) Earthen pits
23. Why are traditional storage structures often treated with cow dung and clay?
o a) To enhance appearance
o b) To prevent insect infestation
o c) To increase weight
o d) To add nutrients
o Answer: b) To prevent insect infestation
24. What is a common traditional storage structure for pulses in India?
o a) Silo bins
o b) Gunny bags
o c) Brick silos
o d) Refrigerator units
o Answer: b) Gunny bags
25. Which of the following is an improved storage structure for grains?
o a) Mud bins
o b) Metal silos
o c) Earthen pots
o d) Grass baskets
o Answer: b) Metal silos
26. What is used in modern grain storage to prevent insect infestation?
o a) Chemical fumigation
o b) Open-air drying
o c) Storing in mud bins
o d) Using plastic sheets
o Answer: a) Chemical fumigation
27. Which gas is used for controlled atmosphere storage?
o a) Oxygen
o b) Nitrogen
o c) Hydrogen
o d) Sulfur dioxide
o Answer: b) Nitrogen
28. Which technology extends shelf life in modern food storage?
o a) Sun drying
o b) Clay pot cooling
o c) Refrigeration and controlled atmosphere
o d) Open storage
o Answer: c) Refrigeration and controlled atmosphere
FSSAI ACT Series Food Safety Officer Mahapack
29. What is the function of hermetic storage bags?
o a) To keep food dry
o b) To create an airtight environment and prevent pests
o c) To increase oxygen levels
o d) To enhance flavor
o Answer: b) To create an airtight environment and prevent pests
30. What helps reduce moisture content in modern grain storage?
o a) Dehumidifiers
o b) Direct sunlight
o c) Open baskets
o d) Water sprinklers
o Answer: a) Dehumidifiers
31. What primarily affects the equilibrium relative humidity (ERH) of stored grains?
o a) Temperature and pressure
o b) Grain moisture content and ambient humidity
o c) Oxygen concentration and airflow
o d) Light exposure and grain variety
o Answer: b) Grain moisture content and ambient humidity
32. Which method prevents insect infestation without chemical fumigants?
o a) CO₂ or nitrogen-based controlled atmosphere storage
o b) Cold storage at -2°C
o c) UV radiation exposure
o d) Direct
o Answer: a)
FSSAI ACT Series Food Safety Officer Mahapack
TIMELINE OF FSSAI PACKAGING LAWS
2006 – FOUNDATION
Food Safety and Standards Act, 2006
Laid the groundwork for unified food laws in India, replacing multiple older acts.
Empowered FSSAI to frame packaging and labeling regulations under Section 23.
2011 – INITIAL REGULATIONS
Food Safety and Standards (Packaging and Labeling) Regulations, 2011
These regulations shall come into force on or after 5th August, 2011. Combined
packaging and labeling rules. Focused more on labeling; packaging was not detailed
or standalone.
2018 – DRAFT FOR SEPARATE PACKAGING REGULATIONS
January 2018:
FSSAI issued a draft notification to separate packaging regulations from labeling due to
growing concerns over safety of packaging materials. Proposed standards for materials like
plastic, glass, paper, metal, etc.
2019 – DEDICATED PACKAGING REGULATION
Food Safety and Standards (Packaging) Regulations, 2018
(Came into force on July 1, 2019)
First exclusive packaging regulation.
Key highlights:
FSSAI ACT Series Food Safety Officer Mahapack
Packaging materials must comply with BIS standards.
Specific standards for plastic, glass, metal, paper & board.
Prohibition on use of recycled plastic in food packaging.
Migration limits for contaminants from packaging to food.
Labeling requirement: "Food Grade" mark on materials.
2022 – FOCUS ON SUSTAINABILITY
Encouragement of Eco-friendly Packaging
FSSAI began promoting alternatives to single-use plastics.
No direct regulation yet, but in alignment with Government of India’s sustainability
push.
2023 – TESTING & COMPLIANCE EMPHASIS
FSSAI notified labs and FBOs for mandatory migration and packaging safety testing.
More rigorous enforcement began for compliance with packaging material standards.
2024 – DRAFT AMENDMENTS AND INNOVATIONS
Proposed Updates to Packaging Standards (Draft Amendment):
More BIS standard references included.
Inclusion of biodegradable packaging, compostable plastics, and nanomaterial
use.
Migration limits aligned with newer technologies and global benchmarks.
KINDLY REFER THE DPP FOR THE ENTIRE LAW
FSSAI ACT Series Food Safety Officer Mahapack