Adapting ‘green’ packaging materials to your products

Governments and regulatory agencies are pushing a “green” agenda, adding to consumer advocate pressure for food packagers to use more environmentally friendly materials. The objectives are to reduce waste and energy used to produce packaging.

The European Union reported that in 2005, 16 countries produced more than 100 kg of packaging waste per person each year, with Ireland and France producing more than 200 kg per person per year. The U.S. EPA reported that in 2005, 20 million tons of plastic waste was produced and it has been estimated that 70 percent of all packaging is devoted to food. (The EPA has developed a pollution prevention hierarchy to direct the reduction of packaging waste.)

A manufacturer wanting to use recycled plastics for food contact applications must first submit critical information to the FDA, including a complete description of the recycling process, a description of the source of the recyclable plastic and description of any source controls in place to ensure that only plastic that initially complied with the applicable regulations is recycled. The use of non-recycled (virgin) material between the recycled material and the food is an option to meet regulations.

Recyclable packaging materials that can be used in meat packaging include polyethylene (PE), polypropylene (PP), polystyrene (PS) and polyvinyl dichloride. The most popular format of case-ready packaging consists of a clear or colored barrier-lined tray made of PS or PP and PE that is paired with a clear or printed barrier film. The film is composed of multiple layers to meet the functional requirements of the film, therefore, using recycled polymers in the non-food-contact layer for meat packages has a great potential.

The use of recycled PE and PP in meat, poultry and seafood packaging was approved in 1992 by the FDA for certain refrigerated packages and for PS for various meat trays in 1993, 1998 and 2000.

Source: Weber, Claus J, “Biobased Packaging Materials for the Food Industry: Status and Perspectives.”, Food Biopack Project, EU Directorate 12, November 2000.

The use of bio-based or renewable materials is also a good way to minimize waste, reduce the environmental impact of packaging and address rising petroleum prices. Bio-based packaging can be derived from carbohydrate, protein and lipid sources. Some of the most advanced bio-based materials for meat packaging are derived from carbohydrate sources such as polylactic acid, cellulose and starch.

Some commercial “green” packaging materials include:

• poly(hydroxyalkanoates) (PHA)—biodegrades in many environments (for example, marine, soil, etc.); however, at this time the production of PHA uses more fossil fuel energy than traditional plastics.
• polylactic acid (PLA)­Uses less fossil fuel energy than traditional plastics and completely composts within 45 days.
• thermoplastic starch (TPS)—Most common worldwide.
• Protein-starch mixtures—Offers functionality options.

Use of recycled materials and bio-based polymers are two ways to move toward a more environmentally friendly packaging platform. Two additional approaches are to reduce packaging needed with the use of thinner, less dense packaging and a total environmental impact analysis (known as life cycle analysis) that considers all aspects, including the energy used to produce the material.

By Paul Dawson, Food Science and Human Nutrition Department, Clemson University