13.1 Introduction
Package integrity is an essential requirement for maintaining the high quality of,
for example, sterilised foods and modified atmosphere packaged foods. The
increasing focus on quality assurance is putting demands on verification of food
package integrity. The foremost noticeable package integrity problem is
probably leaking seals, particularly with flexible plastic packages which are
more prone to mechanical damage than traditional rigid metal packages. A non-
destructive leak test device allowing evaluation of every container produced is,
therefore, of interest to food manufacturers.
Non-destructive package leak testing equipment detects defective packages
immediately in the packaging line. This can be considered as an integral part of
packaging process control. The most effective way to detect a package leakage,
non-destructively, throughout the whole distribution chain from the manufacturer
to the consumer is a leak indicator permanently attached to the package. One key
element in selecting a proper leak test device and leak indicator is knowledge of
the leakages, which are critical to the product shelf-life.
This chapter reviews the integrity requirements of flexible food packages,
non-destructive package leak test methods, and intelligent leak indicators for
modified atmosphere packages.
13.2 Leakage, product safety and quality
Before the selection of leak-testing methods for different packages can be made,
it is essential to have information concerning the required integrity of different
13
Detecting leaks in modified atmosphere
packaging
E. Hurme, VTT Biotechnology, Finland
package types and products. That is, how big a leakage can there be without the
packed product deteriorating microbiologically or chemically before the use-by
date, and how small a leakage should the leak testing method detect (Table
13.1).
In many studies leakages of around 10 m in diameter have been
demonstrated, under strict conditions, to cause microbial contamination in
model packages
1,2
and in commercially processed and packaged aseptic
packages.
3,4,5
The critical leakage size causing accelerated quality
deterioration in gas-flushed modified atmosphere packages (MAP) may,
however, vary considerably between different products and packaging
methods. Small leakages (hole diameter < 169 m, hole length 3mm) in gas
packages have even been reported to retain the quality of packed minced meat
steaks better than in intact packages.
6
Other recent studies have, on the other
hand, revealed accelerated quality deterioration of raw marinated chicken
breast and raw rainbow trout
7
and pizza
8
in gas packages with leakages as
small as 30 m and 55 m (hole length 3mm), respectively. Table 13.1
summarises the most important deterioration factors of different packaged
foods and studies concerning critical leakages.
13.3 Package leak detection during processing
13.3.1 Methods in use
Food package and seal integrity is widely verified using destructive manual
methods, such as a biotest, electrolytic test, dye penetration test and bubble test.
The major drawbacks of destructive test methods are that it is not possible to
check every package produced, and the tests are often laborious. An automated,
reliable, 100% in-line non-destructive leak test machine allowing testing of
every container produced would, therefore, be of interest to companies. This
kind of package testing would serve as an immediate process control tool,
resulting in an overall cost reduction in terms of a reduced number of packages
Table 13.1 Deterioration factors related to critical channel leakages in different
packaged foods
Aseptic and Ready-to-eat- Baked goods Dried goods
sterilised meals
foods
Most important microbial microbial oxidation, oxidation,
deteriorative changes, changes, mould moisture
factors oxidation oxidation growth, changes
moisture
changes
Critical leakage 5–25 m
1,3,5,9–12
30-50 m
6,12–13
50 m
13
> 130 m
13
diameter in
package
Detecting leaks in modified atmosphere packaging 277
lost both in production and in destructive testing. Also, complaints and returns
from retailers and consumers relating to leaky packages and deteriorated
products would be diminished.
Much interest has concentrated on plastic food packages to define their
integrity requirements,
1,2,4,8,14,15
to research and develop new non-destructive
test methods,
16-19
and to evaluate the reliability of commercial non-destructive
test methods.
15,20
In-line non-destructive test equipment should meet demands
such as: reliable identification and rejection of all the defective packages
produced; fast leak detection; non-damaging to the product; easy to use and
maintain; and reasonable supply and operating costs.
Most non-destructive leak inspection systems for flexible and semi-rigid
packages are based on a stimulus response technique: the stimulus to the
package can be, for example, ultrasound,
18
pressure,
22
tracer gas like
helium,
23
carbon dioxide
16
or hydrogen
21
and the response can be, for
example, sound/beam reflection, package movement, pressure change, or
tracer gas detection (Table 13.2). In recent years, numerous new patents
suitable for non-destructive food or medical package integrity testing have
been published.
Although tracer gas detection is a very sensitive method, detection of
pressure differential is perhaps currently the most popular method employed for
flexible and semi-rigid packages with a headspace. Commercial pressure
differential methods are typically based either (i) on detection of an external rise
or fall in pressure in a test chamber created outside the package with compressed
air or a vacuum pump, respectively, or (ii) on detection of an internal fall in
pressure created inside the package either mechanically or by heat. Evaluation
studies of commercial automated non-destructive leak detectors based on
detection pressure differentials revealed that these test methods – although much
used in industry – were not capable of reliably detecting leakages that were
proven to be penetrable by harmful microbes.
20,22,23
Table 13.2 Commercial methods for non-destructive food package leakage detection
Test stimulus Test response Application
External pressure Package movement* Packages with headspace
Pressure decay*
External vacuum Package movement* Packages with headspace
Pressure decay*
Tracer gas (H
2,
CO
2
, He, SF
6
)
Internal pressure Squeezer movement* Packages with headspace
Package movement*
Internal vacuum Package movement* All packages
Machine vision Image change* Foil packages
* On-line application available.
278 Novel food packaging techniques
13.3.2 Novel tracer gas system for in-line application
Tracer gas leak detection methods are very sensitive, and the most commonly
used gas has been helium. Another possibility is to use the more economical
carbon dioxide as a tracer gas. Carbon dioxide is often routinely used as a
protective packaging gas in food packages, which eliminates the need for the
special addition of tracer gas in the package. However, introduction of automatic
in-line leak detectors based on helium or carbon dioxide tracer gases has not
been successful. The reasons for this have possibly been the relatively high
operating and supply costs of the helium method, or the unfavourable physical
characteristics of the carbon dioxide method.
A novel leak-detection system has recently developed at VTT using hydrogen
(H
2
) as a tracer gas.
21,24
The leak tester utilising H
2
and a very sensitive
hydrogen detector is very effective and fast and is especially suitable for MAP.
For example, at least 30 m diameter holes in a gas-flushed package have been
demonstrated to be reliably detected within one second.
21
Using this method, a
package containing H
2
tracer gas is positioned in a specially designed test
chamber. A vacuum pressure is then drawn into the test chamber and the
package expands due to the increased pressure differential between the package
walls. Trace amounts of H
2
are then forced out of leaking packages through a
pipe in which a H
2
sensor is positioned towards the gas flow. The sensor
connected to the H
2
detector reacts to the H
2
, and immediately gives an
electrical signal to the H
2
detector.
H
2
has many characteristics advantageous to its use as a tracer gas in leak
detection. First of all, it is a colourless, odourless, tasteless and non-toxic gas
at atmospheric temperatures and pressures. A non-flammable concentration
(<5% in air) of hydrogen is sufficient for sensitive leak detection.
Nevertheless, the tracer gas concentration in the package headspace is
proportional to the leak detection sensitivity and speed; even concentrations as
low as 0.5% can be used to detect relatively small leakages. The low
background concentration of H
2
in air, only 0.5ppm, enables sensitive leak
detection. That is, the minimum detection limit of H
2
escaping from a
defective package is very low. In comparison, the carbon dioxide and helium
concentrations in air are 300 and 5 ppm, respectively. Hydrogen is also the
lightest of all gases (molecular weight: H
2
2.0, He 4.0, CO
2
44.0, air 29.0g/
mol) thus reducing the risk of background gas contamination in the leak test
area. For example, carbon dioxide as a heavier gas than air may accumulate in
the leak test area creating a risk of false readings.
13.4 Package leak indicators during distribution
The modified atmosphere package for non-respiring food typically has a low (0–
2%) oxygen (O
2
) concentration and a high (20–80%) carbon dioxide (CO
2
)
concentration. Hence, a leak means a considerable increase in O
2
concentration
and a decrease in CO
2
concentration. If the package leaks, microbial growth is
Detecting leaks in modified atmosphere packaging 279
likely to take place. This means that CO
2
may in some cases accumulate in
package. In the worst case, the CO
2
concentration will remain high despite
leakage and microbial growth. Thus, the leak indicators for modified atmosphere
packages should rely on the detection of oxygen rather than on the detection of
CO
2
.
13.4.1 Visual oxygen indicators
At present, the main application of commercially available O
2
-sensitive package
indicators is to ensure the proper functioning of oxygen absorption; companies
that also deal with O
2
absorbers have developed the indicators. For example,
Mitsubishi Gas Chemical Company in Japan has greatly contributed to the
development of O
2
absorbers and was the first to commercialise O
2
-absorbing
sachets under the trade name ‘Ageless’.
25
The ‘Ageless-Eye’ sachets containing
an O
2
indicator tablet have been designed to confirm that the ‘Ageless’
absorbers are functioning properly. The manufacturer claims that indicator tablet
turns from blue into pink within 2–3 hours after O
2
has reached a zero
concentration at 25oC and into blue again in about five minutes when it is in
contact with O
2
. Also some other Japanese companies like Toppan Printing have
been active in developing oxygen indicators.
A typical visual O
2
indicator consists of a redox dye, i.e., a reducing
compound and an alkaline compound. In addition to these main components,
compounds such as a solvent (typically water and/or alcohol) and bulking agent
(e.g. zeolite, silica gel, cellulose materials, polymers) are added to the indicator.
The indicator can be formulated as a tablet
26–27
or a printed layer
28–30
or it can
be laminated in a polymer film.
31
The redox dyes of the indicators are oxidised
by O
2
and a colour change can be observed. The most common dye used in the
indicators is methylene blue, which is typically white in the reduced state and
blue in the oxidised state. Other redox dyes used in O
2
indicators are 2,6-
dichloroindophenol
32
and N,N,N
0
,N
0
-tetramethyl-p-phenylenediamine.
33
A
reducing compound is added to the O
2
indicator to reduce the dye and to keep
it in the reduced state during the packaging process. Common reducing
compounds for O
2
indicators are reducing sugars, but inorganic salts as well as
reduction by irradiation have also been used. An alkaline compound is added to
the indicator to maintain the pH on the alkaline side and thus prevent too rapid
an oxidation reaction of the dye.
34–35
Inorganic compounds, such as sodium
hydroxide, potassium hydroxide, calcium hydroxide and magnesium hydroxide,
have typically been used for this purpose.
27,30
A different approach to constructing a visual O
2
indicator was introduced by
Krumhar & Karel
29
who developed a two-step colour reaction. In the first
reaction step O
2-
sensitive material is oxidised and the formation of an acid or
peroxide occurs. These components will cause a colour change in the specific
colorant included in the system. Oxidative enzyme-based oxygen indicators
have been described by Ahvenainen et al.
36
and Gardiol et al.
37–38
280 Novel food packaging techniques
13.4.2 Invisible oxygen indicators
In addition to the purely visual O
2
indicators, some other systems can also be
considered as indicators even if external equipment is needed. These systems
possess, however, an internal indicator attached to the package and can be
interpreted non-destructively. The concept of luminescent dyes quenched by O
2
as indicators for food packages was preliminarily introduced by Reininger et
al.
39
This optical method can be used for quantitative measurement of O
2
concentration in a non-destructive manner. Maurer
40
suggests a system using the
conversion of O
2
to ozone with the aid of UV radiation or an electric field. The
presence of ozone is shown with a potassium iodide/starch indicator strip.
A more recent approach is an optical oxygen-sensing method developed at
TNO. The measurement principle is based on the fluorescence quenching of a
metal-organic fluorescent dye, which is immobilised in a hydrofobic polymer.
The dye is excited by an excitation pulse, after which the dye emits fluorescent
light proportional to O
2
concentration. The dye is claimed to be very sensitive to
O
2
and the measurement can take less than one second.
41
The system can be
used for measuring O
2
in gas and dissolved in water. In principle, this method
could be used also for in-line application. However, these measurements need
time after packaging to allow oxygen to enter into the package through a
leakage.
42
13.4.3 The applicability and restrictions of oxygen indicators
In MAPs the high sensitivity of oxygen indicators is not advantageous as the
sensitive indicator might also react with the residual O
2,
which is often
entrapped in the modified-atmosphere package during the packaging procedure
(typically <1.0%). Extreme sensitivity also complicates handling of the indicator
and anaerobic conditions are required during the preparation of the indicator and
the packaging procedure. As the O
2
concentration required for the colour change
of most indicators is around 0.1% they cannot be applied to the leak indication
of MAPs as such. It has been claimed that the colour change of O
2
indicators
used in MAPs containing acidic CO
2
gas is not definite enough.
34,43–44
Many of
the patented O
2
indicators are reversible in their colour change and change
colour according to the prevailing O
2
concentration
27,45
However, the rever-
sibility is undesirable if the indicator is used for leakage control since the O
2
entering the package through the leak will be consumed during the microbial
growth that is likely to follow the loss of the package integrity. In the worst case,
the indicator colour will be the same as for intact packages, even if the product
has been spoiled.
A visual O
2
indicator designed specifically for leak detection of MAPs has
been developed at VTT.
34
This indicator, which is based on an oxygen-sensitive
dye, is suitable for the quality control of modified-atmosphere-packed
products
13
and it contains, in addition to the oxygen-sensitive component, an
oxygen-absorbing component, and can hence prolong the product’s shelf-life.
This leak indicator does not react with the residual O
2
entrapped in the
Detecting leaks in modified atmosphere packaging 281
modified-atmosphere package because the O
2
-absorbing component with
adjusted capacity for the residual O
2
is included in the indicator and, moreover,
the indicator is included in a film composition which protects against oxidation
of the indicator during packaging.
13.4.4 Carbon dioxide indicators
CO
2
is widely used as a protective gas in modified-atmosphere packaging.
During the first 12 days after the packaging procedure CO
2
is dissolved into the
product and its concentration in the head-space is decreased, the final
concentration being even as low as half of the original. After this period (1–2
days) a considerable decrease in CO
2
concentration is an evident sign of leakage
in a package. However, CO
2
is also produced in microbial metabolism and its
accumulation in a package headspace can be considered to be a sign of microbial
growth. A leak in a package (decrease in the CO
2
) is often followed by microbial
growth (increase in the CO
2
) and, in the worst case, the CO
2
will remain
constant even in the case of leakage and microbial spoilage. For these two
reasons, CO
2
indicators as leak indicators appear not to be as reliable as O
2
indicators.
In their patent Balderson & Whitwood
44–46
describe a reversible CO
2
indicator
suitable for modified atmosphere packages. The indicator consists of, for example,
five indicator strips. The strips contain CO
2
-sensitive indicator material consisting,
for example, of an indicator anion and a lipophilic organic quaternary cation.
47
The
colour change of each strip has been designed to take place when the CO
2
concentration is below a certain limit (e.g. 25%, 20%, 15%, 10% or 5%). The
concentration of CO
2
is indicated by a change of colour in one or more of the
strips. Sealed Air Ltd has produced a visible CO
2
indicator for MAPs.
13.4.5 Safety aspects
A self-evident requirement for internal indicators placed in the package
headspace is their absolute safety. The legislative aspects are discussed in
Chapters 19 and 22.
13.5 Future trends
Package integrity is an essential requirement for maintaining the high quality of,
e.g., sterilised and modified atmosphere packaged foods. The increasing focus
on quality assurance is putting demands on verification of food package and seal
integrity. On the other hand, much effort is and will also be put into the
development of new materials and packaging systems with minimised risk of
package failures.
Non-destructive package leak detection systems installed in-line are not yet
very widely used, mainly because of high costs and lack of reliability/sensitivity
282 Novel food packaging techniques
to find all defective packages. New reliable and cost-effective systems are
needed. One candidate for this could be the use of hydrogen as a tracer gas.
Another possibility could be oxygen indicator labels or dyes printed onto
packaging material and read automatically at a distance.
Today, application of intelligent package leak-indicating systems in Europe
has been limited to some time-temperature indicators. However, some food
producers are increasingly seeking extra merchandising and safety features.
Intelligent leak indicators marketed, e.g., as ‘premium quality labels’ can be
seen to give added value to the product/brand image. The visible indicators are
ideal in many cases, however, in the future it can be expected that an intelligent
package can contain more complex invisible messages that can be read at a
distance. A label could be introduced as a chip but advances in ink technology
might enable the use of printed circuits as well. The security tags and radio
frequency identity/tracebility tags are the first examples of electronic labelling.
Another approach for the future is the development of different optically read
systems.
Development of these ‘next generation’ intelligent labels/printing systems is
very challenging, e.g., in terms of cost demands, effectiveness and logistics.
Standardisation will undoubtedly be one of the key issues when new systems are
pushed onto the market. The basic requirement for success in making intelligent
systems work in real life is collaboration between research institutes, authorities,
and companies from product manufacturers and raw material supplier to retailer.
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286 Novel food packaging techniques