antimicrobial containers for enhancing food safety and ... · food packaging/containers •food...
TRANSCRIPT
Antimicrobial Containers for Enhancing Food Safety and
Extending Food Shelflife Tony Jin
Eastern Regional Research Center
February 23, 2017
ARS-FSIS Food Safety Workshop
1
Outline
•What are antimicrobial containers and why we need them
•Demonstration of prototypes and case studies
•Applications
•Challenges and future work
2
Food Packaging/Containers
•Food container is part of food packaging
•Sizes: From storage room, truck to single packaged item
•Materials: paper, plastics, glass, metal, wood
•Use: • Liquid Food: Bottles, jars, pouches, drums, etc
• Solid Food: Bags, pouches, baskets, etc
Importance of Food Packaging
• Plays an increasingly important role in the whole food chain ‘from the field to the consumer’s table’
• Lies at the very heart of the modern food industry
4
Functions of Traditional Packaging • Containment
• From one place to another without pollution
• Protection • Water, moisture vapor, gases, odors, light, microorganisms, dust, etc. from
environment.
• Convenience • Size, shape, ready to serve easy opening, reclosable lids
• Communication • Distinctive branding and labeling
• “Silent salesman”
5
What is antimicrobial containers
Antimicrobial containers/packaging have • One or all functions of traditional containers
• Plus antimicrobial properties • reduce or inhibit microorganisms in contained foods
• Or provide “clean or contaminant-free” surface
6
Why do we need them?
7
Microbial contamination/cross-contamination come from anywhere before food consumption
Food Safety Challenges
• Microbial contamination usually starts from food surface
• When microorganisms attach to food, they may survive after pasteurization/sanitizing steps. Under suitable conditions, they may grow during storage, transportation and marketing before home consumption.
9
Final Defense Step • For fresh fruits and vegetables, juices and beverages, and other ready-to-
eat foods, there are not killing steps before food consumption.
• Regular packaging doesn’t have antimicrobial function.
• Antimicrobial packaging (sanitization in package) provides a final defense system to kill or inhibit pathogenic microorganisms in foods.
10
Type of Antimicrobial Containers
• Whole container made of antimicrobial materials
• Part of container made of antimicrobial materials
• Container with antimicrobial patches
11
Prototypes and Case Studies
• Antimicrobial bottles for liquid food
• Antimicrobial films (bag/pouch) for solid food (meat)
• Antimicrobial patch for produce and other solid food
• Container with antimicrobial surface
12
Prototypes and Case Studies (1)
• Antimicrobial bottles for liquid food
13
Second approach is using exist PLA bottles or glass bottle then coat antimicrobials on the bottle surface.
14
Coated Bottle and Jar Samples:
15
Inactivation of pathogens in bottled juices and beverages
0
2
4
6
8
10
0 1 3 7 10 14 17 21 24 28 35 42
Log
CFU
/ml
Days at 10C
L.monocytogenes in milk
No Coat
Coated
0
2
4
6
8
0 1 2 7 14 21 28 35
Log
CFU
/ml
Days at 10C
Salmonella in liquid egg white
No Coat
Coated
0
1
2
3
4
0 1 7 14 21
Log
CFU
/ml
Days at 10C
E.coli O157:H7 in strawberry puree
No Coat
Coated 0
2
4
6
8
0 8 24 48 72
Log
CFU
/ml
Hours at 22C
E. coli O157:H7 in orange juice
No Coat
Coated
16
Prototypes and Case Study (2)
• Antimicrobial films (bag/pouch) for solid food (meat)
17
Antimicrobial package for meat
Antimicrobial coated PLA pouch Pectin/nisin composite film
18
Antimicrobial composite films
0
1
2
3
4
5
6
Control Film Treatment
Log
CFU
/cm
2
Inactivation of L. monocytogenes on RTE meat by composite film
0
1
2
3
4
5
6
7
1 7 14 21 28 35
Log
CFU
/cm
2
Days at 10C
Inactivation of L. innocua on RTE meat by composite film
Control
Composite film
19
Antimicrobial pouch
0
1
2
3
4
5
6
7
8
1 2 7 14 21
Lof
CFU
/cm
2
Days at 10C
Inactivation of L.monocytogenes in RTE meat
by coated pouch
Control
Coated pouch
0
1
2
3
4
5
6
1 2 7 14 21
Log
CFU
/cm
2
Days at 10C
Inactivation of S.Typhimurium in RTE meat by coated pouch
Control
Coated pouch
20
Prototypes and Case Studies (3)
• Antimicrobial patch for produce and other solid food
21
Challenges for Produce
• Surface contact is required for antimicrobial film packaging (bag, pouch, etc.) and usually vacuum packaging is combined.
• There are some limit effectiveness for produce products with irregular shape, crack and crevice, causing no or less contact.
22
Approach: Gaseous Sanitizers
• Gaseous/volatile antimicrobials have rapid penetration capacity and penetrate/diffuse to any hole or pore in food, not limited to product shape or product type.
• Essential oils, alcohols, acids or other antimicrobial vapors in nature or after reaction can be used for gaseous contact.
23
Direct filled method
• Pre-made gaseous/volatile antimicrobials (sanitizers) • Controlled concentration
• Inconvenience for retail and home use
• More suitable for manufacturers and whole sale containers
24
Prototypes of gaseous antimicrobial release materials
• 3-1. Self released antimicrobial film
• 3.2. Self activated antimicrobial film
• 3.3.Read-to-be-activated antimicrobial film
25
Prototypes of gaseous antimicrobial release materials (1)
• 3-1. Self released antimicrobial film
26
Use – Place antimicrobial coat or film on container
27
Self release antimicrobial Film
PLA+AIT film
4
6
8
10
12
0 2 7 14 21
Log
CFU
/g
Days at 4C
Inactivation of E. coli on greens
Control
Film treatment
28
Self release film for deli meat
L is teria monoc ytog enes in T urkey Deli Meat
-1.4
-1.2
-1.0
-0.8
-0.6
-0.4
-0.2
0.0
Antimc obial film 1/4 Antimc obial film 1/8 Antimc obial film 1/16
Mic
rob
ial
Re
du
cti
on
(L
og
CF
U)
Mold & Yeast on Deli Turkey at room temperature for 2 weeks
0
1
2
3
4
5
6
7
8
Control Film 1/4 Film 1/8 Film 1/16
Mic
rob
ial
co
un
t (L
og
CF
U)
29
Self release film for fresh-cut cantaloupe
Mold and Yeast in Cantaloupe
0
1
2
3
4
5
6
Control Film 1/4
Mic
rob
ial
co
un
ts (
Lo
g C
FU
)
S almonella s pp on C antaloupe
-0.80
-0.70
-0.60
-0.50
-0.40
-0.30
-0.20
-0.10
0.00
Antimcobial film 1/4 Antimcobial film 1/8
Mic
rob
ial
Re
du
cti
on
(L
og
CF
U)
after 10 days at 10°C. A: Film1/4; B: Control.
30
Self release antimicrobial film for cake
Appearance changes of cake in boxes with antimicrobial films after 17 days at room temperature. A: Film1/4; B: Control; C: in cake box
31
Self release antimicrobial films
• Advantages: • Simple and easy to use
• Any type, size or shape of containers
• Any solid food
• Anywhere (home, store, warehouse, etc
• Low cost
• Disadvantages: • Loss of antimicrobial activity during manufacturing and storage
• Unpleasant odors from some gaseous antimicrobials
32
Prototypes of gaseous antimicrobial release materials (2)
• 3-2. Self activated antimicrobial film
33
Self activated antimicrobial film-moisture triggered
Sodium chlorite (NaClO2)
+
Acid
+
Moisture
Gas ClO2
In many countries, such as the USA, chlorine dioxide gas may not be transported at any concentration and is almost always produced at the application site using a chlorine dioxide generator
34
Moisture-triggered films for chlorine dioxide release
Polymer films were developed for encapsulation of two active agents
35
Moisture-triggered films for chlorine dioxide release (2)
36
37
Inactivation of Salmonella and E. coli O157:H7 on grape tomato
Microorganism Temperature Treatment Bacterial population
(log CFU/tomato)
Salmonella spp. 22oC Control 4.26±0.23
Film ND*
Salmonella spp. 10oC Control 5.17±0.35
Film ND
E. coli O157:H7 22 oC Control 3.61±0.01
Film ND
Ray, S., Jin, T., etc. 2012. Journal of Food Science 78 (2): M276 - M284.
*ND: not detectable (< 5 CFU/tomato) 38
Moisture-triggered films • Advantages:
• Simple and easy to use
• Any type, size or shape of containers
• Any solid food
• Anywhere (home, store, warehouse, etc)
• Low odor, colorless
• Disadvantages: • Sensitive to moisture and loss of antimicrobial activity during manufacturing and
storage
39
Self activated antimicrobial film – triggered by food
• New type of self activated antimicrobial film/patch developed: • Be stable during manufacturing stable and storage
• Activated only by food in container
40
Self activated antimicrobial film – triggered by food
0
2
4
6
24 48
Log
CFU
/pie
ce
Hours at 10C
Inactivation of Listeria on tomato stem scar
Control
Film treatment 0
2
4
6
24 48
Log
CFU
/pie
ce
Hours at 10C
Inactivation of E. coli on tomato stem scar
Control
Film treatment
Self activated antimicrobial film – triggered by food (2)
• Advantages: • Simple and easy to use
• Any type, size or shape of containers
• Anywhere (home, store, warehouse, etc)
• Low cost
• Stable for manufacturing and storage
• Disadvantages: • Antimicrobial efficiency depends on type of foods
• May be not suitable for certain foods
42
Prototypes of gaseous antimicrobial release materials (2)
• Read-to-be-activated antimicrobial film • Independent on foods
43
Read-to-be-activated antimicrobial film/pad/cartridge
44
Example 1: Use of read-to-be-activated antimicrobial pad
45
Example 2: Use of read-to-be-activated antimicrobial cartridge
Case study for grape tomato
0
2
4
6
24 48
Log
CFU
/pie
ce
Hours at 10C
Inactivation of Salmonella on tomato stem scar
Control
Film treatment 0
2
4
6
8
24 48
Log
CFU
/pie
ce
Hours at 10C
Inactivation of E. coli on tomato stem scar
Control
Film treatment
0
2
4
6
24 48
Log
CFU
/pie
ce
Hours at 10C
Inactivation of Listeria on tomato stem scar
Control
Film treatment 0
2
4
6
8
Bateria Y&M
Log
CFU
/pie
ce
(After 4 weeks at 10C)
Inactivation of native microflora on tomato stem scar
Control
Film treatment
47
4 Weeks at 10C
48
Case study for broccoli
0
1
2
3
4
5
6
7
8
24 48
Log
CFU
/g
Hours at 10C
Inactivation of E. coli in broccoli
Control
Film treatment
49
Read-to-be-activated antimicrobial film/pad/cartridge (2)
• Advantages: • Containers are reusable (just replace pad/cartridge)
• Stable for manufacturing and storage
• Simple and easy to use
• Any solid food
• Anywhere (home, store, warehouse, etc)
• Low cost
50
Prototypes developed in lab
• Antimicrobial bottles for liquid food
• Antimicrobial films (bag/pouch) for solid food (meat)
• Antimicrobial patch for all produce and other solid food
• Container with antimicrobial surface
51
• Antimicrobial coating for food container with antimicrobial surface to prevent cross contamination during food transportation.
52
Principle
• Coating includes metal doped nano Titanic Dioxide and polymer binders
• Activated by UV or Fluorescent (visible) light (in warehouse)
(Superoxide radical)
53
Survival of E. coli after light treatment and multiple washing
A A
B B
B B B B
0.00.51.01.52.02.53.03.54.0
Mic
ob
ial c
ells
(lo
g C
FU/m
l)
3 hours under regular fluorescent light
A A
B* B* B* B* B* B*
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
No-Coating Control CW0 CW1 CW2 CW3 CW4 CW5
Mic
rob
ial c
ells
(Lo
g C
FU/m
l)
15 hours under regular fluorescent light
Lamp illumination density was 11 μmol/s∙m2 *under limit (<10 CFU)
Liu, L and Jin, T. US Patent Pending, 14/287,672 54
Advantages
•No requirement of UV treatment
•Activation by daytime light or warehouse/store light (fluorescent light)
•Containers are reusable
•Coatings can be used for any food contact surface
•Antimicrobial activity not affected by multiple use and water washing
•Prevent cross-contamination during transportation
55
Prototypes developed in my lab
• Antimicrobial bottles for liquid food
• Antimicrobial patch for all produce and other solid food • Self released
• Self activated
• Read-to-activated
• Antimicrobial films (bag/pouch) for solid food (meat)
• Container with antimicrobial surface
• Edible and non-edible antimicrobial food surface
56
Edible and non-edible food surface coatings
57
Foods Evaluated
• Juice/beverage: • Fruit juice/puree • Liquid egg • Milk
• Produce:
• Apple • Banana • Cantaloupe • Orange • Tomato • Strawberry • Blueberry • Spinach • Lettuce • Broccoli
• Poultry and meat: • Shell egg • Read-to-eat deli meat • Roast beef
• Seafood • Raw and RTE Shrimp
•Dessert • Cake
•Dairy • Cheese
58
Summary and Conclusion
•Multiple prototypes developed for various food • Simple and easy to use
• For home, store, warehouse, manufacturers, etc.
•Antimicrobial packaging/container is an unique and effective approach to: • reduce foodborne pathogens
• Extend shelf life
• Reduce waste
• Maintain quality
59
Future Work
• Collaborate with industry partner
• Scale up lab prototypes to pilot scale and then to production/commercial scale
60
Challenges
61
Antimicrobial container/package is a complicated system
62
Many factors should be considered • antimicrobial agent characteristics,
• incorporation methods,
• permeation and evaporation,
• resistance of microorganisms,
• controlled release,
• release mechanisms,
• chemical nature of foods and antimicrobials,
• storage and distribution conditions, film/container casting process conditions,
• physical and mechanical properties of antimicrobial packaging materials, organoleptic characteristics
• toxicity of antimicrobials, and corresponding regulations.
63
What we need
• Dedication and hard work
• Knowledge • Sciences
• Engineering
• All level supports
• Team work and collaborations
64
Acknowledgements
• 108 CRIS 101 • Xuetong Fan
• Sudarsan Mukhopadhyay
• Anita Parameswaran
• Kim Sokorai
• Non 108 SYs • LinShu Liu
• Madhav Yadav
• Phoebe Qi
• John Nghiem
• Victor Wyatt
• Other 108 SYs • Brendan Niemira
• Joshua Gurtler
• Chris Sommers
• David Geveke
• Dike Ukuku
• Domestic and Int. collaborators • Rutgers Univ.
• Auburn Univ.
• Univ. of Delaware
• Univ. of Tennessee
• Zhejiang Acad. of Agri. Sci
• Guangton Acad. of Agri.Sc.
• Agritech
65
Final Notice
• Some materials presented are proprietary, Please keep them within you!
• For more details and collaborations, please contact me at [email protected]
66
