Harvested produce takes in oxygen,
and releases carbon dioxide, water, heat
and metabolites. The rate at which
these processes occur is known as the
respiration rate. Packaging plays a
unique role by matching the respiration
rate of the product with the gas transmission rates of the packaging material.
This is critical to achieve an appropriate
balance of gases in the package. As a
result, a wide variety of packaging
materials is used today, and the concept of “one film fits all” is clearly not
applicable in the refrigerated foods
industry.
Depending on the product, and on
the approach that is used to provide for
safety and shelf life, the packaging
phase may occur before or after the
thermal or non-thermal processing
steps. One, some or all of these packaging hurdle technologies can be employed to improve product quality and/or
safety. These packaging hurdles are:
• Modified atmosphere packaging (MAP)
in which product is packaged in an
atmosphere that is different from that
of air, which normally contains about
78% nitrogen, 21% oxygen and 1% percent of other components including
carbon dioxide. MAP helps to delay
the onset of product degradation, typically by reducing the amount of oxygen exposed to the product during its
shelf life. In high-moisture products,
such as cooked entrees and fresh-cut
produce, MAP may delay microbial
and sensory spoilage, reduce browning,
slow respiration rate and lower ethylene
production. In high-fat products, MAP
delays rancidity and preserves the
smell, taste, texture and appearance.
MAP also helps to delay staling in bakery products. Elevated carbon dioxide
above about 10% selectively inhibits
the growth of Gram-negative bacteria,
such as pseudomonads and other related psychrotrophs, which otherwise
grow rapidly and produce off-odors and
off-flavors. Elevated carbon dioxide is
not effective in preventing the growth
of most human pathogens such as
Listeria, E. coli or Salmonella. In addition, because resultant oxygen levels
can be extremely low, and product can
be held for an elongated period of
time, an atmosphere that is conducive to growth of anaerobic bacteria, such as
Clostridium botulinum, may evolve. Therefore, competing organisms and/or incorporation of other barriers and/or the testing of product via challenge studies will minimize such risks. Vacuum packaging and vacuum-skin packaging are other forms of
modified atmosphere packaging in which the overall quality and safety objectives
are the same. However, a different and potentially more aesthetically pleasing product may result.
• Packaging in a “high care” or “cleanroom” environment in which product should flow
in one direction from raw material receipt, to raw material preparation, to processing, to packaging and air pressure should be positive to the outside. Typically, this
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