Cereal and Confectionary Packaging: Background, ...

As can be seen from the above text, choosing the right packaging material concept can have a positive effect on quality maintenance and therefore shelf-life of cereal and confectionary products and food in general. Where particularly sensitive products (e.g., high aw value, high fat content or oxidation potential) are present (e.g., fresh pasta, fried snacks) or an elevated shelf-life has to be achieved (e.g., ready-to-bake rolls, fine bakery wares), modern packaging concepts such as modified atmospheric packaging or active (AP) and intelligent packaging (IP) are used (combined abbreviation: AIP). Manifold different approaches can be found regarding MAP, AP, and IP, each with different relevance for the discussed product subgroups, cereals and cereal products, confectionary, bakery wares and ready-to-eat savouries and snacks. However, for an impression of these, depicts selected examples.

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Using these approaches, other product preservation actions (e.g., heating, use of preservatives) may be reduced, which supports attempts to reach a healthier diet (e.g., reduction of salt) or a clean label (e.g., avoidance of excess additives) [141] These allow specifically addressing other remaining challenges in the chemical, biological, mechanical, and physical fields [12,13]. Thus, they are also often implemented in the hurdle technology, a concept of combining diverse adverse factors or treatments to control microbial growth in food products [13,142]. According to studies found, also biobased and/or biodegradable packaging material is experimentally combined with AIP approaches. These materials offer new opportunities, for example in making use of different barrier properties, that allow a certain shelf-life extension [134,135]. Examples for MAP and AP with traditional as well as biobased/biodegradable packaging materials can be found in .

Turning to ready-to-eat savouries and snacks (e.g., crisps) Sanches et al. [ 128 ] investigated inter alia the effects of different packaging atmospheres under 40 °C and room temperature on multiple crisp samples, linked to lipid oxidation. They included marketed products under unknown MAP concentrations, air, N 2 , vacuum and oxygen scavengers in the analysis. Reflecting changes in the fatty acid profile of the crisps, it was resumed that changes in the package&#;s atmospheres, mostly cutting out oxygen, was crucial for the shelf-life of the crisps. Vacuum packaging options would also allow stable lipid profiles, however, they are not suitable for easily breakable crisps. Del Nobile [ 129 ] was similarly questioning the optimal packaging for crisps, however, focused on finding the best headspace gas composition for two different multilayer film packages (metallized PP and PVdC coated PE) through simulated storage. He proposed that N 2 combined with water vapour would lead to a shelf-life extension up to 80%.

Turning to bakery wares such as (pita)bread, cakes, crumpets, crepes, (fruit)pies, Robertson [ 13 ] reports a frequent use of CO 2 :N 2 60:40% MAP. However, in the scientific literature, a more diverse application of CO 2 :N 2 MAP can be seen. For example, Rodriguez et al. [ 126 ] investigated extending the shelf-life of bread using MAP packaging in a combination with preservatives. The research referred to bread slices packaged in a 60 µm bag. The results showed that in the samples without added preservative, and CO 2 :N 2 50:50% MAP, the increases in shelf-life were 117% and 158% (at 22&#;25 °C and 15&#;20 °C). For the samples with calcium propionate addition and in N 2 100% MAP, shelf-life was increased by 116%. Furthermore, calcium propionate addition and CO 2: N 2 20:80% MAP increased the shelf-life by 150% and 131% at 22&#;25 °C and 15&#;20 °C. When the CO 2 concentration was increased to 50%, the increased shelf-life of the samples with added preservative was 167% at 22&#;25 °C. For the same settings at 15&#;20 °C the increase was even 195%. Fernandez et al. [ 149 ], conducted a similar research with soy bread. They as well used different settings of MAP and preservative adding but expanded the question of packaging options. They used two multilayer packaging solutions, high and medium barrier. The high barrier was LLDPE/PA/EVOH/PA/LLDPE, whereas the medium barrier solution was LLDPE/PA/LLDPE. As controls, LDPE and air atmospheres were used. The combination of high barrier packaging in CO 2 :N 2 50:50% or CO 2 :N 2 20:80% MAP without calcium propionate addition extended the shelf-life of the samples by at least 200%.

In the category of cereals and cereal products, and in more detail in fresh pasta, MAP often contains elevated amounts of CO 2 (up to 80%) and corresponding low N 2 values (balance) [ 13 , 108 , 120 , 121 ]. For instance, Lee et al. [ 120 ] conducted a comparative study on fresh pasta packaged under air (PS tray with PVC film) and under CO 2 :N 2 78:22% MAP (PA/EVOH/LLDPE). As a result, the shelf-life was doubled from 20 to 40 days at a storage temperature of 8 °C. Even higher rates of shelf-life increase for fresh filled pasta were shown in two other studies [ 108 , 121 ]. In the first case, samples included fresh pasta filled with cheese in a sealed tray (EVOH/PS/PE) with a barrier film (EVOH/OPET/PE) and two different atmospheres (air; CO 2 :N 2 50:50% MAP). Quality maintenance was increased from 7&#;10 days up to 42 days [ 108 ]. Similarly, in the second case, gluten-free fresh pasta was packaged in trays (control: PET; test: EVOH/PS/PE) sealed with films (control: PET; test: EVOH/OPET/PE). Shelf life under air was compared to CO 2 :N 2 30:70% MAP. Here, an increase from 14 to 42 days was notable [ 121 ].

Regarding the food categories at the centre of the present review, confectionary products are less frequently in the centre of research and application of MAP than cereals and cereal products, bakery wares or ready-to-eat savouries and snacks (see ). One case of MAP use, however, is reported by Mexis et al. [ 119 ], for dark chocolate with hazelnuts. The authors found, that when conventionally used aluminium packaging together with storage under surrounding atmosphere was replaced with a PET/LDPE or PET-SiO x packaging and vacuum or N 2 , the shelf-life (dark storage at 20 °C) was increased from 8 to 8&#;9 and 11 months, respectively. Also Kita et al. [ 152 ], investigated the effects of different packaging types and shelf-life extension strategies for chocolate coated products (fruits and nuts). They analysed air, vacuum and MAP (N 2 &#; 98%) of coated cherries, figs, hazelnuts and almonds in long term storage conditions in three different types of packaging. PP film closed with a clip was chosen for air, PP film sealed for vacuum and metallized sealed film for MAP. They resumed that the best packaging solutions for the chosen chocolate coated products, ensuring quality (for example bioactive compounds, antioxidative activity) were, on one hand, air and vacuum packaging for fruits, vacuum packaging for hazelnuts and MAP for almonds.

A more advanced modification can be found in a so-called modified atmosphere packaging, MAP [ 147 ]. Here, an active modification takes place in a two-step process, where first the initial atmosphere is removed (vacuum) and then replaced with a specific artificially composed atmosphere before closure of the barrier packaging. Commonly, in product-dependent concentrations used, colourless and odourless gases in MAP mainly encompass CO 2 and N 2 . Due to its formation of hydrated carbonate species in aqueous phase CO 2 is valued for its bacteriostatic and fungistatic effect, which increases with increasing concentration. Due to the solubility in water and fat, formation of under-pressure in the package and, consequently, possible collapse of the latter is possible. To avoid this and to act as a filler gas, the inexpensive and inert N 2 is applied. Hence, passively, also this gas contributes to quality maintenance of the product. Furthermore, O 2 is a frequently used gas but of little relevance for the cereal and confectionary sector. Its field of application is mostly in meat (e.g., bright-red colour preservation via high-oxygen MAP) and fish products and to lower extent in plant products [ 145 , 148 , 149 ]. More recently, permitted noble gases such as argon are subject to research but not broadly applied on cereal and confectionary products [ 150 , 151 ]. Depending on the chosen MAP gas composition, food shelf-life can increase manifold (50&#;400%) and with this advantage along the supply chain can be recorded (e.g., less food waste, longer remaining shelf-life, less frequent production and transport). However, disadvantages linked to MAP, in general encompass the need for more sophisticated packaging materials and filling equipment, costs for gas and increased packaging volume [ 13 ].

Leaving quality sensitive products exposed to atmospheric conditions (gas composition of N 2 , O 2 , Ar, CO 2 , traces of other gases) can trigger undesirable changes such as quality-related oxidative decay or growth of (non)pathogenic aerobic microorganisms. On the contrary, modifying the atmosphere inside a packaging can help maintain the quality of a product over an elevated timeframe. Consequently, common mitigation strategies include the reduction of packaging headspace and, thus, total available atmosphere or even removal of the atmosphere (to a value below one percent), which in turn results in vacuum packaging. To maintain these conditions over time, it is necessary to assure an appropriate containment function of the packaging by choosing packaging materials with an appropriate gas barrier and proper sealing. Challenges in this case are often the structure of the products and the corresponding residual oxygen in the packaging in the case of e.g., pores and the collapse of the product in the case of e.g., a soft structure [ 13 , 125 , 146 ].

4.2. Active and Intelligtent Packaging (AIP)

While MAP is firmly established in the market, active and intelligent packaging has not yet reached its full potential in food packaging applications but is at the threshold of more widespread use in the European market and subject to intense research and development activities [153,154,155]. Accordingly, the following paragraphs aim at outlining the concept of AIP and highlighting applications most relevant for cereal and confectionary packaging.

Just as conventional packaging applications, AIP define as food contact materials as given in Regulation (EC) No /. While conventional packaging has to be sufficiently inert not to transfer substances to the food in quantities that endanger human health or bring an unacceptable change of the food product (composition, organoleptic properties), AIP are intentionally designed not to be inert. This allows them to actively maintain or even improve the quality or shelf-life of food products [39]. Hence, AIP deliberately includes &#;active&#; components that are either aimed to be released to the food or that aim at absorbing substances from it. This justifies the division of active packaging into so-called releaser and absorber systems. However, a clear distinction is made to traditional substance releasing materials (e.g., wooden barrels) in food contact. The use of active substances aimed to be released to the food must also comply with the Directive / on food additives and should be authorized accordingly by applicable community provisions [63]. Furthermore, specific requirements regarding labelling and information, avoidance of misleading consumers as well as safety assessment and authorisation is given [39]. In addition to Regulation (EC) No /, Commission Regulation (EC) No 450/ gives specific rules for the use of AIP (e.g., community list of allowed substances for use and evaluation of these) [39,156].

In response to major challenges in food quality and safety [12,13], key technologies in the area of active packaging are emitters (e.g., CO2, ethanol, antimicrobials, antioxidants) and scavengers (e.g., O2, CO2, ethylene), absorbers (e.g., H2O, flavour and odour), self-venting packages, microwave susceptors, and temperature control packaging [13,40,157,158,159,160,161,162,163,164,165]. Intelligent packaging on the other hand refers to packaging that monitors the food product and provides information about its condition [39]. Related key technologies are mostly indicators and sensors (e.g., time, temperature) and linked processing and communication systems (e.g., (printed) electronics). Further, tamper evident packaging and anti-counterfeiting applications exist [163,166].

Due to their effectiveness, the growth forecasts for AIP in the coming years are high, but it must be emphasised that the sustainability of such sophisticated packaging solutions should be evaluated case by case [167]. In addition to the actual reduction of food losses and food waste, factors such as, e.g., the recyclability of AIP, which may include metal-based components, should be evaluated [153,163,168,169].

Going into detail about cereal and confectionary packaging (see also ), an application example for oxygen absorbers is in sliced bread. Where O2 concentration decreased below 0.1% within a few days of packaging, microbial shelf-life was shown to be extended. It was reported that there was no effect on sensory quality [170]. Oxygen absorber can also be used in combination with MAP. In , Del Nobile et al. [127] showed that the application of CO2:N2 80:20% MAP in the packaging of durum wheat bread prolonged the shelf-life from 3 to about 18 days at 30 °C. However, if the packaging film itself possesses a high barrier against oxygen, neither the use of scavengers nor MAP are necessary to achieve the desired shelf-life of white bread [171]. Finally, an oxygen scavenger system, consisting of a multilayer coextruded bag associated with an oxygen scavenger, was tested in different storage conditions (accelerated storage, room temperature, refrigerator), for its effect on preservative-free tortillas shelf life. The results indicated a protective effect of the packages including the oxygen scavenger system. Specifically, the weight and thickness of flour tortillas under room temperature conditions could be maintained, opposed to respective decreases detected in control packages (consisting of LDPE/LLDPE). In parallel, yeast and mold growth were hold back in the packages containing the oxygen scavenger versus control (room temperature and accelerated storage). Under refrigerated conditions, a shelf-life up to 31 days was estimated, however, independed of the use of oxygen scavengers [172].

It has been also shown that the use of ethanol emitters extend shelf-life even without establishment of an additional modified atmosphere. For ciabatta, a shelf-life of 16 days, at 21 °C could be obtained, packaged in air atmosphere and ethanol emitter addition [122].

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Antimicrobial, antifungal, and antioxidative agents as active food packaging include multiple research topics. Options include the applications of essential oils, edible films, and nanocomposites, which are often used with products susceptible to microbiological degradation, e.g., sliced bread. For example, oregano essential oil has been observed to be a successful application against yeasts and moulds in sliced bread. It was applied in the form of antimicrobial sachet at concentrations of 5, 10, and 15% (v/w) at room temperature [136]. In addition to that, methylcellulose edible films produced with clove and oregano essential oil have displayed antimicrobial activity against spoilage fungi in bakery products and have improved sliced bread shelf-life to 15 days, at 25 ± 2 °C [137]. Also, cinnamaldehyde was used as an active ingredient to increase the shelf-life of sliced bread. It was incorporated in gliadin films (5%), which allowed to keep the quality of the product for 27 days of storage at 23 °C [173]. Next to having antimicrobial effects, essential oils are also antioxidative agents that can be included in packaging material like HDPE, LDPE, EVA. Zhu et al. [138] for example tested this approach with sesame essential oils for the packaging of oat cereals. However, there are also biological threats that could shorten the shelf-life of cereal and confectionery products. Essential oils from garlic, black pepper, ginger, fennel, and onion already have been tested as insect repellents for grain packaging. All these tested essential oils were characterized by significant fumigant insecticidal properties. For example, allyl mercaptan deriving from allium plants added as a sachet with rice flour, was proven as potential protective active packaging against S. oryzae contamination leaving sensory properties unaffected [174]. In general, the incorporation of essential oils in packaging materials is a growing sector [175,176]. One background can be that they are waterproof, so it could be the ideal material for the incorporation into a film, which will turn it from a conventional packaging material to an active one, increasing both its value and its functionality [175].

One further option of active packaging is the targeted use of composites at the nanoscale, whether organic (oils/proteins/carbohydrates) and/or inorganic, e.g., clays. This topic is of interest as active agents might have different properties in smaller scales. Materials of which at least one of its external dimensions belongs to the nanoscale (1 to 100 nm) are considered nanomaterials [177,178]. They are characterized for their unique properties such us high surface-area-to-volume ratio, fine particle size, and high reactivity [179]. One common area of research interest is represented by publications including essential oils. For example, bio-nano-composite films prepared with corn starch incorporated with chitosan nano-clay, and further enriched with a variety of ratios of grapefruit seed extracts have been studied. It was shown that this solution was capable of inhibiting fungal proliferation for a period of 20 days, compared to that of 6 days in bread packaged samples with synthetic plastic, indicating a successful active packaging approach to extent the shelf-life of bakery products [133]. Furthermore, two different formulations mainly consisting of essential oils from several plants were evaluated for their potential antifungal properties in maize grains. Specifically, in a recent study, bioactive EVOH films including various essential oils have been characterized. Cinnamaldehyde, citral, linalool and isoeugenol were investigated to decrease the activity of A. steynii and A. tubingensis strains. It was shown that the ochratoxin A production by these strains in partly milled maize grains could be reduced significantly. The inhibitory effect was the highest in EVOH with cinnamaldehyde, followed by isoeugenol and citral [180]. In parallel, EVOH copolymer films incorporated with essential oils from Origanum vulgare, Cinnamomum zeylanicum and/or their major active constituents have been studied. The results showed that carvacrol and cinnamaldehyde were effective in decreasing Aspergillus flavus and A. parasiticus-induced aflatoxin production in maize, respectively. Overall, cinnamaldehyde showed the highest inhibitory effect, followed by combinations of EVOH with essential oils from Origanum vulgare, Cinnamomum zeylanicum and carvacrol [181].

Next to these highly discussed organic nanoparticles, inorganic particles like Ag (silver) and TiO2 (titan dioxide) have also been applied to packaging solutions, for example cereal products, due to their antimicrobial effects [182,183,184,185]. However, there is a concern on potential risk of nanoparticles migrating into food, although limited data showed that obtained values were within the limits set by the legislation [185,186,187,188,189]. It was shown that Ag-TiO2 nanocomposite incorporated in HDPE considerably extended shelf-life and microbiological safety of bread in comparison with control sample stored in an open atmosphere or in HDPE bags [144]. Not only the characteristics of plastic packaging can be optimized by the inclusion of nanoparticles. The modification of paper with Ag-TiO2-SiO2 (silicon dioxide) or Ag/N-TiO2 composites can improve the papers material characteristics. It was shown that such paper was capable to extend the shelf-life of bread by 2 days in comparison to the control, in both ambient (18&#;20 °C) and refrigerated (0&#;4 °C) conditions [190].

Research in optimizing packaging with nanostructures goes even further to high-tech materials. An example is a packaging material with a montmorillonite layer. It was shown that montmorillonite composite polyamide 6 nano-fibres placed over PP films, increased the shelf-life of bread by 2 days at room temperature, due to inhibition of microbial growth [191].

Intelligent packaging, on the other hand, is a special packaging technique aiming to monitor the quality of the packaged food and to predict or measure the safe shelf-life better than a best before marking date [122,130,171,192,193,194]. It provides functions beneath the ones considered as conventional e.g., protection and containment and is used to monitor the condition and provide quality information of packed foods to the consumers [158]. Different indicators, such as time-temperature, microbial growth, product freshness, pack integrity etc., are used as intelligent packaging systems. High temperatures and/or temperature fluctuation are often correlated with food deterioration as result of detrimental biochemical reactions combined with microbial growth. Depending on the food sensitivity specific intelligent indicators can be applied to specific food products. The time-temperature indicator measures the change that imitates the targeted quality characteristics with the same behaviour under the same time-temperature exposure. The pH and enzymatic indicators can also give information about the quality of food [195]. Commercially available time-temperature indicators can be used to monitor quality changes of many perishable and semi-perishable foods. Among other products, these indicators have been applied to canned fruitcake for 10 days&#; storage at constant (12, 25 and 37 °C) temperatures. Sensory analysis, as quality characteristic of the product, was correlated with indicator response [140,196].

Reflecting the above chapters and findings, it can be summarized and confirmed that, if chosen correctly, cereal and confectionary packaging, as well as food packaging in general can make a valuable contribution to maintaining the quality and safety of food [12,13,17]. Accordingly, it can also help to prevent food losses and waste, an important point when it comes to making our food systems more sustainable [11,16]. This point is also taken up in the SDGs and influences current political efforts such as the European Union's Green Deal [2,3,6].

However, packaging redesign or optimizations should not simply be carried out without evaluating the effects on ecological, social, and economic sustainability as objectively as possible. This is the only way to avoid possible hidden trade-offs [17].

In addition, close cooperation between a wide range of disciplines is required. In this context, and among others, material science, sustainability science and social sciences, and humanities can be mentioned in addition to food science and technology. The latter in particular has, however, an important enabling function [197,198]. The future focus here could be on the points of promoting (i) diverse and sustainable primary produce, (ii) new processes and systems for sustainable manufacture, (iii) reduction of food and material waste along the supply chain, (iv) safety and traceability, (v) affordable and balanced nutrition, (vi) healthy diets as well as (vii) digitalization. MAP and AIP are important approaches in this context, which are particularly present in the points (ii), (iii) and (iv) [198].

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