The Main achievements
The Development of active and smart functional bio-based packages addressing the demands of selected food market segment.
Different smart functionalities (sensors, barrier coatings, antimicrobial and antifungal solutions) have been implemented in biobased and compostable modified atmosphere film sealed trays for fish, ham and cheese packaging, to monitor food shelf life. Also paper/plastic laminated packaging have been scaled up implementing barrier coatings and sensors.
Scale up active and smart functionally technologies to prototype at pilot scale.
The manufacturing productivity of antimicrobial and antifungal lipopeptides increased by a factor of 40, reducing the price by a factor of 50. The actives have been linked to the biobased polylactic (PLA) films and introduced as a blotter into the packaging. Biodegradable oxygen and water barrier coatings were scaled up to protect PLA films. Smart sensors to detect oxygen and amine concentration have also been developed and applied at the inner side of the top film to control food self-life.
The Improvement of mechanical properties of the Polylactide (PLA) film were achieved using nanoclay composites using cast extrusion processes at pilot scale, increasing up to 25% the young’s modulus and the elongation to fracture by up to 36%. The barrier properties have been also improved in relation to PLA, reducing oxygen transmission rate (OTR) by up to 25% and the water vapour transmisión rate (WVTR) by up to 30%.
The paper packaging innovations
The biodegradable flexible film (PLA with nanoclays coated with biodegradable nanocomposite) has been laminated with cellulose, applying the sensors in transparent windows.
The recyclability and design for recycling
The recyclability of the paper/PLA laminate and paper/PE laminated has been compared, being more efficient for the cellulose paper/PLA laminated solution. The cellulose/PLA laminate reduces the environmental impact by 40% in comparison with the cellulose/polyethylene (PE) laminate.
The monitoring of food shelf life
The active and smart technologies were applied to food package demonstrators (fish, ham and cheese) including antimicrobial or antifungal actives linked to PLA films by plasma, barrier coatings and oxygen, carbon dioxide and/or amine sensors. Modified atmosphere has been used to elongate shelf life. Sensors have been applied allowing a 100% control of the protective gas composition and monitor packaging self-life.
The packaging sustainability
The overall environmental impact of the value chain, including the novel material selection was studied. The carbon footpring has been reduced by 19% due to the use of biobased plastics in comparison to fossil based plastics. The environmental footprint of the food waste is much higher than the bioplastic footprint.
Protocols development and contribution to standardization
The standard protocol to evaluate antimicrobial properties of the actives has been improved to better assess the antimicrobial properties during the different steps of the analysis. Also innovative protocols have been used to assess consumer preference, sensory and microbiological assessment during food self life degradation.
The packaging design application.
An application has been developed to calculate the barrier properties at the packaging design phase.
The communication and dissemination activities are described in the project website
https://biosmart-project.eu(se abrirá en una nueva ventana). The oxygen sensor 100% safe and sustainable food packaging process has been awarded the Solar Impulse Efficient Solution Label !. The PLA with nanoclays were patented before the Biosmart project. During the project, it was improved the mechanical and barrier properties, reaching also the Food Approval label.
