Active packaging
Encyclopedia
The terms active packaging, intelligent packaging, and smart packaging refer to packaging systems used with food
s, pharmaceuticals, and several other types of products. They help extend shelf life, monitor freshness, display information on quality, improve safety, and improve convenience.
The terms are closely related. Active packaging usually means having active functions beyond the inert passive containment and protection of the product. Intelligent and smart packaging usually involve the ability to sense or measure an attribute of the product, the inner atmosphere of the package, or the shipping environment. This information can be communicated to users or can trigger active packaging functions.
Depending on the working definitions, some traditional types of packaging might be considered as "active" or "intelligent". More often, the terms are used with new technologically advanced systems.
s can be applied to items to help prevent rust and corrosion. Volatile corrosion inhibitors (VCI) or vapor phase corrosion inhibitors can be provided inside a package in a pouch or can be incorporated in a saturated overwrap of special paper. Many of these are organic salts that condense on the metal to resist corrosion. Some films also have VCI emmitting capability.
Films are available with copper ions in the polymer structure, These neutralize the corrosive gas in a package and deter rust.
VCI create a neutral environment in the packaging. It works on the principle of difference in vapour pressure and causes reaction with Metals and Non metals and also with Moisture to render it active to corrosion. There are different forms of VCI's available like Papers, Plastics, HDPE Papers, Oils, Foams, Bubble, Emitters etc that can prevent corrosion at many stages.
s help remove oxygen from a closed package. Some are small packets or sachets containing powdered iron: as the iron rusts, oxygen is removed from the surrounding atmosphere. Newer systems are on cards or can be built into package films or molded structures. In addition, the physical characteristics of the packaging itself (oxygen transmission rate
- OTR) can dictate how effective an oxygen absorber can be, and how long it will stay effective. Packaging with a low OTR will let less oxygen in the closed package through the polymer barrier itself .
More recently, other mixtures of gas have been used inside the package to extend the shelf life. The gas mixture depends on the specific product and its degradation mechanisms. Some package components have been developed that incorporate active chemistry to help maintain certain atmospheres in packages.
Oxygen scavengers, carbon dioxide generators, ethanol generators, etc. are available to help keep the atmosphere in a package at specified conditions.
s, signal when a critical accumulation of temperature deviation over time has been exceeded. When the mechanism of the indicator is tuned to the mechanism of product degradation, these can provide valuable signals for consumers.
Digital temperature data logger
s record the temperatures encountered throughout the shipment. This data can be used to predict product degradation and help determine if the product is suited for normal sale or if expedited sale is required. They also determine the time of the temperature excess: this can be used to direct corrective action.
Thermochromic inks are sometimes used to signal temperature excess or change. Some are reversible while others have a permanent change of color. These can be used alone or with other packaging functions such as barcode
s.
The inks can also signal a desired temperature for consumers. For example, one type of beer can has ink that graphically shows when an ideal drinking temperature is achieved.
s are passive packaging to help control the temperatures fluctuations seen even with a controlled cold chain
s. In addition, gel packs are often used to actively keep the temperature of the contents within specified acceptable temperature ranges.
Some newer packages have the ability to heat or cool the product for the consumer. These have segregated compartments where exothermic or endothermic reactions provide the desired effect.
Self-heating can
s are available for several products.
. These are used for products ranging from precision inhaler
s for medications to spray bottles of household cleaners.
Some dispensing packages for two-part epoxy
adhesives do more than passively contain the two components. When dispensed, some packages meter and mix the two components so the adhesive is fully functioning at the point of application.
s that are used to track and trace packages and unit load
s throughout distribution. Newer developments include recording the temperature history of shipments and other intelligent packaging functions.
methods, security hologram
s, and specialized label
s are available to help confirm that the product in the package is not counterfeit
. RFID chips are being used in this application also.
Electronic article surveillance
(on the product or on the package) is used to help counter shoplifting.
s are used as a susceptor
for cooking in microwave oven
s. These increase the heating capacity and help make foods crisp and brown.
Recently, digital data logger
s have been available to more accurately record the shocks and vibrations of shipment. These are used to monitor critical shipments to determine if extra inspection and calibration is required. They are also used to monitor the types of shocks and vibrations encountered in transit for use in package testing
in a laboratory.
s, anti-bacterial agents, scavengers, and other active components to help control food degradation and extend shelf life.
Edible films have been developed to allow consumers to eat the package along with the product.
.
Food packagers take extra care with some types of active packaging. For example when the oxygen atmosphere in a package is reduced for extending shelf life, controls for anaerobic bacteria need to be considered. Also when a controlled atmosphere reduces the appearance of food degradation, consumers need to retain a means of determining whether actual degradation is present.
Food
Food is any substance consumed to provide nutritional support for the body. It is usually of plant or animal origin, and contains essential nutrients, such as carbohydrates, fats, proteins, vitamins, or minerals...
s, pharmaceuticals, and several other types of products. They help extend shelf life, monitor freshness, display information on quality, improve safety, and improve convenience.
The terms are closely related. Active packaging usually means having active functions beyond the inert passive containment and protection of the product. Intelligent and smart packaging usually involve the ability to sense or measure an attribute of the product, the inner atmosphere of the package, or the shipping environment. This information can be communicated to users or can trigger active packaging functions.
Depending on the working definitions, some traditional types of packaging might be considered as "active" or "intelligent". More often, the terms are used with new technologically advanced systems.
Moisture control
For many years, dessiccants have been used to actively control the water vapor in a closed package. A desiccant is a hygroscopic substance usually in a porous pouch, is placed inside of a package. They have been used to reduce corrosion of machinery and to extend the shelf life of moisture sensitive foods and drugs.Corrosion
Corrosion inhibitorCorrosion inhibitor
A corrosion inhibitor is a chemical compound that, when added to a liquid or gas, decreases the corrosion rate of a material, typically a metal or an alloy. The effectiveness of a corrosion inhibitor depends on fluid composition, quantity of water, and flow regime...
s can be applied to items to help prevent rust and corrosion. Volatile corrosion inhibitors (VCI) or vapor phase corrosion inhibitors can be provided inside a package in a pouch or can be incorporated in a saturated overwrap of special paper. Many of these are organic salts that condense on the metal to resist corrosion. Some films also have VCI emmitting capability.
Films are available with copper ions in the polymer structure, These neutralize the corrosive gas in a package and deter rust.
VCI create a neutral environment in the packaging. It works on the principle of difference in vapour pressure and causes reaction with Metals and Non metals and also with Moisture to render it active to corrosion. There are different forms of VCI's available like Papers, Plastics, HDPE Papers, Oils, Foams, Bubble, Emitters etc that can prevent corrosion at many stages.
Oxygen control
Oxygen scavengers or oxygen absorberOxygen absorber
An oxygen absorber is a small packet of material used to prolong the shelf life of food. They are used in food packaging to prevent food colour change, to stop oils in foods from becoming rancid, and also retard the growth of oxygen-using aerobic microorganisms such as fungi.Oxygen supports the...
s help remove oxygen from a closed package. Some are small packets or sachets containing powdered iron: as the iron rusts, oxygen is removed from the surrounding atmosphere. Newer systems are on cards or can be built into package films or molded structures. In addition, the physical characteristics of the packaging itself (oxygen transmission rate
Oxygen Transmission Rate
Oxygen transmission rate is the measurement of the amount of oxygen gas that passes through a substance over a given period. It is mostly carried out on non-porous materials, where the mode of transport is diffusion, but there are a growing number of applications where the transmission rate also...
- OTR) can dictate how effective an oxygen absorber can be, and how long it will stay effective. Packaging with a low OTR will let less oxygen in the closed package through the polymer barrier itself .
Atmosphere
With some products, such as cheese, it has long been common to flush the package with nitrogen prior to sealing: the inert nitrogen is absorbed into the cheese, allowing a tight shrink film package. The nitrogen removes oxygen and "actively" interacts with the cheese to make the package functional.More recently, other mixtures of gas have been used inside the package to extend the shelf life. The gas mixture depends on the specific product and its degradation mechanisms. Some package components have been developed that incorporate active chemistry to help maintain certain atmospheres in packages.
Oxygen scavengers, carbon dioxide generators, ethanol generators, etc. are available to help keep the atmosphere in a package at specified conditions.
Temperature monitor
Some temperature indicators give a visual signal that a specified temperature has been exceeded. Others, Time temperature indicatorTime temperature indicator
A time temperature indicator is a device or smart label that shows the accumulated time-temperature history of a product. Time temperature indicators are commonly used on food, pharmaceutical, and medical products to indicate exposure to excessive temperature .-Technology:There are a large number...
s, signal when a critical accumulation of temperature deviation over time has been exceeded. When the mechanism of the indicator is tuned to the mechanism of product degradation, these can provide valuable signals for consumers.
Digital temperature data logger
Data logger
A data logger is an electronic device that records data over time or in relation to location either with a built in instrument or sensor or via external instruments and sensors. Increasingly, but not entirely, they are based on a digital processor...
s record the temperatures encountered throughout the shipment. This data can be used to predict product degradation and help determine if the product is suited for normal sale or if expedited sale is required. They also determine the time of the temperature excess: this can be used to direct corrective action.
Thermochromic inks are sometimes used to signal temperature excess or change. Some are reversible while others have a permanent change of color. These can be used alone or with other packaging functions such as barcode
Barcode
A barcode is an optical machine-readable representation of data, which shows data about the object to which it attaches. Originally barcodes represented data by varying the widths and spacings of parallel lines, and may be referred to as linear or 1 dimensional . Later they evolved into rectangles,...
s.
The inks can also signal a desired temperature for consumers. For example, one type of beer can has ink that graphically shows when an ideal drinking temperature is achieved.
Controlling package temperatures
For critical vaccines, insulated shipping containerInsulated shipping container
Insulated shipping containers are a type of packaging used to ship temperature sensitive products such as foods, pharmaceuticals, and chemicals. They are used as part of a cold chain to help maintain product freshness and efficacy...
s are passive packaging to help control the temperatures fluctuations seen even with a controlled cold chain
Cold chain
A cold chain is a temperature-controlled supply chain. An unbroken cold chain is an uninterrupted series of storage and distribution activities which maintain a given temperature range...
s. In addition, gel packs are often used to actively keep the temperature of the contents within specified acceptable temperature ranges.
Some newer packages have the ability to heat or cool the product for the consumer. These have segregated compartments where exothermic or endothermic reactions provide the desired effect.
Self-heating can
Self-heating can
A self-heating can is an enhancement of the common food can. Self-heating cans have dual chambers, one surrounding the other. The inner chamber holds the food or drink, and the outer chamber houses chemicals that undergo an exothermic reaction when combined...
s are available for several products.
Dispensing systems
Some packages have closures or other dispensing systems that actively change the contents from a liquid to an aerosolAerosol
Technically, an aerosol is a suspension of fine solid particles or liquid droplets in a gas. Examples are clouds, and air pollution such as smog and smoke. In general conversation, aerosol usually refers to an aerosol spray can or the output of such a can...
. These are used for products ranging from precision inhaler
Inhaler
An inhaler or puffer is a medical device used for delivering medication into the body via the lungs. It is mainly used in the treatment of asthma and Chronic Obstructive Pulmonary Disease . Zanamivir , used to treat influenza, must be administered via inhaler...
s for medications to spray bottles of household cleaners.
Some dispensing packages for two-part epoxy
Epoxy
Epoxy, also known as polyepoxide, is a thermosetting polymer formed from reaction of an epoxide "resin" with polyamine "hardener". Epoxy has a wide range of applications, including fiber-reinforced plastic materials and general purpose adhesives....
adhesives do more than passively contain the two components. When dispensed, some packages meter and mix the two components so the adhesive is fully functioning at the point of application.
RFID
Radio-frequency identification chips are becoming more common as smart labelSmart label
Smart Label, also called Smart Tag, is an extremely flat configured Transponder under a conventional print-coded label, which includes chip, antenna and bonding wires as a so-called inlay...
s that are used to track and trace packages and unit load
Unit load
A unit load combines individual items or items in shipping containers into a single "unit" that can be moved easily with pallet jack or forklift truck...
s throughout distribution. Newer developments include recording the temperature history of shipments and other intelligent packaging functions.
Security
A variety of security printingSecurity printing
Security printing is the field of the printing industry that deals with the printing of items such as banknotes, passports, tamper-evident labels, product authentication, stock certificates, postage stamps and identity cards...
methods, security hologram
Security hologram
Security holograms are very difficult to forge because they are replicated from a master hologram which requires expensive, specialized and technologically advanced equipment. They are used widely in several banknotes around the world, in particular those that are of high denominations...
s, and specialized label
Label
A label is a piece of paper, polymer, cloth, metal, or other material affixed to a container or article, on which is printed a legend, information concerning the product, addresses, etc. A label may also be printed directly on the container or article....
s are available to help confirm that the product in the package is not counterfeit
Counterfeit
To counterfeit means to illegally imitate something. Counterfeit products are often produced with the intent to take advantage of the superior value of the imitated product...
. RFID chips are being used in this application also.
Electronic article surveillance
Electronic article surveillance
Electronic article surveillance is a technological method for preventing shoplifting from retail stores or pilferage of books from libraries. Special tags are fixed to merchandise or books. These tags are removed or deactivated by the clerks when the item is properly bought or checked out...
(on the product or on the package) is used to help counter shoplifting.
Microwave packaging
Metallised filmMetallised film
Metallised films are polymer films coated with a thin layer of metal, usually aluminium. They offer the glossy metallic appearance of an aluminium foil at a reduced weight and cost...
s are used as a susceptor
Susceptor
A susceptor is a material used for its ability to absorb electromagnetic energy and convert it to heat . This energy is typically radiofrequency or microwave radiation used in industrial heating processes, and also occasionally in microwave cooking...
for cooking in microwave oven
Microwave oven
A microwave oven is a kitchen appliance that heats food by dielectric heating, using microwave radiation to heat polarized molecules within the food...
s. These increase the heating capacity and help make foods crisp and brown.
Shock and vibration
Shock detectors have been available for many years. These are attached to the package or to the product in the package to determine if an excessive shock has been encountered. The mechanisms of these shock overload devices have been spring-mass systems, magnets, drops of red dye, and several others.Recently, digital data logger
Data logger
A data logger is an electronic device that records data over time or in relation to location either with a built in instrument or sensor or via external instruments and sensors. Increasingly, but not entirely, they are based on a digital processor...
s have been available to more accurately record the shocks and vibrations of shipment. These are used to monitor critical shipments to determine if extra inspection and calibration is required. They are also used to monitor the types of shocks and vibrations encountered in transit for use in package testing
Package testing
Package testing or packaging testing involves the measurement of a characteristic or property involved with packaging. This includes packaging materials, packaging components, primary packages, shipping containers, and unit loads, as well as the associated processes.Testing measures the effects...
in a laboratory.
Other developments
Some engineered packaging films contain enzymeEnzyme
Enzymes are proteins that catalyze chemical reactions. In enzymatic reactions, the molecules at the beginning of the process, called substrates, are converted into different molecules, called products. Almost all chemical reactions in a biological cell need enzymes in order to occur at rates...
s, anti-bacterial agents, scavengers, and other active components to help control food degradation and extend shelf life.
Edible films have been developed to allow consumers to eat the package along with the product.
Regulations
Active packaging is often designed to actively interact with the contents of the package. Thus extra care is often needed for active or smart packagings that are food contact materialsFood contact materials
Food contact materials are materials that are intended to be in contact with food. These can be things that are quite obvious like a glass, a can for soft drinks, but also machinery in a food factory or a coffee machine....
.
Food packagers take extra care with some types of active packaging. For example when the oxygen atmosphere in a package is reduced for extending shelf life, controls for anaerobic bacteria need to be considered. Also when a controlled atmosphere reduces the appearance of food degradation, consumers need to retain a means of determining whether actual degradation is present.
See also
- Automatic identification and data capture
- Electronic article surveillanceElectronic article surveillanceElectronic article surveillance is a technological method for preventing shoplifting from retail stores or pilferage of books from libraries. Special tags are fixed to merchandise or books. These tags are removed or deactivated by the clerks when the item is properly bought or checked out...
- Scavenger (chemistry)Scavenger (chemistry)A scavenger in chemistry is a chemical substance added to a mixture in order to remove or inactivate impurities or unwanted reaction products. Their use is wide-ranged:...
- Security printingSecurity printingSecurity printing is the field of the printing industry that deals with the printing of items such as banknotes, passports, tamper-evident labels, product authentication, stock certificates, postage stamps and identity cards...
- Self-heating food packaging
Books, General References
- Yam, K. L., "Encyclopedia of Packaging Technology", John Wiley & Sons, 2009, ISBN 978-0-470-08704-6
- Brody, A. L., “Active Packaging for Food Applications”, CRC Press, 2001
- Kerry, J, and Butler, P, "Smart Packaging Technologies for Fast Moving Consumer Goods", Wiley, ISBN 978-0-470-02802-5