QLK5-2000-00799 BIOPACK: Proactive biobased cheese packaging

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Website: www.biopack.org
Summary Information



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Biopolymers/Gums : Packaging : Paints/Coatings/Plastics : Quality of Life - 5.2 Non-Food Development

Contract No:	QLK5-2000-00799
Source:	Second Progress Report Summary - 2003
Source:	First Progress Report Summary - 2002

Second Progress Report Summary
July 2003

Introduction

This project has been extended to include participation from the accession countries, with a supplementary project NAS-BIOPACK (QLKS-CT-2002-02891)

The work of BIOPACK (including NAS-BIOPACK) continues with the primary aim to develop new types of proactive biobased packaging material for grated, sliced and whole cheeses. The biobased material is based on polylactides (PLA) and chitosan. Preservatives encapsulated in cyclodextrines (CDs) are incorporated into the biobased material in order to avoid growths of moulds at the surface of the cheeses. The incorporation of preservatives in CDs into a biopackaging material is a completely new concept and a successful result will potentially open up the concept for other types of biopackaging. Possible bottlenecks and technical barriers to larger scale production are being identified with the objective of producing the packaging at a price competitive with that of conventional materials used at present.

Results

In the BIOPACK project we have succeeded in developing cyclodextrin (CD)/preservative complexes, and the complexes have been tested for antimicrobial activity on cheese related moulds and yeasts. The tests have been performed under various environmental conditions in a cheese model system. Based on the results of the antimicrobial activities CD/preservative complexes have been selected and produced in larger scale, and quality specifications and stability tests have been made. In addition, #the biodegradability of the CD/preservative complexes has been evaluated.

We have succeeded in producing a range of polylactides of varying molecular weights and molecular structures and the granulates have been converted into films. In order to improve the barrier properties of PLA combinations of PLA and chitosan have been made. CD/PLA films have also been produced. The PLA granulates and the films have been characterised and performance aspects in relation to cheese packaging have been evaluated. The most important results obtained until now are:

• The biobased materials have mechanical properties comparable to conventional materials. However, the brittleness of the films is too high and this defficiency has to be improved.
• The PLA films have high transparency.
• Oxygen and water transmission rates of PLA are too high compared to barrier requirements of cheeses. Chitosan has been shown to improve the oxygen barrier considerably. Improvements of the oxygen and water transmission rates will be further explored by use of nanoclay.
• The growth of fungi directly on the biobased packaging materials was determined. None of the tested cheese-related moulds or yeasts grew on the materials.
• Chitosan has been shown to inhibit growth of cheese related moulds.
• The overall migration was acceptable for most of the developed Biopack PLA films. The overall migration exceeded the limit value set in the European legislation on plastics for two films when 95% ethanol was used as an alternative fatty food simulant (reduction factor I). This is probably due to migration of the monomer (lactic acid). The total migration was low for all other food simulants.
• The selected CD's and chitosan materials are biodegradable. The PLA films show good disintegration.

Information on oxygen absorbers has been collected and discussed. It has been decided to focus on iron scavengers as the main oxygen absorbing material, Oxygen scavengers will not be incorporated in the polymer. Sachets or labels are the most promising scavenging types for this project.

An initial packaging and storage experiment is running at the moment in which cheeses have been packed in PLA film and the packed cheese samples placed under realistic storage conditions. The quality of the cheeses is being evaluated at the moment.

The preliminary planning and scope defining work on an environmental impact assessment on the biobased packaging has started. PLA was chosen as the material to be studied.

Conclusions

Chitosan has been shown to improve the oxygen barrier considerably and to have antimicrobial effects.

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First Progress Report Summary
July 2002

Objectives

The objective of BIOPACK is to develop new types of proactive biobased packaging. This will extend the shell-life of grated, sliced and whole cheeses from 2-3 months up to 9 months by incorporating oxygen scavengers and preservatives encapsulated in cyclodextrines (CDs) into a biobased material (polylactides (PLA) and alternatives). This will expand the export volume for these products considerably, in particular to overseas markets. Additionally, the project will improve the shelf-life after opening due to incorporation of the active components in the packaging, which will reduce the growth of moulds. The incorporation of preservatives in CDs into a biopackaging material is a completely new concept, and a successfull result will open up other biopackaging concepts. Possible bottlenecks and technical barriers to larger scale production will be identified. The packaging will be produced to a competitive price as related to conventionally used materials.

Results and Milestones

In the Biopack project we have succeeded in developing cyclodextrin (CD)/preservative complexes, and the complexes have been tested for antimicrobial activity on cheese related moulds and yeasts. The tests have been performed under various environmental conditions in a cheese model system. Based on the results of the antimicrobial activities CD/preservative complexes have been selected and produced in larger scale, and preliminary quality specifications and stability tests have been made, in addition, the biodegradability of the CD/preservative complexes has been evaluated.

We have succeeded in producing a range of polylactides of varying molecular weights and molecular structures and the granulates have been converted into films. In addition, PHB films have been produced from a commercial PUB granula product. The first CD/PLA films have been produced. The PLA and PHB granulates and the films have been characterised and performance aspects in relation to cheese packaging have been evaluated. The most important results obtained until now are:

• The biobased materials have mechanical properties comparable to conventional materials.
• The PLA films have high transparency, whereas the light transmission is lower for PHB. As consumers expect cheese packaging materials to have high transparency, it was decided to concentrate our efforts on PLA based materials.
• Oxygen and water transmission rates were too high compared to barrier requirements of cheeses. Improvements of the barrier properties will be further explored.
• The growth of fungi directly on the biobased packaging materials was determined. None of the tested cheese-related moulds or yeasts grew on the materials
• The overall migration was acceptable for most of the developed Biopack PLA films. The overall migration exceeded the limit value set in the European legislation on plastics for two films when 95% ethanol was used as a alternative fatty food simulant (reduction factor 1). However, the total migration was low for all other food simulants.

Information on oxygen absorbers has been collected and discussed. It has been decided to focus on iron scavengers as the main oxygen absorbing material. Oxygen scavengers will not be incorporated in the polymer. Sachets or labels are the most promising scavenging types for this project

The preliminary planning and scope definition of environmental impact assessment on the biobased packaging have started. PLA was chosen as material to be studied.

Besides the activities mentioned above, decisions have been made in relation to packaging experiments with cheeses, and two types of cheese (a Danbo cheese 45+ and a low fat cheese) have been selected for the packaging and storage experiments to be performed later on in the project.

Benefits and Beneficiaries

In the Biopack project, we have succeeded in producing a 100% biobased material, if we succeed in improving the barrier properties of the PLA based materials these new materials have great potential as packaging material for cheeses and other food products.

In addition we have succeeded in making CD/preservative complexes with the potential for slow release of antimicrobial components from the biobased materials. The latter will reduce the growths of moulds, which will extend the shelf life of the cheeses.