Opportunities for BioOpportunities for Bio--Based Packaging Based Packaging Technologies to Improve the Quality Technologies to Improve the Quality

and Safety of Fresh and Further and Safety of Fresh and Further Processed Muscle FoodsProcessed Muscle Foods

Catherine Nettles CutterCatherine Nettles CutterDepartment of Food ScienceDepartment of Food Science

The Pennsylvania State University The Pennsylvania State University

OverviewOverview•• IntroductionIntroduction•• Active/intelligent/interactive packagingActive/intelligent/interactive packaging•• BioBio--based polymers or biopolymers* based polymers or biopolymers*

–– BiomassBiomass--derivedderived–– BioBio--derived monomersderived monomers–– MicroorganismMicroorganism--derivedderived

•• Composite filmsComposite films•• Antimicrobial filmsAntimicrobial films•• SummarySummary

IntroductionIntroduction•• Plastic (polyethylene or coPlastic (polyethylene or co--

polymers)polymers)–– Manufactured from petroleumManufactured from petroleum–– $100 billion market$100 billion market–– 70% is used for food and 70% is used for food and

beveragesbeverages–– < 10% of plastic packaging is < 10% of plastic packaging is

recycled (not including recycled (not including bottles) bottles) llandfill issues andfill issues

(Comstock et al., 2004. Green (Comstock et al., 2004. Green packaging report. University of packaging report. University of

Washington Symposium)Washington Symposium)

Issues with plastic packagingIssues with plastic packaging•• “…“…With the exception of paper and With the exception of paper and

boardboard……most packaging materials aremost packaging materials are…….non.non--renewable materialsrenewable materials……therefore, more therefore, more alternative packaging materials based on alternative packaging materials based on renewable resources need to be found.renewable resources need to be found.””

•• “…“…biobio--based packaging materials are based packaging materials are beginning to replace standard packaging beginning to replace standard packaging materialsmaterials…”…”

(Weber, et al. 2002. Food Additives (Weber, et al. 2002. Food Additives and Contaminants 19:172and Contaminants 19:172--177)177)

PackagingPackaging•• Globalization of the food supplyGlobalization of the food supply•• Consumer trends towards convenienceConsumer trends towards convenience•• Consumers want packaging materials that Consumers want packaging materials that

are more natural, disposable, recyclable or are more natural, disposable, recyclable or biodegradablebiodegradable

Active/Intelligent/Interactive Active/Intelligent/Interactive packagingpackaging

•• ChemicalsChemicals–– Chelators, antioxidants, flavors, Chelators, antioxidants, flavors,

essential oils, etc.essential oils, etc.

•• AntimicrobialsAntimicrobials–– Bacteriocins, organic acids, Bacteriocins, organic acids,

lysozyme, etc.lysozyme, etc.

•• GasesGases–– Ethylene, carbon dioxide, Ethylene, carbon dioxide,

oxygen, nitrogen, etc.oxygen, nitrogen, etc.

Active/Intelligent/Interactive Active/Intelligent/Interactive packagingpackaging

•• Humidity absorbers/controllersHumidity absorbers/controllers•• Scavengers or emittersScavengers or emitters•• Aroma absorbersAroma absorbers•• Active enzyme systemsActive enzyme systems

(Lopez(Lopez--Rubio et al. 2004. Rubio et al. 2004. Food Reviews International 20:357Food Reviews International 20:357--387)387)

BioBio--based polymersbased polymersor biopolymersor biopolymers

•• May be compostable or May be compostable or biodegradablebiodegradable

•• Some bioSome bio--based packaging based packaging materials may be biodegradablematerials may be biodegradable

•• Not all biodegradable packaging Not all biodegradable packaging materials are biomaterials are bio--basedbased

•• Can be processed similarly to Can be processed similarly to petroleumpetroleum--based plasticsbased plastics–– Extrusion, spinning, injection Extrusion, spinning, injection

molding, thermoformingmolding, thermoforming

Desirable properties of biopolymersDesirable properties of biopolymers

•• Good sensory qualitiesGood sensory qualities•• High barrier propertiesHigh barrier properties•• Mechanical efficiencyMechanical efficiency•• Microbial, biochemical, Microbial, biochemical,

& & physiophysio--chemical stabilitychemical stability•• NonNon--toxictoxic•• SimpleSimple•• NonNon--pollutingpolluting•• InexpensiveInexpensive

Desirable properties of biopolymers Desirable properties of biopolymers applied to muscle foodsapplied to muscle foods

•• EdibleEdible•• TransparentTransparent•• Reduces moisture lossReduces moisture loss•• Minimizes lipid oxidationMinimizes lipid oxidation•• Prevents discolorationPrevents discoloration•• Reduces dripReduces drip•• Flexible Flexible •• Resistant to breakage and abrasionResistant to breakage and abrasion•• Improves microbial safety and stability of Improves microbial safety and stability of

foodfood

Application of biopolymersApplication of biopolymersto muscle foodsto muscle foods

•• FoamingFoaming•• Dipping/SubmergingDipping/Submerging•• SprayingSpraying•• CastingCasting•• BrushingBrushing•• WrappingWrapping•• RollingRolling

BIO-BASED POLYMERS

Polymers extracted from biomass Polymers synthesized from bio-derived monomers

Polymers produced from microorganisms

Polysaccharides Proteins Lipids Polylactate Other polyesters Bacterial compounds

Starch Cellulose Gums Chitosan/chitinpotato cotton guarcorn wood locust beanwheat other derivatives alginaterice carrageenanother derivatives pectins

agar

Animalcaseinwhey

collagengelatin

Plantzeinsoy

gluten

waxesfats oils

xanthan curlan

pullulan

(Adapted from Weber, et al. 2002. Food (Adapted from Weber, et al. 2002. Food Additives and Contaminants 19:172Additives and Contaminants 19:172--177)177)

StarchStarch•• Compounds are generally derived from cereal Compounds are generally derived from cereal

grains, potatoes, tapioca or arrowrootgrains, potatoes, tapioca or arrowroot•• Starch films tend to be odorless, tasteless, Starch films tend to be odorless, tasteless,

colorless, noncolorless, non--toxic, absorbable, semitoxic, absorbable, semi--permeable permeable to COto CO22, & oxygen impermeable, & oxygen impermeable

•• Starch films can retard moisture migration into Starch films can retard moisture migration into muscle food during storage muscle food during storage lowers water activity lowers water activity

retards mretards microbial growth icrobial growth longer shelf life longer shelf life

CelluloseCellulose•• NonNon--digestible component of digestible component of

plant cell wallsplant cell walls•• Used primarily for production Used primarily for production

of readyof ready--toto--eat sausages; eat sausages; peeled and discarded after peeled and discarded after cookingcooking

•• Films typically are water Films typically are water solublesoluble

CelluloseCellulose•• Films are resistant to fats and oils, tough, Films are resistant to fats and oils, tough,

flexible, transparent, & peelableflexible, transparent, & peelable•• When used with muscle foods, cellulose films When used with muscle foods, cellulose films

can reduce oil uptake during frying, minimize can reduce oil uptake during frying, minimize runrun--off during cooking, and reduce moisture off during cooking, and reduce moisture loss when applied as a glazeloss when applied as a glaze

AlginateAlginate•• Derived from Derived from

seaweedseaweed•• Divalent cations Divalent cations

(calcium) are used (calcium) are used as gelling agentsas gelling agents

•• Other edible Other edible polysaccharides polysaccharides can be added to can be added to improve properties improve properties of alginate filmsof alginate films

AlginateAlginate•• When applied to muscle When applied to muscle

foods, alginate films are foods, alginate films are known to improve known to improve moisture retention, retard moisture retention, retard oxidation, improve oxidation, improve adhesion between batter adhesion between batter and muscle food surfaces, and muscle food surfaces, extend shelf life, reduce extend shelf life, reduce shrink, and improve shrink, and improve product texture, juiciness, product texture, juiciness, color, and odor color, and odor

CarageenanCarageenan•• Isolated from red algae, Isolated from red algae,

seaweed, or seaweed, or seamossseamoss•• Mix of polysaccharidesMix of polysaccharides•• Can incorporate Can incorporate

antioxidants, salt, antioxidants, salt, antimicrobials into the antimicrobials into the matrixmatrix

•• When used with muscle When used with muscle foods, coatings can foods, coatings can prolong the shelf life and prolong the shelf life and safety of beefsafety of beef

PectinPectin•• Plant derived polysaccharidePlant derived polysaccharide•• Limited research conducted Limited research conducted

with pectinwith pectin•• Works well with lowWorks well with low--moisture moisture

foods since they are poor foods since they are poor moisture barriersmoisture barriers

•• With muscle foods, pectin With muscle foods, pectin gels reduced cooler gels reduced cooler shrinkage and bacterial shrinkage and bacterial growth on beef platesgrowth on beef plates

AgarAgar•• SeaweedSeaweed--derived derived

polysaccharidepolysaccharide•• Used in microbiological Used in microbiological

media to provide media to provide firmnessfirmness

•• Forms strong gels with Forms strong gels with higher melting pointshigher melting points

•• Used as delivery system Used as delivery system for antimicrobials to for antimicrobials to improve safety of improve safety of muscle foodsmuscle foods

Chitin/ChitosanChitin/Chitosan•• Derived from the Derived from the exoexo--skeleton skeleton

of insects, crustaceans and of insects, crustaceans and some fungisome fungi

•• One of the most abundant One of the most abundant biopolymers available in the biopolymers available in the worldworld

•• Desirable properties include: Desirable properties include: good oxygen & COgood oxygen & CO22permeability, good mechanical permeability, good mechanical properties, acts a chelator in properties, acts a chelator in biological systems, and biological systems, and exhibits antimicrobial activityexhibits antimicrobial activity

•• Exhibits high sensitivity to Exhibits high sensitivity to waterwater

BIO-BASED POLYMERS

Polymers extracted from biomass Polymers synthesized from bio-derived monomers

Polymers produced from microorganisms

Polysaccharides Proteins Lipids Polylactate Other polyesters Bacterial compounds

Starch Cellulose Gums Chitosan/chitinpotato cotton guarcorn wood locust beanwheat other derivatives alginaterice carrageenanother derivatives pectins

agar

Animalcaseinwhey

collagengelatin

Plantzeinsoy

gluten

waxesfats oils

cellulose xanthan curlan

pullulan

(Adapted from Weber, et al. 2002. Food (Adapted from Weber, et al. 2002. Food Additives and Contaminants 19:172Additives and Contaminants 19:172--177)177)

Casein & WheyCasein & Whey•• Derived from milkDerived from milk•• High nutritional valueHigh nutritional value•• Exhibit good mechanical and barrier Exhibit good mechanical and barrier

properties, soluble in water, act as properties, soluble in water, act as emulsifiers, & industrial surplusemulsifiers, & industrial surplus

•• When applied to muscle foods, films can When applied to muscle foods, films can reduce moisture loss, delay lipid oxidation, reduce moisture loss, delay lipid oxidation, reduce peroxide valuesreduce peroxide values

•• Enzymes may degrade films; allergen Enzymes may degrade films; allergen issuesissues

GelatinGelatin•• Excellent gas and solute barrierExcellent gas and solute barrier•• Improves oxidative and color stability, Improves oxidative and color stability,

retains flavor, taste, and aroma of muscle retains flavor, taste, and aroma of muscle foodsfoods

•• Can be used as delivery systems for Can be used as delivery systems for antioxidants and antimicrobialsantioxidants and antimicrobials

•• Decreases oil adsorption during fryingDecreases oil adsorption during frying•• Lacks strength; requires drying to form Lacks strength; requires drying to form

more durable filmsmore durable films

CollagenCollagen•• Commercial use with Commercial use with

processing of cooked meat processing of cooked meat products (Coffiproducts (Coffi™™ films)films)

•• Forms edible Forms edible ““skinskin”” on on cooked productcooked product

•• Reduces shrink loss, Reduces shrink loss, increases permeability of increases permeability of smoke, enhances juiciness, smoke, enhances juiciness, absorbs fluid absorbs fluid exudateexudate

•• Reduces transport of gas Reduces transport of gas and moistureand moisture

Cereal & oilseedCereal & oilseed•• Limited information on use of Limited information on use of

these compounds with muscle these compounds with muscle foodsfoods

•• Corn zein treated with Corn zein treated with antioxidants, emulsifier, and antioxidants, emulsifier, and plasticizer plasticizer reduce lipid reduce lipid oxidation in muscle foodsoxidation in muscle foods

•• Soy protein/wheat gluten films Soy protein/wheat gluten films can reduce moisture loss & lipid can reduce moisture loss & lipid oxidation oxidation

•• Allergen issuesAllergen issues

BIO-BASED POLYMERS

Polymers extracted from biomass Polymers synthesized from bio-derived monomers

Polymers produced from microorganisms

Polysaccharides Proteins Lipids Polylactate Other polyesters Bacterial compounds

Starch Cellulose Gums Chitosan/chitinpotato cotton guarcorn wood locust beanwheat other derivatives alginaterice carrageenanother derivatives pectins

agar

Animalcaseinwhey

collagengelatin

Plantzeinsoy

gluten

waxesfats oils

cellulose xanthan curlan

pullulan

(Adapted from Weber, et al. 2002. Food (Adapted from Weber, et al. 2002. Food Additives and Contaminants 19:172Additives and Contaminants 19:172--177)177)

Lipid FilmsLipid Films•• Reduce shrinkage, prevent Reduce shrinkage, prevent

lipid oxidation, act as lipid oxidation, act as moisture & oxygen barriersmoisture & oxygen barriers

•• Impart hydrophobicity, Impart hydrophobicity, cohesiveness, flexibilitycohesiveness, flexibility

•• Transparent, reduces freezer Transparent, reduces freezer burn on muscle foodsburn on muscle foods

•• Prolongs freshness, color, Prolongs freshness, color, aroma, tenderness, and aroma, tenderness, and microbial stability of muscle microbial stability of muscle foodsfoods

Lipid FilmsLipid Films•• Can be used as flavor Can be used as flavor

carrierscarriers•• At higher storage At higher storage

temperatures, films may temperatures, films may create anaerobic create anaerobic conditions,conditions, lack lack structural integrity, & structural integrity, & poor adherencepoor adherence

•• Films may be subject to Films may be subject to oxidation, cracking, oxidation, cracking, flaking, retention of offflaking, retention of off--flavorsflavors

BIO-BASED POLYMERS

Polymers extracted from biomass Polymers synthesized from bio-derived monomers

Polymers produced from microorganisms

Polysaccharides Proteins Lipids Polylactate Other polyesters Bacterial compounds

Starch Cellulose Gums Chitosan/chitinpotato cotton guarcorn wood locust beanwheat other derivatives alginaterice carrageenanother derivatives pectins

agar

Animalcaseinwhey

collagengelatin

Plantzeinsoy

gluten

waxesfats oils

cellulose xanthanpullulan

(Adapted from Weber, et al. 2002. Food (Adapted from Weber, et al. 2002. Food Additives and Contaminants 19:172Additives and Contaminants 19:172--177)177)

Polylactic Acid FilmsPolylactic Acid Films

Polylactic Acid FilmsPolylactic Acid Films•• Biodegradable polymer made from Biodegradable polymer made from

corn following fermentation of starchcorn following fermentation of starch•• Made up of chains of lactic acid Made up of chains of lactic acid

strengthstrength•• Resistant to oils, are sealable at low Resistant to oils, are sealable at low

temperatures, act as flavor/odor temperatures, act as flavor/odor barrierbarrier

•• Can be used as delivery system for Can be used as delivery system for antimicrobials or combined with antimicrobials or combined with irradiation to improve safety of muscle irradiation to improve safety of muscle foods foods

•• Incompatible with chitosanIncompatible with chitosan

BIO-BASED POLYMERS

Polymers extracted from biomass Polymers synthesized from bio-derived monomers

Polymers produced from microorganisms

Polysaccharides Proteins Lipids Polylactate Other polyesters Bacterial compounds

Starch Cellulose Gums Chitosan/chitinpotato cotton guarcorn wood locust beanwheat other derivatives alginaterice carrageenanother derivatives pectins

agar

Animalcaseinwhey

collagengelatin

Plantzeinsoy

gluten

waxesfats oils

cellulose xanthanpullulan

(Adapted from Weber, et al. 2002. Food (Adapted from Weber, et al. 2002. Food Additives and Contaminants 19:172Additives and Contaminants 19:172--177)177)

XanthanXanthan•• Produced by Produced by XanthomonasXanthomonas campestriscampestris•• Used to keep ingredients suspended Used to keep ingredients suspended

uniformly and provide thickening uniformly and provide thickening •• Soluble in both hot and cold water, Soluble in both hot and cold water,

stable over a wide range of pH levels stable over a wide range of pH levels and temperaturesand temperatures

•• Functionality is not influenced by Functionality is not influenced by salts, pH, acids, alkalis or enzymessalts, pH, acids, alkalis or enzymes

•• When used in combination with equal When used in combination with equal amounts of locust bean, an elastic gel amounts of locust bean, an elastic gel is formedis formed

•• Can be used in pâtCan be used in pâtéés, aspics, brawnss, aspics, brawns

PullulanPullulan•• Produced from starch following Produced from starch following

fermentation by fermentation by Aureobasidium Aureobasidium pullulanspullulans•• WaterWater--soluble polysaccharidesoluble polysaccharide•• Odorless, flavorless, and highly stableOdorless, flavorless, and highly stable•• Heat sealable, exhibits good oxygen Heat sealable, exhibits good oxygen

barrier properties barrier properties •• Surface can be printed, colors or flavors Surface can be printed, colors or flavors

added to matrix added to matrix

Composite FilmsComposite Films•• Combinations of 2+ materials (including Combinations of 2+ materials (including

plasticizers) can improve flexibility, plasticizers) can improve flexibility, permeability, solubility of filmspermeability, solubility of films

•• Can improve gas exchange and moisture Can improve gas exchange and moisture vapor permeability and adherence to vapor permeability and adherence to coated muscle foodscoated muscle foods

•• Reduces drip loss, handling, and Reduces drip loss, handling, and packaging waste packaging waste

•• Enhances juicinessEnhances juiciness•• More research needed on consumer More research needed on consumer

acceptabilityacceptability

Antimicrobial FilmsAntimicrobial Films•• Compounds applied to muscle foods via films:Compounds applied to muscle foods via films:

–– Organic acidsOrganic acids–– Bacteriocins Bacteriocins –– Grape seed extractsGrape seed extracts–– Spice extractsSpice extracts–– ThiosulfinatesThiosulfinates–– EnzymesEnzymes–– IsothiocyanatesIsothiocyanates–– ChelatorsChelators–– MetalsMetals–– Parabens Parabens

Antimicrobial FilmsAntimicrobial Films•• Antimicrobials are more Antimicrobials are more

effective against bacteria effective against bacteria associated with fresh and associated with fresh and further processed muscle further processed muscle foods when delivered via foods when delivered via film system as compared to film system as compared to direct application (liquid) direct application (liquid)

•• Application of biopolymers Application of biopolymers treated with antimicrobials treated with antimicrobials can control spoilage and can control spoilage and enhance the safety of enhance the safety of muscle foodsmuscle foods

SummarySummary•• Alternatives are needed to petroleumAlternatives are needed to petroleum--based based

packaging materialspackaging materials•• New materials should be natural, recyclable, New materials should be natural, recyclable,

biodegradable, and/or compostablebiodegradable, and/or compostable•• A variety of biopolymers have been A variety of biopolymers have been

extracted from biomass, synthesized from extracted from biomass, synthesized from biobio--derived monomers, or produced from derived monomers, or produced from microorganismsmicroorganisms

SummarySummary•• Examples of biopolymers extracted from Examples of biopolymers extracted from

biomass include polysaccharides, proteins, biomass include polysaccharides, proteins, or lipids from plant, animal, or marine or lipids from plant, animal, or marine sourcessources

•• Polylactic acid is an example of a Polylactic acid is an example of a biopolymer synthesized from biobiopolymer synthesized from bio--derived derived monomersmonomers

•• Xanthan and pullulan are biopolymers Xanthan and pullulan are biopolymers produced from microorganisms produced from microorganisms

SummarySummary•• When applied to muscle foods, When applied to muscle foods,

biopolymers should impart desirable biopolymers should impart desirable characteristics such as stability, gas characteristics such as stability, gas permeability, transparency, moisture permeability, transparency, moisture retention, edibility, etc.retention, edibility, etc.

•• The application of biopolymers with The application of biopolymers with antimicrobials can enhance the quality antimicrobials can enhance the quality and safety of fresh and further processed and safety of fresh and further processed muscle foodsmuscle foods

Questions?Questions?