Inactivation of Neosartorya fischeri and Paecilomyces variotii on paperboard packaging material by hydrogen peroxide and heat

This study reports on the influence of heat and hydrogen peroxide combination on the inactivation kinetics of two heat resistant molds: Neosartorya fischeri and Paecilomyces variotii. Spores of different ages (1 and 4 months) of these molds were prepared and D-values (the time required at certain temperature/hydrogen peroxide combination to inactivate 90% of the mold ascospores) were determined using thermal death tubes. D-values found for P. variotii ranged from 1.2 to 25.1 s after exposure to different combinations of heat (40 or 60 degrees C) and hydrogen peroxide (35 or 40% w/w) while for N. fischeri they varied from 2.7 to 14.3 s after exposure to the same hydrogen peroxide concentrations and higher temperatures (60 or 70 degrees C). The influence of temperature and hydrogen peroxide concentration on the d-values varied with the genus of mold and their ages. A synergistic effect of heat and hydrogen peroxide in reducing D-values of Paecilomyces variotti and N. fischeri has been observed. In addition to strict control of temperature, time and hydrogen concentration, hygienic storage and handling of laminated paperboard material must be considered to reduce the probability of package's contamination. All these measures together will ensure package's sterility that is imperative for the effectiveness of aseptic processing and consequently to ensure the microbiological stability of processed foods during shelf-life. (C) 2011 Elsevier Ltd. All rights reserved.

Food Safety and Mineral Oil Contaminated Paperboard Packaging: an Analytical Challenge and a Migration Study

Food packaging protects food, but it can sometimes become a source of undesired contaminants. Paper based materials, despite being perceived as “natural” and safe, can contain volatile contaminants (especially if made from recycled paper) able to migrate to food, as mineral oil, phthalates and photoinitiators. Mineral oil is a petroleum product used as printing ink solvent for newspapers, magazines and packaging. From paperboard printing and from recycled fibers (if present), mineral oil migrates into food, even if dry, through the gas phase. Its toxicity is not fully evaluated, but a temporary Acceptable Daily Intake (ADI) of 0.6 mg kg-1 has been established for saturated mineral oil hydrocarbons (MOSH), while aromatic hydrocarbons (MOAH) are more toxic. Extraction and analysis of MOSH and MOAH is difficult due to the thousands of molecules present. Extraction methods for packaging and food have been optimized, then applied for a “shopping trolley survey” on over 100 Italian and Swiss market products. Instrumental analyses were performed with online LC-GC/FID. Average concentration of MOSH in paperboards was 626 mg kg-1. Many had the potential of contaminating foods exceeding temporary ADI tens of times. A long term migration study was then designed to better understand migration kinetics. Egg pasta and müesli were chosen as representative (high surface/weight ratio). They were stored at different temperatures (4, 20, 30, 40 and 60°C) and conditions (free, shelved or boxed packs) for 1 year. MOSH and MOAH kinetic curves show that migration is a fast process, mostly influenced by temperature: in egg pasta (food in direct contact with paperboard), half of MOSH is transferred to food in a week at 40°C and in 8 months at 20°C. The internal plastic bag present in müesli slowed down the startup of migration, creating a “lag time” in the curves.

Occurrence of molds on laminated paperboard for aseptic packaging, selection of the most hydrogen peroxide- and heat-resistant isolates and determination of their thermal death kinetics in sterile distilled water

This study aimed at enumerating molds (heat-labile and heat-resistant) on the surface of paperboard material to be filled with tomato pulps through an aseptic system and at determining the most heat-and hydrogen peroxide-resistant strains. A total of 118 samples of laminated paperboard before filling were collected, being 68 before and 50 after the hydrogen peroxide bath. Seven molds, including heat-resistant strains (Penicillium variotii and Talaromyces flavus) with counts ranging between 0.71 and 1.02 CFU/cm(2) were isolated. P. variotii was more resistant to hydrogen peroxide than T. flavus and was inactivated after heating at 85 degrees C/15 min. When exposed to 35 % hydrogen peroxide at 25 degrees C, T. flavus (F5E2) and N. fischeri (control) were less resistant than P. variotti (F1A1). P. citrinum (F7E2) was shown to be as resistant as P. variotti. The D values (the time to cause one logarithmic cycle reduction in a microbial population at a determined temperature) for spores of P. variotii (F1A1) and N. fischeri (control) with 4 months of age at 85 and 90 degrees C were 3.9 and 4.5 min, respectively. Although the contamination of packages was low, the presence of heat-and chemical-resistant molds may be of concern for package sterility and product stability during shelf-life. To our knowledge, this is the first report that focuses on the isolation of molds, including heat-resistant ones, contaminating paperboard packaging material and on estimating their resistance to the chemical and physical processes used for packaging sterilization.

The modular forming press for paperboard packages

In this master’s thesis the structural and functional features of a forming tool are developed to meet the needs of modern packaging production for paperboard packaging are studied. The goal of the study is to develop a new type of machine for the manufacture of the paperboard package by pressing. In the structure of the developed forming press the possibility to modify the packaging as well as the requirements of industrial production, food hygiene and other operational matters are accounted for. The press has been sized based on the main dimensions of a single food-grade paperboard tray. In the LUT Packaging Laboratory the forming press is designed suitable for on-line operation. In addition, suggestions for further development of packaging line and equipment have been made based on the information gathered during this thesis study.

Press forming of paperboard – advancement of converting tools and process control

Press forming is nowadays one of the most common industrial methods in use for producing deeper trays from paperboard. Demands for material properties like recyclability and sustainability have increased also in the packaging industry, but there are still limitations related to the formability of paperboard. A majority of recent studies have focused on material development, but the potential of the package manufacturing process can also be improved by the development of tooling and process control. In this study, advanced converting tools (die cutting tools and the press forming mould) are created for production scale paperboard tray manufacturing. Also monitoring methods that enable the production of paperboard trays with enhanced quality, and can be utilized in process control are developed. The principles for tray blank preparation, including creasing pattern and die cutting tool design are introduced. The mould heating arrangement and determination of mould clearance are investigated to improve the quality of the press formed trays. The effect of the spring back of the tray walls on the tray dimensions can be managed by adjusting the heat-related process parameters and estimating it at the mould design stage. This enables production speed optimization as the process parameters can be adjusted more freely. Real-time monitoring of pressing force by using multiple force sensors embedded in the mould structure can be utilized in the evaluation of material characteristics on a modified production machinery. Comprehensive process control can be achieved with a combination of measurement of the outer dimensions of the trays and pressing force monitoring. The control method enables detection of defects and tracking changes in the material properties. The optimized converting tools provide a basis for effective operation of the control system.

Markkinointiviestinnän välittämä imago business-to-business markkinoilla, mielikuvatavoitteena kestävä kehitys

Tässä pro gradu -tutkielmassa tarkasteltiin kansainvälisen metsäteollisuudessa toimivan yrityksen markkinointiviestintää ja sen välittämien imagoviestien siirtymistä business-to-business markkinoilla. Tutkittavat viestit liittyivät kartonkipakkausten kestävän kehityksen ja ympäristöystävällisyyden imagon rakentumiseen. Tutkimuksessa käytettiin kvalitatiivista tutkimusmenetelmää. Tutkimus pohjautui yrityksen teettämän aiemman asiakastutkimuksen aineistoon, jossa selvitettiin pakkauskartonkien mielikuvia kohderyhmässä. Lisäksi tutkittiin imagon viestintää markkinointiviestinnän näkökulmasta. Yrityksen online viestintää verrattiin asiakkaiden vastaavaan viestintään loppukäyttäjille ja selvitettiin siirtyivätkö kestävän kehityksen viestit loppukäyttäjille asti. Tuloksena saatiin osittain yhtenevä viestintä sekä yrityksen asiakkaiden että näiden loppukäyttäjille viestimien teemojen sisällöstä. Tutkimus osoitti, että tärkein viestinnällinen teema on pakkauksen kierrätettävyys. Toisena tärkeänä teemana ilmeni hiilijalanjäljen pienentämisestä viestivät seikat. Nousevana teemana voitiin havaita biohajoavia materiaaleja kohtaan osoitettu kiinnostus. Tutkimuksessa jaettiin vastaajat eri segmentteihin pakkauskartonkien käyttötarkoituksen mukaan ja verrattiin kestävän kehityksen tärkeyttä näiden segmenttien välillä. Segmenteittäin tarkasteltuna suuria eroja ei ollut havaittavissa.

Kartonkipakkauslinjaston anturointi

Tässä diplomityössä tutkitaan kartonkiastioiden valmistukseen tarkoitetun linjaston ohjausjärjestelmän anturoinnin tarpeita. Linjasto on suunniteltu Lappeenrannan teknillisen ylipiston pakkauslaboratorioon vastaamaan nykyaikaisen pakkaustuotannon tarpeita. Linjasto on suunniteltu modulaariseksi sekä mahdollisimman helposti muunneltavaksi. Työn tavoitteena on selvittää anturoinnin tarpeet moduulikohtaisesti sekä tehdä tarvittava mekaniikkasuunnittelu. Suunnittelussa otetaan huomioon elintarvikehygienia, turvallisuus, modulaarisuuden vaatimukset, tuotantomäärän tarpeet sekä muut toiminnan kannalta kriittiset tekijät. Tutkimuksen lopputuloksena saadaan valmistettavan prototyypin oikean toiminnan edellyttämät edulliset anturointiratkaisut oleellisimpien moduuleiden osalta. Lisäksi työssä esitetään jatkokehitysehdotuksia kun prototyyppi saadaan valmiiksi jolloin mittaustuloksia voidaan alkaa tutkimaan.

The Value System of Consumer Board Packaging

Olemassa olevien teollisuuden rakenteiden ja arvoketjujen muutos on usein onnistuneiden liiketoimintainnovaatioiden takana. Yritysten tulisikin olla tietoisia rakenteista, jotka määrittelevät arvon jakaantumista niiden arvoketjuissa. Tämän työn tavoitteena oli tutkia ja arvioida kartongin pakkausketjujen rakenteita kartongintuottajalta aina kauppiaalle asti. Työn kuluessa yritysketjujen arviointia varten oli kehitettävä uudenlainen analysointityökalu. Työssä käsitellyt kartonkipakkausketjut olivat nestekartonkipakkaaminen, elintarvikepakkaaminen, lääkepakkaaminen sekä graafisten kartonkien ketju. Jokaista edellä mainituista ketjuista arvioitiin käyttämällä kehitettyä analysointityökalua. Työn merkittävin tulos on kehitetty työkalu, jolla pakkausketjuja sekä myös muita yritysketjuja on mahdollista analysoida. Kehitettyä työkalua käyttämällä oli mahdollista tehdä johtopäätöksiä vertikaalin integraation mahdollisuudesta sekä pakkausketjujen suotuisuudesta uusille bisnesmalleille. Sekä analysointityökalua että saatuja johtopäätöksiä voidaan käyttää hyväksi, kun kartongintuottaja suunnittelee tulevaisuuden toimenpiteitä.

Hermetic sealing of food packaging trays

Suojakaasupakkaaminen on lisääntynyt voimakkaasti viime vuosina elintarvikkeiden pakkaamisessa sillä pakkaamalla elintarvike suojakaasuun voidaan sen hyllyikää pidentää ilman säilöntäaineita. Tällainen pakkaaminen vaatii kuitenkin täysin kaasutiiviin pakkauksen, jonka kaasunläpäisevyys on myös alhainen. Yleisimmin käytetyt pakkausmateriaalit suojakaasupakkaamisessa ovat monikerroksiset muovimateriaalit, joissa yhdistyy monen eri muovin parhaimmat ominaisuudet. Yleisimmin käytettyjä muovilaatuja näissä monikerrosrakenteissa ovat PE, PET, PA ja EVOH polymeerit. Myös muita perinteisiä polymeerejä käytetään jonkin verran näissä rakenteissa. Uudemmat muovilaadut, kuten biohajoavat muovit, eivät ole vielä yleistyneet kaupallisessa käytössä pääasiallisesti niiden korkean hinnan vuoksi. Muovisten pakkausten korvaamista esimerkiksi muovipäällystetyillä kartonkipakkauksilla on viime vuosien aikana tutkittu enenevissä määrin. Muovipakkausten korvaamista helpommin kierrätettävillä ja mahdollisesti biohajoavilla materiaaleilla edistävät EU:n direktiivit, jotka käsittelevät pakkausjätteen käsittelyä. Kartonkivuokien saumaamista kaasutiiviisti tutkittiin myös tässä työssä. Tavoitteena oli löytää pakkaus, joka soveltuisi kanasuikaleiden pakkaamiseen suojakaasuun. Kana on herkkä mikrobiologiselle hajoamiselle, minkä johdosta se tulee pakata suojakaasuun jossa happipitoisuuden tulee olla alle 1 % pakkauspäivästä viimeiseen käyttöpäivään saakka. Suorittamalla erilaisia tiiveystutkimuksia voitiin osoittaa, että kartonkivuoka on mahdollista saumata kaasutiiviisti luotettavalla tavalla. Tämä vaatii kuitenkin kartonkivuokien valmistuksen optimoimista päällystemuovikerroksen ja kartongin paksuuden mukaan sekä kannen saumaamista optimoiduilla saumausparametreilla. Tiivein vuoka saavutettiin muovifilmikannella, jonka saumaus perustui samaan muoviin kuin vuoan saumaus. Polyeteenillä saavutettiin tiivein ja kestävin saumaustulos.

Identifying Critical Business Success Factors of Paperboard Tray

Työn tavoitteena oli kartonkivuoan kriittisten menestystekijöiden ja kilpailuaseman selvittäminen jäähdytettyjen ruokatuotteiden markkinoilla Euroopassa. Kilpailija- ja tavoiteanalyysi suoritettiin kahden suomalaisen pakkaajan kesken. Pakkaajien haastattelut toteutettiin joko henkilökohtaisena tai sähköpostihaastatteluna. Muovi on yleisimmin käytetty jäähdytettyjen ruokatuotteiden pakkausmateriaali. Alumiinivuokien osuus on merkittävä erityisesti laatikkoruokien pakkauksena. Kartonkivuoille on kuitenkin havaittavissa selvää menestyspotentiaalia jäähdytettyjen ruokien pakkauksena. Kartonkivuokien hyvä imago ja edistyksellinen tuotekehitystyö mahdollistavat pakkaajien erityisvaatimuksien täyttämisen ja menestymisen markkinoilla. Kartonkivuoilla on useita ainutlaatuisia kilpailuetu- ja menestystekijöitä, kuten hyvä ulkonäkö ja painojälki. Suurin haaste on saada ruokatuotteiden pakkaajat tietoisiksi kartonkivuokien tuomista pakkausmahdollisuuksista.

Transmission properties of high barrier coated paperboard packages

High barrier materiaaleilla pyritään pidentämään pakattujen elintarvikkeiden hyllyikää. Barrierin tärkein tehtävä on elintarvikkeen suojaaminen hapelta ja kosteudelta. Alumiinin käyttöä barriermateriaalina pyritään vähentämään korvaamalla alumiini polymeereillä, jotka täyttävät elintarvikkeiden asettamat korkeat säilyvyysvaatimukset. Etyylivinyylialkoholin (EVOH) hapenläpäisevyys on kuivissa olosuhteissa alhaisin kaupallisista muovilaaduista. EVOH tarjoaa myös erinomaisen suojan muita kaasuja, rasvoja, hajuja ja aromeja vastaan ja sitä on helppo prosessoida. Polyamideilla on erinomainen kaasutiiveys sekä hyvä lujuus ja sitkeys. Eri muovilaatuja sekoittamalla voidaan vähentää hapenläpäisyä ja parantaa prosessointia. Polyolefiineja käytetään yleisesti päällystysmateriaaleina, koska ne suojaavat tuotetta erinomaisesti kosteudelta. Hapenläpäisyllä tarkoitetaan hapen kulkeutumista materiaalin läpi joko permeaation kautta tai reikien ja vuotojen läpi. Kaasun permeoitumiseen materiaalin läpi vaikuttavat materiaalin vapaa tilavuus, kiteisyysaste, orientaatio, substituointi, suhteellinen kosteus, lämpötila, barrierkerroksen paksuus, paine-ero ja permeoituvan molekyylin ominaisuudet. Kokeellisessa osassa analysoitiin ja vertailtiin kartonkipohjaisia mehutölkkejä, joissa käytettävät high barrier materiaalit olivat EVOH ja PA. Kartonkipohjaisia alumiinitölkkejä käytettiin referenssinä. Pakkausten hapenläpäisevyysmittauksissa saatiin samasta näytteestä toistettavia tuloksia, vaikka vuotomittauksissa saadut tulokset eivät olleet vertailukelpoisia hapenläpäisytulosten kanssa. Tölkkien valmistus vaikutti oleellisesti pakkausten tiiveysominaisuuksiin. Hapenläpäisy vuotojen ja reikien läpi oli merkittävämpää kuin hapenläpäisy materiaalin läpi. Pakkausten tiiveysominaisuuksia analysoitiin mittaamalla appelsiinimehun askorbiini-happopitoisuus. Askorbiinihapon hajoaminen mitattiin koetölkkeihin pakatusta appelsiinimehusta, ja lämpötilan, valon ja hapen vaikutusta askorbiinihapon hajoamiseen tutkittiin 12 viikon ajan. Lämpötilalla oli suurin vaikutus askorbiinihapon hajoamiseen huolimatta käytetystä pakkausmateriaalista.

Deinking flotation of recycled linerboard for food packaging applications

Brown packaging linerboard, made entirely from recovered pulp, was subjected to deinking flotation for evaluating the possible improvements in its chemical, optical and mechanical properties. The increase in the rate of recovered paper utilisation, along with the tendency towards lower basis weights, in the packaging paper production, has created a growing need for the utilisation of secondary fibers of improved quality. To attain better quality fibers, flotation deinking of brown grades is being considered, along with the addition of primary fibers to recovered paper furnish. Numerous conducted studies, in which the flotation technology was used in the treatment of brown grades, support this idea. Most of them show that the quality of fibers is improved after flotation deinking, resulting in higher mechanical properties of the deinked handsheets and in lower amounts of chemical contaminants. As to food and human health safety, packaging paper has to meet specific requirements, to be classified as suitable for its direct contact with foods. Recycled paper and board may contain many potential contaminants, which, especially in the case of direct food contact, may migrate from packaging materials into foodstuffs. In this work, the linerboard sample selected for deinking was made from recycled fibers not submitted previously to chemical deinking flotation. Therefore, the original sample contained many noncellulosic components, as well as the residues of printing inks. The studied linerboardsample was a type of packaging paper used for contact with food products that are usually peeled before use, e.g. fruits and vegetables. The decrease in the amount of chemical contaminants, after conducting deinking flotation, was evaluated, along with the changes in the mechanical and optical properties of the deinked handsheets. Food contact analysis was done on both the original paper samples and the filter pads and handsheets made before and after deinking flotation. Food contact analysis consisted of migration tests of brightening agents, colorants, PCPs, formaldehydes and metals. Microbiological tests were also performed to determine the possible transfer of antimicrobial constituents

Priorization of Customer Needs for Paperboard Trays

The objectives of the study were to introduce current issues of chilled and frozen food packaging, priorize certain customer needs and review brand owners’ opinions and ways of actions. Packaging industry and packaged food markets were reviewed. Interviews of food industry brand owners are used as data sources. Analytic hierarchy process was used to prioritize the customer needs. Food packaging, special features of ready meals, chilled and frozen food packaging, packaging industry and packaged food markets in Europe are approached using literature and market reviews and forecasts. In empirical part the customer needs of paperboard trays are prioritized. The most important features for brand owners are related in product safety and environmental issues. Paperboard trays have benefits compared to its competing packaging solutions. Paperboard is recyclable, from renewable source and it has good printability. Emerging issues of packaging technology are biodegradable package, elderly friendly features such as easiness of opening and re-closing possibility, brand protection and tamper evident solutions.

Drivers and Barriers of Collaboration in the Value Chain of Paperboard-Packed Consumer Goods

Value chain collaboration has been a prevailing topic for research, and there is a constantly growing interest in developing collaborative models for improved efficiency in logistics. One area of collaboration is demand information management, which enables improved visibility and decrease of inventories in the value chain. Outsourcing of non-core competencies has changed the nature of collaboration from intra-enterprise to cross-enterprise activity, and this together with increasing competition in the globalizing markets have created a need for methods and tools for collaborative work. The retailer part in the value chain of consumer packaged goods (CPG) has been studied relatively widely, proven models have been defined, and there exist several best practice collaboration cases. The information and communications technology has developed rapidly, offering efficient solutions and applications to exchange information between value chain partners. However, the majority of CPG industry still works with traditional business models and practices. This concerns especially companies operating in the upstream of the CPG value chain. Demand information for consumer packaged goods originates at retailers' counters, based on consumers' buying decisions. As this information does not get transferred along the value chain towards the upstream parties, each player needs to optimize their part, causing safety margins for inventories and speculation in purchasing decisions. The safety margins increase with each player, resulting in a phenomenon known as the bullwhip effect. The further the company is from the original demand information source, the more distorted the information is. This thesis concentrates on the upstream parts of the value chain of consumer packaged goods, and more precisely the packaging value chain. Packaging is becoming a part of the product with informative and interactive features, and therefore is not just a cost item needed to protect the product. The upstream part of the CPG value chain is distinctive, as the product changes after each involved party, and therefore the original demand information from the retailers cannot be utilized as such – even if it were transferred seamlessly. The objective of this thesis is to examine the main drivers for collaboration, and barriers causing the moderate adaptation level of collaborative models. Another objective is to define a collaborative demand information management model and test it in a pilot business situation in order to see if the barriers can be eliminated. The empirical part of this thesis contains three parts, all related to the research objective, but involving different target groups, viewpoints and research approaches. The study shows evidence that the main barriers for collaboration are very similar to the barriers in the lower part of the same value chain; lack of trust, lack of business case and lack of senior management commitment. Eliminating one of them – the lack of business case – is not enough to eliminate the two other barriers, as the operational model in this thesis shows. The uncertainty of the future, fear of losing an independent position in purchasing decision making and lack of commitment remain strong enough barriers to prevent the implementation of the proposed collaborative business model. The study proposes a new way of defining the value chain processes: it divides the contracting and planning process into two processes, one managing the commercial parts and the other managing the quantity and specification related issues. This model can reduce the resistance to collaboration, as the commercial part of the contracting process would remain the same as in the traditional model. The quantity/specification-related issues would be managed by the parties with the best capabilities and resources, as well as access to the original demand information. The parties in between would be involved in the planning process as well, as their impact for the next party upstream is significant. The study also highlights the future challenges for companies operating in the CPG value chain. The markets are becoming global, with toughening competition. Also, the technology development will most likely continue with a speed exceeding the adaptation capabilities of the industry. Value chains are also becoming increasingly dynamic, which means shorter and more agile business relationships, and at the same time the predictability of consumer demand is getting more difficult due to shorter product life cycles and trends. These changes will certainly have an effect on companies' operational models, but it is very difficult to estimate when and how the proven methods will gain wide enough adaptation to become standards.

Paperboard cup with a window

Packaging has to fulfill a lot of demands and the main purpose is to be able to protect the foodstuff packed inside. Typically requirements set on packaging materials reflect the consumer needs. Based on the consumer studies the importance of product visibility is considered as an important property among consumers. However, making the package more transparent the actual shelf life of the product might be reduced. It might have an effect on sensitive foods which contain ingredients vulnerable to light and start to deteriorate more rapidly. The aim for this Masters of Science Thesis was to develop a paperboard cup with a plastic window where different kind of fatty/dry foodstuffs could be stored. The main target was to be able to create an instruction manual how this kind of cup with a window had to be produced without decreasing air tightness and other barrier properties of cupboard material used as a base board. The focus in this work was on designing a shape of the window and finding critical limits for the size, shape and location of the window in the final paperboard cup. Windows were made by cutting holes with different sizes and shapes to different places in the cup blank by using a model cutter. For the windows one plastic film type was selected due to its low oxygen and water vapour transmission properties. The window film was attached to the cup blank by using hot bar and laser seaming methods. Cup manufacturing was done at Stora Enso InnoCentre, Imatra. As a result critical limits for the place, size and shape of the window could be found. The sealing method had a significant effect on the tightness of the cups. Windows didn’t decrease the grip stiffness of the cup. The cup itself gave better light protection than the plastic film used in the windows. The bigger the window, the less the cup could protect the possible foodstuff. Bursting strength was lower in the windows compared to the cup material itself. From environmental point of view DSD licence fees have to be paid due to the amount of used plastic.When using bigger windows the ratio of plastic to fibres increase. This would raise the DSD fee. However, the amount of material is overall reduced which lowers the fee.