Training UPEMI 26/06/2013. IQ-Freshlabel

Transcription

1 Training UPEMI 26/06/2013 IQ-Freshlabel Developing novel intelligent labels for chilled and frozen food products and promoting the influence of smart labels application on waste reduction, food quality and safety in the European supply chains

2 IQ-FRESHLABEL

3 IQ-FRESHLABEL 7 th Research Framework Program (FP7) Capacities Theme: Research for the Benefit of SME Associations Grant Agreement: Project Duration:

4 IQ-FRESHLABEL Aim of the project

5 Substantial portion of chilled and frozen products are exposed, to effective temperatures that deviated significantly from the recommended range MS7 gestionenlacosta.blogspot.com radiocoronelsuarez.com enlineaweb.blogspot.com

6 Folie 5 MS7 Please always remeber to add the source for graphics/figures! ttz BN, Shrestha, Marie;

7 Food waste 40% of the food thrown away could have been eaten. In the UK: 6.7 million tons of food is thrown away by households every year Cost of 10billion Environmental Impact 1 tone waste 4.5 tons of CO 2 emitted to the atmosphere.

8 Producers Sale Transport Consumer Quelle: Quelle: cold chain Continuous Temperature Control Introduction of TTIs to Meat & Fish Industry Improvement of consumers confidence in product quality

9 Producers Sale Transport Consumer Quelle: Quelle: 10 Temperature ( C) Product shelf life days

10 Producers Sale Transport Consumer Quelle: Quelle: Temperature ( C) shelf life days

11 Food quality assurance Current philosophy : Decrease of focus on end product testing and verification of quality and regulatory control Development and application of structured quality assurance systems based on prevention by monitoring, controlling and recording critical parameters through product s entire life cycle.

12 Market needs Global consumer trends: Food quality Freshness Consumer confusion regarding shelf live and use by dates Multiple food safety scares Main factors contribute to loss of hygienic, nutritional and sensory quality of perishable products TIME TEMPERATURE

13 Chill Chain-Need for better management Food Industries Retailers Food authorities Consumers Weakest Link affecting safety and qualityof chilled products = actual chill chain A big percentage of foodborne disease is due to temperature abuse in the chill chain.

14 Questions?

15 Aim of IQ-Freshlabel??? Promote smart labels: Time Temperature Integrators (TTI) Oxygen sensor For chilled and frozen food products

16 Time Temperature Indicators (TTI)

17 Whatisa TTI? label that cumulatively indicates time-temperature history of the products

18 Characteristics (1) Self-adhesive labels easily integrated in the packaging process Simple, easy to handle and measure Long shelf-life before activation Storage: under normal conditions (room temperature) Low price per unit: under 3% of the product price

19 Characteristics (2) reproducible, consistent and flexible Irreversible activation Indicates cumulatively time-temperature history of the product from the point of manufacture to the consumer

20 Time Temperature Indicators (1) TTI displays a visualsummary of the time-temperature history of the product Several TTIs are under investigation for application to food products

21 Time Temperature Indicators (2) Types of TTIs Diffusion based Photochemical Microbial Enzymatic Polymer based

22 Time Temperature Indicators (3) Avery Dennison Vitsab Cryolog TempTime OnVu TM

23 OnVu TM TTI Technology (photochromic TTI)

24 OnVu TM TTI Technology organic crystals change color according to accumulated temperature history of the product hν Crystals form the basis of a pigment which is used to formulate the intelligent ink

25 The structure of an OnVu TM TTI Printing OnVu TM as simple labels using water-based flexo inks UV-Vis filter Active material Reference scale Self-adhesive label

26 The activation of an OnVu TM TTI (1) Activated TTI F1, F4 inactivated TTI labels Hand charger use Activated TTI Activated TTI B1 inactivated TTI labels Bizerba Desktop charger GLP80

27 The activation of an OnVu TM TTI (2) Industrial / High speed chargers Manual chargers

28 Vitsab TTI Technology (enzymatic TTI)

29 Vitsab TTI Technology colour change caused by a ph decrease as result of a controlled enzymatic hydrolysis of a lipid substrate determining factor = concentration of the substrate

30 The activation of a Vitsab TTI (1) The indicator starts with two liquid-filled bags heat sealed into plastic The contents are mixed by bursting the seal between the pouches by pressure After exposure to time and temperature, the contents turn from green to yellow to red

31 The activation of a Vitsab TTI (2) Enzyme and substrate at different pouches Mechanical breakage of the seal between the pouches Activated CTTIs Enzymatic CTTIs colourscale

32 Aluminium based TTI Technology coolvu

33 Aluminium TTIs Reactive layer (Adhesive + Etchant) Barrier layer Aluminum layer Color/visual signal underneath the aluminum TTIs with a barrier layer of varying thicknesses were delivered by and Herbert, Rossaint, Kreyenschmidt, 2012, unpublished data

34 Aluminium TTIs Dissolving process of the Al-TTI over time at 2 C First, the large field dissolved Secondly, the medium field dissolved Finally the small field dissolved Time [days] Herbert, Rossaint, Kreyenschmidt, 2012, unpublished data

35 Questions?

36 Applications of TTIs

37 Application - Use of TTIs TTIs can be used on any perishable food item that has a limited shelf life.

38 How can TTIs be adapted to specific food products? 1) By knowing very precisely which parameters determine the lifetime of the food product shelf life test 2) By knowing the response of TTIs under defined storage conditions (temperature, time) and various level of activation Different charging times for the photochromic TTIs Different enzymes concentration for the enzymatic TTIs Select the most suitable TTI as well as activation parameters

39 Shelf Life Tests

40 Is the shelf life of food related to food safety and quality? Shelf life testing describes how long a food will retain its quality during storage During the shelf life of a food it should: Remain safe to eat Keep its appearance, color, odor, texture and flavor Meet any nutritional property provided on the label

41 Who influences the shelf life? Growers/ Producers Other suppliers Manufacturers Distributors Retailers Consumer

42 Some fresh food products tested in the project PRODUCT TYPE OF PROCESSING COMPANY SHELF LIFE UNDER RECOMENDED TEMPERATURE (+4 C) Chicken breast filets Chicken legs with skin Fresh / MAP packaging (65%O2 30%CO2 & 5%N2) Fresh / MAP packaging (65%O2 30%CO2 & 5%N2) 8 days 8 days

43 Storage tests: Parameters studied - Chicken breasts fillets - Chicken legs with skin Microbiological analysis Total Aerobic Viable Count (TVC) 30 C Brochothrix Thermosphacta 25 C Pseudomonas spp. 25 C Enterobacteriaceae 37 C Lactobacillus spp. 37 C ph measurement Parameters under investigation Gas composition Sensory analysis Regular spoilage process Influence of a leakage on the spoilage process Sensory attributes on a 1 to5 descriptive hedonic scale (1 being the highest quality score and 5 the lowest)

44 Results Microbiological Analyses 9 8 TVC 4 C B. Thermosphacta 4 C Pseudomonas 4 C Enterobacteriaceae 4 C Lactobacillus 4 C log 10 (cfu/g) log 10 (cfu/g) TVC 20 C B. Thermosphacta 20 C Pseudomonas 20 C Enterobacteriaceae 20 C Lactobacillus 20 C Time (h) Time (h) Growth of typical spoilage microorganisms under different temperatures, fitted with the Gompertz model (MAP: 65%O2 / 30%CO2 / 5% N2, n=3)

45 Results: Quality Index 5,0 Quality index 4,5 Quality Index 4,0 3,5 3,0 2,5 2,0 1,5 1,0 0,5 QI (2 C) QI (4 C) QI (7 C) QI (20 C) Quality index 5,0 4,5 4,0 3,5 3,0 2,5 2,0 1,5 0, Shelf life (h) 2 C C C C 96 70%O2 Time (h) QI = 1,0 0,5 0,0 2 G + 2 C + T + 2 O + D 8 O2 N Time (h) Shelf life (h) 70%O %N C

46 Response of the TTIs

47 Instrumental measurement of TTI colour Measurement of visual response with CIE Lab X-rite Eye1pro Colorimeter, Illumination D50

48 Effect of the storage temperature on the response of the Photochromic TTI TTIs

49 TTIs Response time (days) of the B1 CTTI stored at 5, 0, -5, -9, -12 and 15 C

50 CTTIs Determination of predicted response times of Photochromic CTTI for different levels of activation (tc) from 5 to -18 C

51 Selection of appropriate TTI for monitoring Blueshark Shelf-life

52 Selection of appropriate Enzymatic CTTI for monitoring Blueshark Shelf-life based on sensory evaluation M-type Enzymatic TTI - Blueshark sensory evaluation Shelf Life (days) M-10U M-15U M-20U M-25U M-30U M-40U M-50U M-80U M-100U Blueshark T ( C)

53 Selection of appropriate Enzymatic CTTI for monitoring Blueshark Shelf-life based on sensory evaluation LP enzymatic TTI - blueshark sensory evaluation Shelf Life (days) LP-200U LP-400U LP-600U LP-800U LP-1000U LP-1200U LP-1400U LP-1500U LP-1600U LP-2000U blueshark sensory evaluation Temperature (C)

54 M-type Enzymatic TTI - Blueshark sensory evaluation LP enzymatic TTI - blueshark sensory evaluation Shelf Life (days) M-10U M-15U M-20U M-25U M-30U M-40U M-50U M-80U M-100U Expon. (Series10) Shelf Life (days) LP-200U LP-400U LP-600U LP-800U LP-1000U LP-1200U LP-1400U LP-1500U LP-1600U LP-2000U blueshark sensory evaluation T ( C) Temperature (C) M-type Enzymatic TTI - Blueshark sensory evaluation LP enzymatic TTI - blueshark sensory evaluation Selected CTTI: M-20U Selected CTTIs: LP1200U or LP1400U Shelf Life (days) M-20U Blueshark Shelf Life (days) LP-1200U LP-1400U blueshark sensory evaluation T ( C) Temperature (C)

55 Application of the Arrhenius-type models for shelf life prediction of frozen arrow squid Storage temperatur e ( C) t SL = k ln C ref, TVB N TVB N, l ln C E exp R a TVB N, o 1 1 T T ref Shelf life (d) based on TVBN (limit= 12mgN/100g) t SL E exp R 1 1 T T Shelf life (d) based on TBARs (limit=2 mgmda/kg) Shelf life (d) based on sensory scores (limit=5 score for overall acceptability) = k C ref, TBARS TBARS, l C TBARS, o a ref t SL = k ref, s so sl E a 1 1 exp R T T ref

56 Questions?

57 Impact on the meat qualityof a leakage in the packaging?

58 Results 5 O 2 /CO 2, intact O 2 /CO 2, leakage Quality Index N 2 /CO 2, intact N 2 /CO 2, leakage Shelf life (20d) leakage (20d) intact h 225 h time [h] Reduction in shelf life of 33% Herbert, Rossaint, Kreyenschmidt, 2012, unpublished data

59 Results Change of the gas atmosphere 70% N 2, 30% CO 2 Gascontent caused by leakage [%] O 2 Leakage top foil CO 2 Leakage top foil time [h] Herbert, Rossaint, Kreyenschmidt, 2012, unpublished data

60 Results Gas content caused by leakage [%] Modification of the experimental leakage test setup 70% N 2, 30% CO time [h] Herbert, Rossaint, Kreyenschmidt, 2012, unpublished data O 2 leakagetop foil CO 2 leakage top foil O 2 leakage sealing area CO 2 leakage sealing area The leakage were prepared in the sealing area using needles with diamters of 0.2mm

61 CONCLUSIONS Leakages inside the package have a significant effect on the development of the spoilage organisms of the sensory parameters Shelf life is reduced of 33% (with oxygen) due to a leakage (0.2mm) Changes in the gas atmosphere: - 70 % O 2 : O 2 decrease by 35% in 48 h % O 2: O 2 increases by 10% in 48 h Herbert, Rossaint, Kreyenschmidt, 2012, unpublished data

62 Questions?

63 Anothersmart label: Oxygen Sensor

64 Modified Atmosphere Packaging (MAP) The atmosphere within the food package contains an inert gas (N 2, CO 2 ), maintaining the oxygen content to % or <70%. Longer shelf-life / colour/ appearance of the product

65 O2 SENSORS WHY DO WE NEED O2 SENSORS? Provides information on gas composition over time. Close food quality prediction

66 Oxygen is needed in red meat packaging to preserve its colour (oxymioglobin) Why high?

67 Requirements Cost effective, irreversible and tunable Sensor for the producer to authentically monitor every MAP on line in a non destructive way. Targets: Detection of the momentary O 2 concentration. Tunable sensitivity from 0 to >25% oxygen. Eye and Machine readable. no Direct food contact. Low cost. O2 SENSORS

68 O2 SENSORS Optical sensing based on luminescence turn-on O O 2 Oxidation site Fluorophore

69 General reaction O 2 hν O2 and light necessary!

70 Under development A label showing a leakage in the packaging by showing the presence of O2 with a fluorescent response

71 Questions?

72 Smart Labels: Advantages & Disadvantages

73 Advantages Control of the cold chain control freshness during critical situations(transportation, )

74 Product improvement enhance current products and add value to end customers PRODUCT QUALITY Marketing tool promoted as added feature in product to ensure the quality of product Consumer confidence Advantages Product loyalty Brand value Market competitiveness Sales volume peopleforfashion.wordpress.com

75 Limitations Consumer confusion Expiration date TTI Color interpretation TTIs inability to record and store time and temperature history. Who pays the bill? : How consumers handle the products after purchase. Increase product costs (2-3 cents) Consumers might leave products in warm places in supermarkets causing product spoilage and waste. Consumer best product selection.

76 RESEARCHFOR MOREQUALITY OF LIFE THANK YOU FOR YOUR ATTENTION Marie Shrestha Team Leader Food Technology & Bioprocess Engineering ttz Bremerhaven Fischkai 1 D Bremerhaven fon: +49 (0) fax: +49 (0) mshrestha@ttz-bremerhaven.de