Food Packaging and T F h o e o Food Alterations: d U Published by Smithers Rapra Technology Ltd, 2012 s P e a r c -o k The User-oriented Approach a r i g e i n n t g e d a n The so-called Hazard Analysis and Critical Control Points (HACCP) acronym is well known in the food A d p industry in relation to the management of microbiological, chemical and physical risks. In relation p F o to HACCP risks, packaging materials should be studied and recognised as one of the key factors r o o affecting food safety. a d c h A HACCP studies highlight the role of food production. On the other hand, detailed information about l t e packaging materials is needed. This lack of information is very evident for official inspectors (hygiene r and preventive medicine), veterinary auditors and food operators. Consequently, the role of food a t packaging is known but its implications are often difficult to understand. io n s The first objective of this title is to provide detailed and comprehensible information about packaging : materials. Food operators and official inspectors are not accustomed to understanding these concepts Salvatore Parisi (chemical and physical properties, marketing, QC failures). Consequently, a descriptive approach will be used to explain the world of packaging materials, differences between various packaging categories/subclasses and regulatory implications (REACH, the British Retail Consortium and the Packaging Society Global Standard for Packaging and Packaging Materials, and so on). The second objective is to provide the reader with a detailed selection of food failures and different causes: • Incorrect design of package materials. • Incorrect storage and use of package materials. • Lack of technical information. • Synergetic effects (packaging and food-related causes). Every situation will be described and analysed with the aim of providing a reliable diagnosis of the problem (microbial spreading, alteration of shelf-life values, unpleasant appearance, possible safety problems). This volume is intended to be a practical guide on food packaging and HACCP implications and a quick reference for official safety inspection bodies, students and researchers from academia and S industry. a l v a t o r Shawbury, Shrewsbury, Shropshire, SY4 4NR, UK e Telephone: +44 (0)1939 250383 P Fax: +44 (0)1939 251118 a Web: www.polymer-books.com r i s i Food Packaging and Food Alterations: The User- oriented Approach Salvatore Parisi A Smithers Group Company Shawbury, Shrewsbury, Shropshire, SY4 4NR, United Kingdom Telephone: +44 (0)1939 250383 Fax: +44 (0)1939 251118 http://www.polymer-books.com First Published in 2012 by Smithers Rapra Technology Ltd Shawbury, Shrewsbury, Shropshire, SY4 4NR, UK ©2012, Smithers Rapra Technology Ltd All rights reserved. Except as permitted under current legislation no part of this publication may be photocopied, reproduced or distributed in any form or by any means or stored in a database or retrieval system, without the prior permission from the copyright holder. A catalogue record for this book is available from the British Library. Every effort has been made to contact copyright holders of any material reproduced within the text and the authors and publishers apologise if any have been overlooked. ISBN: 978-1-84735-606-2 (Hardback) 978-1-84735-607-9 (Softback) 978-1-84735-608-6 (ebook) Typeset by Argil Services Indexed by Argil Services P reface The so-called hazard analysis and critical control points (HACCP) acronym is well known in the food industry in relation to the management of microbiological, chemical and physical risks. In relation to HACCP risks, packaging materials should be studied and recognised as one of the key factors affecting food safety. HACCP studies highlight the role of food production. On the other hand, detailed information about packaging materials is needed. This lack of information is very evident for official inspectors (hygiene and preventive medicine), veterinary auditors and food operators. Consequently, the role of food packaging is known but its implications are often difficult to understand. The first objective of this book is to provide detailed and comprehensible information about packaging materials. Food operators and official inspectors are not accustomed to understanding these concepts (chemical and physical properties, marketing, QC failures). Consequently, a descriptive approach will be used to explain the world of packaging materials, differences between various packaging categories/subclasses and regulatory implications (REACH, BRC-IoP, and so on). The second objective is to provide the reader with a detailed selection of food failures and different causes: • Incorrect design of package materials. • Incorrect storage and use of package materials. • Lack of technical information. • Synergetic effects (packaging and food-related causes). Every situation will be described and analysed with the aim of providing a reliable diagnosis of the problem (microbial spreading, alteration of shelf life values, unpleasant appearance, possible safety problems). This volume is intended to be a practical guide on food packaging and HACCP iii Food Packaging and Food Alterations: The User-oriented Approach implications and a quick reference for official safety inspection bodies, students and researchers from academia and industry. Acknowledgements I am indebted to many people – professors, senior executives, technicians, professional consultants – from different sectors because this book has been profoundly shaped by their active participation. These people have given me their insights, during crowded seminars and conferences, towards the best communication strategy in relation to food companies, official authorities and their needs. In fact, food packaging may be explained in a variety of manners and situations but only one of these is really useful when discussing similar materials with food operators and inexperienced people. In my opinion, the explanation should be made ‘on the same ground’ of the trained subject and this person is generally interested in particular aspects of their own work without direct connection to packaging materials (and related disciplines). Consequently, I am very grateful to these professionals for their perspectives and comments. I particularly want to thank Dr Franco Ottaviani, Consal (Italy), whose unfailing encouragement has been essential to the publication of this work. He suggested the necessity of a similar book several years ago. In addition, I am also indebted to a group of debaters, speakers and professionals who have permeated my evolving vision of the food and packaging sectors. Consequently I owe a lot to Dr Flavio Lusian, formerly executive at Oxoid Italy, Dr Roberto Ligugnana, International pbi (Italy), Dr Alejandro Hochköppler, University of Bologna (Italy), and Dr Maurizio Zucchi, Coop Italy. For the different perspectives and welcome contributions, my thanks go to Dr Valter Orlandi, Salchi Metalcoat srl, Italy. This friend represents in my mind many of my past and current colleagues in the packaging sector. I also want to thank Professor Franco Montenero, University of Parma, Italy, for the encouraging help in the academic sector. My appreciation and thanks are also due to a huge number of professionals and executives from every country across the interconnected worlds of food and packaging. It is not practical to mention all the names, so I apologise for this. All my colleagues have supported me during my professional years. Among these people, I want to remember Robert York and Kumar Patel (Food Packaging Bulletin, UK). iv Preface Moreover, I am indebted to Smithers Rapra Technology with particular reference to: • Frances Gardiner and Eleanor Garmson for their assistance with the book Polymer Electronics – A Flexible Technology, 2009. • Frances Gardiner, Eleanor Garmson, Calpreta Parkinson, Stuart Fairgrieve and Rachel Parkinson, for the publication of this book. They have demonstrated much patience during the last months. Particular thanks are due to Mr Michele Barone, Italy, for his contribution. He is the owner of all the published photographs. Finally, I am very grateful to a small group of people who have encouraged me and followed my life: Caterina, my wife and best friend for the last ten years, and my children, Carmelo and Vita, who have to put up with a lot. My role has always been the easier one. v Food Packaging and Food Alterations: The User-oriented Approach vi C ontents 1 The Role of Food Packaging – General Considerations ...............1 1.1 Theory of Food Packaging .................................................1 1.2 Food Packaging and Subliminal Messages .........................5 1.3 Food Products: Good and Bad Appearances ......................7 1.4 The Food/Packaging Integrated System ..............................9 1.5 Logistics and Rising Costs ...............................................12 1.6 Food Packaging as Future Waste ......................................16 2 Categories and Subclasses of Packaging Materials .....................21 2.1 Metal Packages ................................................................21 2.1.1 Three-piece Cans ..................................................23 2.1.2 Two-piece Single Drawn Cans ..............................27 2.1.3 Two-piece Drawn and Wall-ironed Cans ..............29 2.1.4 Two-piece Drawn and Redrawn Cans ..................32 2.1.5 Flexible Tubes ......................................................34 2.1.6 Aerosol Containers ...............................................35 2.1.7 Kegs .....................................................................35 2.1.8 Aluminium Foils and Roll-on Closures for Bottles 36 2.1.9 Crowns ................................................................37 2.1.10 Twist-off Closures ................................................38 2.1.11 Self-heating and Self-cooling Cans (Metallic and Plastic Chambers) ...........................40 vii Food Packaging and Food Alterations: The User-oriented Approach 2.1.12 Technology, Production and Failures of Metal Packages ....................................................41 2.1.12.1 PF01 Failures of the Metallic Support ....46 2.1.12.2 PF02 Drawing Failures ..........................47 2.1.12.3 PF03 Coating Failures ...........................47 2.1.12.4 PF04 Failures Related to Superficial Adhesion ...............................................50 2.1.12.5 PF05 Side Seam Failures ........................51 2.1.12.6 PF06 Other Superficial Imperfections on Beaded Cans .....................................52 2.1.12.7 PF07 Double-seaming Failures ...............52 2.1.12.8 PF08 Sterilisation Failures .....................53 2.1.12.9 PF09 Reduced Flexibility .......................55 2.1.12.10 PF10 Inclusion of Organic and Foreign Materials ..................................57 2.1.12.11 PF11 Other Superficial Imperfections on Aluminium and Steel Coils ...............57 2.2 Plastic Packages ...............................................................59 2.2.1 Polyethylene Terephthalate Bottles and Non-coupled Containers: Technology, Production and Failures .......................................60 2.2.1.1 PF12 Bubbling .......................................63 2.2.1.2 PF13 Aesthetical Defects ........................63 2.2.1.3 PF14 Extrusion Failures .........................64 2.2.1.4 PF15 Coupling Failures .........................65 2.2.1.5 PF16 Coextrusion Failures .....................65 2.2.1.6 PF17 Failures Related to the Stretch Blow Extrusion Step ..................65 2.2.1.7 PF18 Injection, Moulding and Thermoforming Defects .........................66 viii Contents 2.2.1.8 PF19 Defects Related to the Calendering Step ....................................68 2.2.1.9 PF20 Inner Superficial Defects by Rotational Moulding .............................68 2.2.2 Flexible Packages and Coupled Containers: Technology, Production and Failures ....................68 2.2.2.1 PF21 Printing Failures Related to Rotogravure and Flexographic Steps, including Bleeding .................................75 2.2.2.2 PF22 Coupling Failures .........................76 2.3 Paper and Paper-based Packages ......................................77 2.3.1 Technology, Production and Failures of Paper and Paper-based Packages ..........................78 2.3.1.1 PF23 Excessive Rigidity of Materials .....79 2.3.1.2 PF24 Colorimetric Variations ................79 2.3.1.3 PF25 Paper Wrinkling ............................80 2.3.1.4 PF26 Bleeding (Paper Packaging, Off-set Printing) .....................................80 2.3.1.5 PF27 Flexographic Printing and Related Failures (Paper Packaging, Corrugated Cardboard) .........................81 2.3.1.6 PF28 Excessive Dripping (Corrugated Board) ...............................81 2.3.1.7 PF29 Adhesion Defects (Paper Packaging) ..................................83 2.3.1.8 PF30 Paper Pulverisation (All Paper Packages) ..............................83 2.3.1.9 PF31 Paper Mildewing (All Paper Packages) ..............................83 2.4 Glass-based Packages and Ceramic Containers ................84 ix