Advances in Meat PackagingAdvances in Meat PackagingM C Hunt & Anand MohanM. C. Hunt & Anand MohanDept of Animal Sciences & Industry

Kansas State UniversityyManhattan, Kansas-66506

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

General Overview

Where have we been?Where have we been?

Current short comings?Current short comings?

Managing meat colora ag g eat co o

What “Advances” are needed?

Some intriguing possibilities

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

What’s Right/Wrong Here?

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Over-wrapped Trays

Leaky, messy packagesPoor appearance and imageSh t h lf lifShort shelf lifeSub-optimal functionalitySub-optimal functionality

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Over-wrapped Trays

Ease of applicationEase of applicationControlled weight lossEnhanced appearanceProtected palatability Marketable packageE

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Economy

Meat Package Types

NoneNoneBag in a boxgPaper

All good if done properly,All good if done properly, BUT LIMITED ATTRIBUTES

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Meat Package Types

O er rap o gen permeableOverwrap - oxygen permeableVacuum - oxygen impermeableVacuum oxygen impermeable Modified Atmosphere Packaging

All used extensivelyAll used extensively, LONGER SHELF LIFE

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Vacuum Packaging

Very good for subprimal cutsVery good for subprimal cutsRequires good temperature controlBloom and Purge can be problems

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Another Solution:

Modified Atmosphere Packagingp g gand / or

Case Ready Meats

An Evolution, Not Revolution

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Types of MAP“Vacuum”Oxygen/Carbon dioxide/NitrogenHigh OxygenLow Oxygen - must scavenge O2Low Oxygen - must scavenge O2

Peelable FilmsGas Exchange SystemI di id l t M t b

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Individual cuts or Master bag

What is Packaging?

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Packaging Needs for Meatg gAttractivenessProduct weight controlEasy to handle / managey gMeat colorMeat flavorMeat flavorShelf-lifeAntimicrobials

So, what d tAntimicrobials

Product safetyneeds to

“ADVANCE”?© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

“Green”ADVANCE ?

Need Package Diversity

Fresh vs FrozenFresh vs. FrozenFresh vs. CuredRaw vs. CookedIntact muscle vs. RestructuredIntact muscle vs. RestructuredDried vs. MarinatedSpecies differencesSpecies differencesIrradiation

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Meat Color & Color Stability

Most important visual traitpDrivers of retail saleDiscoloration: Cost - millionsP k i d t t bili th lPackaging needs to stabilize the color

Maintaining meat’s red colorMaintaining meat’s red colorhas been a more persistent challengethan retarding microbiological spoilage

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

than retarding microbiological spoilage....

The Colors of Meat

D l biD l biDeoxymyoglobinDeoxymyoglobinDMb Fe**DMb Fe**

OxymyoglobinOMb Fe**Oxygenation

O2 UptakeandMMb+ CO MMb

Reduction+ CO

Very low

Carboxymyoglobin Metmyoglobin

O2

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

COMb Fe** MMb Fe***

Drivers for Advancements?

Consumer’s demandMatch advances of other foods Mi i l d f dMinimal processed foods Increased regulatory requirementsc eased egu ato y equ e e tsMarket globalizationIncreased concern for food safetyRecent threats of food bioterrorism

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Recent threats of food bioterrorismYam et al., 2005

Drivers for Advancements?

IndulgenceConvenience Individualized culture g

Natural and healthy Changing lifestyles

Convenience Lifestyles Culture Health Indulgence Packaging

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Should We Think Outside or Inside the Box?Inside the Box?

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Clockwise Color of Meat

DMb OMbDMb OMb

MMb

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

You MUST work the clock!

Packaging Formats

M difi d At h P k iModified Atmosphere Packaging

Removal or replacement of the atmosphere surrounding the productatmosphere surrounding the product

before sealing.

Vacuum Low-Oxygen MAP High-Oxygen MAP

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Types of MAP

MAPMAP

AerobicAnaerobic

N2/CO2 O2/CO2AnaerobicN2/CO2 2 2Anaerobic

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

CO/CO2/N2

Which is Most Promising?

MAPMAP

Can’t science, quality and Can’t science, quality and AerobicAnaerobic

, q y, q yproduct safetyproduct safety

overcome consumer issues?overcome consumer issues?O2/CO2AnaerobicN2/CO2

overcome consumer issues?overcome consumer issues?2 2AnaerobicN2/CO2

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

CO/CO2/N2

Two Red MAPs

HiOx MAPNoOx-CO MAP

ShorterShelf lifeLonger

LimitedFlavor stabilityVery goodShorterColor-lifeLongerShorterShelf-lifeLonger

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

LimitedFlexibilityGoodLimitedFlavor stabilityVery good

ActiveTechTM MAP – R3

Ult l O ith COUltra-low O2 with CO1. PVC Overwrapp2. O2 Scavenger3 0 4% CO Fl h3. 0.4% CO Flush

PVC packages are removed from the 0 4% CO d l

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

0.4% CO prior to display

Packaging “Advances” Must

Consider:Consider:Properties of meatP k l & t t itPackage polymer & tray traitsPlant processingp gOperations schedulingSafetySafetyRegulatory issues

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Package ConsiderationsFilm DesignB i

Tray designSiBarrier

Anti-fog/Anti-greaseSizeShape

EZ OpenRe-closable

ColorDraw depth

MicrowaveableFreezable

Draw depthFoam or plasticO l d ll

OvenableIrradiation-ability

Open or closed cellSoaker pad type

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Irradiation abilityCompartments Labeling

Meat ConsiderationsState (raw or cooked)Ti f hTime after harvestConditions at harvestTemperature of storageAnatomical locationIntact or mincedMeat-to-Gas ratioExposure to light, heatAnaerobic or aerobic

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Anaerobic or aerobicOther conditions

Processing ConsiderationsBlooming time and conditionsResidual OResidual O2Gas mixtures – CO2, N2, O2, CO, Ar, He, O3

Enhancement and ingredientsEnhancement and ingredientsOxidative stabilityHeadspace requirements and tray optionsHeadspace requirements and tray optionsMerchandising and productivityLabeling, pre-pricing, datingLabeling, pre pricing, datingFreight, cube, transport issuesIllumination sources

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Film and tray compatibility

Operational ConsiderationsPostmortem age of whole muscle cutsInjected and enhanced productsSlicing bone-in productsBone discolorationHigh or low O meat color during transitHigh or low O2 meat color during transitPackage seal integrity

/Pre-pricing/datingFreight, cube and tray size issues

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Productivity measurements

Productivity Considerations

Packaging machine maintenanceg gGas mixer or vacuum calibrationDenesting trays and/or packagingDenesting trays and/or packagingSeal time and temperature parametersVacuum levelLoading and unloadingReworkInventory management

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Inventory management

Active / Intelligent Packaging

System where the product, the package, and the environment interact in a

positive way to extend the shelf life.positive way to extend the shelf life.Often NANO-TechnologyIntegrity indicatorsIntegrity indicators.Temperature indicators.Fluorescent oxygen sensorsFluorescent oxygen sensors Biosensors Freshness indicators

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Freshness indicators Radio Frequency ID

Components of NanotechnologyHeat/Mass Transfer Reaction

EngineeringNano

BiotechnologyMolecular Synthesisgy

PROCESSING

NanoparticlesA

L

Delivery

FormulationPR

Nanoemulsions

MAT

ERIA

Formulation

Packaging

RO

DC

UT

Nanocomposites

Nanostructured

M g g

BIOSAFETY AND SECURITYNanostructuredMaterials

BIOSAFETY AND SECURITY

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Nanosensors Nanotracers

Packaged in Nano Materials

Time-temperature sensing

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

http://www.cibasc.com/med-photos_onvu-meat_nr_print.jpg

Bio-based MaterialsReplenishable agricultural feedstocksAnimal sourcesMarine food processing industry wastesMarine food processing industry wastesMicrobial sourcesFilm-formingPlasticizersPlasticizersFunctional additives

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Edible coatings

Bio-based PackagingBagassePalm Fiber

MoldedfiberCorn based tray

Sugar based cups

Earthshell WrapWhey Coating

Bi d d bl

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Biodegradablepolyester Anti Pathogens

Summary

Packaging Advances May Be:Creative

InnovativeFunctional

Value addingValue addingMore expensive

Challenging to useChallenging to useNecessary to compete

S t bl th th th© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Some - more trouble than they are worth

A Good Recommendation

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Thanksforfor

ListeningListening

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

Clockwise Color of Meat

DMb OMbDMb OMb

MMb

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

You MUST work the clock!

The Best Kept Secret

MAPMAP

AnaerobicAnaerobic

© Hunt, M. C. & A. Mohan (2008). Advancement in meat packaging. Sept 18-20th, Canadian Meat Council, Canada

CO/CO2/N2