COMPETENCY-BASED LEARNING MATERIAL
PROCESSED FOOD AND BEVERAGE SECTOR
FOOD PROCESSING NC Level III
Module 4
Preparing the Packaging Materials
LEARNER’S GUIDE
Unit of Competency:
PROCESS FOOD BY SUGAR CONCENTRATION
HOW TO USE THIS COMPETENCY-BASED LEARNING MATERIAL
Welcome to the module in Preparing the Packaging Materials. This module
contains training materials and activities for you to complete.
The unit of competency “Process Food by Sugar Concentration” contains
knowledge, skills and attitudes required for Food Processing. It is one of the
specialized modules at National Certificate level (NC III).
You are required to go through a series of learning activities in order to complete
each learning outcome of the module. In each learning outcome are Information
Sheets and Resource Sheets (Reference Materials for further reading to help you
better understand the required activities). Follow these activities on your own and
answer the self-check at the end of each learning outcome. You may remove a blank
answer sheet at the end of each module (or get one from your facilitator/trainer) to write
your answers for each self-check. If you have questions, don’t hesitate to ask your
facilitator for assistance.
Recognition of Prior Learning
You may have some or most of the knowledge and skills (RPL) covered in this
learner’s guide because you have:
been working for some time
already completed training in this area.
If you have demonstrated to your trainer that you are competent in a particular skill,
you don’t have to do the same training again.
If you feel you have some of the skills, talk to your trainer about having them
formally recognized. If you have qualification or Certificate of Competence from
previous training, show it to your trainer. If the skills you acquired are still relevant to
the module, they may become part of the evidence you can present for RPL.
This module was prepared to help you achieve the required competency in
processing food by sugar concentration. This will be the source of information for you to
acquire knowledge and skills in this particular trade, with minimum supervision or help
from your instructor. With the aid of this material you will acquire the competency
independently and at your own pace.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 1
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Talk to your trainer and agree on how you will both organize the Training of this
unit. Read through the learning guide carefully. It is divided into sections, which
cover all the skills, and knowledge you need to successfully complete in this
module.
Work through all the information and complete the activities in each section.
Read information sheets and complete the self-check. Suggested references are
included to supplement the materials provided in this module.
Most probably your trainer will also be your supervisor or manager. He/she is
there to support you and show you the correct way to do things. Ask for help.
Your trainer will tell you about the important things you need to consider when
you are completing activities and it is important that you listen and take notes.
You will be given plenty of opportunity to ask questions and practice on the job.
Make sure you practice your new skills during regular work shifts. This way you
will improve both your speed and memory and also your confidence.
Talk to more experienced workmates and ask for their guidance.
Use the self-check questions at the end of each section to test your own
progress.
When you are ready, ask your trainer to watch you perform the activities outline
in the learning guide.
As you work through the activities, ask for written feedback on your progress.
Your trainer keeps feedback/pre-assessment reports for this reason. When you
have successfully completed each element, ask your trainer to mark on the
reports that you are ready for assessment.
When you have completed this module (or several modules), and feel confident
that you have had sufficient practice, your trainer will arrange an appointment
with registered assessor to assess you. The results of your assessment will be
recorded in your competency Achievement Record.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 2
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SECTOR : AGRI-FISHERY
FOOD PROCESSING NC III
QUALIFICATION : Process Food by Sugar Concentration
Preparing the Packaging Materials
UNIT OF COMPETENCY :
MODULE :
INTRODUCTION:
The packaging of the product should be designed to make the products more
attractive to consumers. Good packaging enhances the products selling point.
A good packaging material should be able to protect the products against
conditions that adversely affect the quality of the foods. In choosing appropriate
packaging materials great considerations for cost, size, shape and ease of use should
be taken into account.
This module covers preparing the packaging materials.
After completing this module, you will be assessed through written tests,
demonstration of process foods by sugar concentration.
LEARNING OUTCOMES
At the end of this module, you will be able to:
1. Identify and prepare glass bottle and jar of varying sizes intended for each
commodity.
2. Wash, sterilize and cool bottle glass and jar in inverted position.
3. Wash, sterilize and cool new caps (PVC and plastic).
ASSESSMENT CRITERIA:
1. Glass bottle and jar of varying sizes are prepared intended for each commodity.
2. Packaging materials are checked and readied according to enterprise
requirements.
3. Glass bottle and jar are washed, sterilized and cooled in inverted position.
4. New caps (PVC and plastic) are washed, sterilized and cooled.
PRE-REQUISITE:
The trainee taking this module should be able to complete the common and specialized
competencies specified in National Certificate (NC) Level II of a Food Processing
Technician.
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QUALIFICATION : Food Processing NC III
UNIT OF COMPETENCY : Process Food by Sugar Concentration
MODULE : Preparing the Packaging Materials
LEARNING OUTCOME #1: Identify and prepare glass bottle and jar of varying
sizes intended for each commodity.
ASSESSMENT CRITERIA:
1. Glass bottle and jar of varying sizes are prepared intended for each
commodity.
2. Packaging materials are checked and readied according to enterprise
requirements.
RESOURCES: Tools and Instruments Supplies and Materials
Stainless enameled Glass bottle
Equipment and Facilities Plastic casserole Jar
None
REFERENCES:
1. Carpio, E. V. 2000. Engineering for Food Technologist. University of the
Philippines:
2. De Leon, S.Y. and Guzman M.P. 1998. Preservation of Philippine Foods, A
Manual of Principles and Procedures.
3. Gonzales, Olympia N., et.al. 1982. Philippine Handbook on Canned Low Acid
Foods. A project of NSDB-NIST and No. 7801. National Institute of Science and
Technology Authority.
4. Hayter, R. 2000. Food Preparation and Cooking. Singapore: Thompson Learning.
5. Introduction to Agricultural Products and Processing. 1990. Oklahoma:
Department. Of Vocational and Technical Education Curriculum and Materials
Center.
6. Institute of Science and Technology, national Science and Technology Authority.
7. Larousse, J. and Bruce E. Brown. 1997. Food Canning Technology.
8. McSwane, D. N. Rue and R. Linton. 2002. Essentials of Food Safety and
Sanitation. 3rd ed. Singapore: Pearson Education South Asia Pte Ltd.
9. Packaging and Labeling for Processed Foods. 1999. Philippine Trade and
Training Center, Philippines:
10. Philippine Trade and Training Center. 2003. Philippines : Current Good
Manufacturing Practices for the Food Industry/ Establishment.
11. ServSafe Serving Safe Food Course Book. 1999. Food Safety Institute
Foundation, Inc
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 4
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Learning Experiences
Learning Outcome #1: Identify and prepare glass bottle and jar of varying sizes
intended for each commodities.
LEARNING ACTIVITIES SPECIAL INSTRUCTIONS
1. Read Information Sheet # 1-1 or View Information Sheet # 1-1 or CD:
CD: Power Point Presentation: PowerPoint Presentation: “Food
“ Food Packaging “ Packaging “
2.Read Information Sheet # 1-2: Information Sheet # 1-2: “Packaging
“Packaging Materials for Canned Foods: Materials for Canned Foods: Glass
Glass Container” Container”
3. View: Power Point Presentation: Power Point Presentation:“ Types of
“ Types of Glass Container Bottle Parts” Glass Container Bottle Parts”
4. Read Information Sheet # 1-3: “ Information Sheet # 1-3
Characteristics of a Good Packaging
Material” Power Point Presentation:
“Characteristics of a Good
5. View: CD Power Point Presentation: Packaging Material”
“Characteristics of a Good Packaging
Material” Job Sheet #1-1 “ Packaging”
6. Perform: Job Sheet # 1-1: “Packaging” Self Check #1-1
7. Complete Self Check #1-1 Answer Key #1-1
8. Check your answer: Answer Key#1-1
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 5
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INFORMATION SHEET # 1-1
Food Packaging
Modern concepts about packaging
More than just a container
The “silent salesman”.
Cost effective
Socially-oriented
Global character
Environmentally-responsible
Definition
Packaging protects what it sells, and sells what it protects
Packaging is the art, science and technology of bringing goods from its
sources to places of consumption at minimum cost possible.
Principles
Packaging development aims at increasing sales and profits.
Success of packaged products depends heavily on knowing market
conditions.
Packaging is not all about product protection. Its development must treat the
customer as “King”. The ability to understand customer/consumer needs is a
powerful selling point.
Packaging is a wise investment.
Packaging substitution should be based on good reasons.
Observe all legal requirements.
Packaging is part of the production process.
Packaging is constantly changing. It can be very controversial.
Why we need packaging?
Functional: Product containment and protection
Protection from climatic, biological and other environmental hazards
Protection from handling, warehousing and distribution hazards
Protection during product expected shelf-life
Marketing: Enhancement of product sales appeal.
“AIDA” (Attract, Interest, Desire, Action)
Consumer information
Convenience features
Tamper-evidence/product integrity
Product promotion
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Cost control: Helping keep production and distribution costs at minimum
possible levels.
Production line efficiency
Minimum spoilage and losses
Efficient product movement
Standardization, maximum utilization of resources, spaces, etc.
Classification
Retail/Consumer
Transport
Hazardous products
Military
Primary
Secondary
Tertiary
Quarternary
Types of Packaging Materials and Formats
Glass – bottles, jars, tumblers, vials, ampoules, carboys
Plastics – bottles, jars, tubes, tumblers, cups, closures, disposable, vials,
ampoules, pails, drums, trays, crates, pallets, intermediate bulk containers
(IBCs)
Flexibles – wrappers, labels, pouches, sachets, strip/skin packs, tubes,
blisters, tapes, straps, bags, sacks, IBCs
Metal – cans, bottles, closures, tubes, tins, canisters, pails, drums, trays,
blisters
Paper – wrappers, labels, folding cartons, multipack carriers, corrugated
boxes, trays, molded pulps, pallets
Others – cushion materials, “kaings”, indigenous packaging materials,
capseals, tags, etc.
Packaging and Marketing
Packaging is designed to meet consumer demands.
Product greatly influences packaging material choice and final design.
Branding and packaging are key ingredients to product sales.
The common goal is – to bring good products to consumers.
Consumers develop the packaging they want. Market research can probe
into real consumer attitudes towards products and packaging. It is in this light
that packaging is truly an effective marketing tool.
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INFORMATION SHEET # 1-2
Packaging Materials for Canned Foods
Glass containers
Glass is produced by melting together silica, lime, soda, alumina, magnesia, potash with
the proper colorant in a furnace at a temperature of at least 1,500OC. The material is
then molded into the desired form.
Characteristics of glass
Glass is ideal for use in food packaging because it is:
a) Chemically inert: it does not have any effect on the food contained nor
does the food have an effect on the container; no reactions between the container and
contents
b) Clear, transparent: clarity and transparency provide for visibility of the food
contents; the consumer actually sees what he is buying; it is possible to see if the
product is good or whether or not it has been tampered with.
c) Non-toxic: does not contain any poisonous substances that may migrate
to the food contents.
d) Reusable: for as long as glass containers are washed and sterilized these
may be used repeatedly.
e) Impermeable to gas and liquid: it does not allow for transmission of gases,
hence vapor/odors and liquids.
f) Rigid: for ease in handling on the filling lines: for retention of shape during
all paces of marketing.
g) Resistant to internal pressure: this property makes it possible for
carbonated beverages to be packed in bottles.
a. Heat resistant: high temperature resistance (up to 500OC) makes it
possible for hot filling, cooking or sterilizing in the container, or sterilizing
the container itself.
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Disadvantages
Glass also has its limitations when used in food packaging. These includes:
a) Fragility: risk of breakage, which causes loss of products and hold-ups on
the processing line.
b) Heavy weights: heavier than equivalent size of tin can or plastic container.
b. Poor heat transfer characteristics: poor heat transfer characteristics
compared to tin cans.
Types of Glass Containers
Type Description
Jar A wide mouthed glass container
with no appreciable neck; a utensil
or fingers used for both taking out
the contents: maybe used for both
liquid and dry products.
Bottle A glass container with a long neck
compared with the jar used for
liquid products that are poured.
Tumbler Shaped like a drinking glass; used
Jug for both liquid and dry products.
A large glass container with a
capacity of about half gallon to
one gallon with carrying handle;
used for liquid products.
Vials/Ampoules Small glass containers for small
quantities of food ingredients such
as spices and colorants.
Wide mouth bottle
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BOTTLE PARTS
FINISH This section called the finish is the very top section of the bottle and is
made to seal a cap. This is the section where the contents are filled or
removed. The top surface of the mouth especially made the sealing
surface
NECK The neck is the section from the neck ring seam down to where the form
curve makes a wide bend at the base of the neck.
SHOULDER The shoulder is the section that widens out up the straight from the body.
BODY The body is the section where the contents go in.
BOTTOM The bottom is the flat section where the bottle is placed. The curve section
down from the bottom plate seam to where the flat bottom surface start is
specially named the heel.
Various Bottle Parts Name
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INFORMATION SHEET #1-3
Characteristics of a Good Packaging Material
Some of the important characteristics considered in selecting appropriate
packaging materials are barrier property, dimensional stability, sealability,
appearance and cost. Barrier properties refer to the ability of the package to prevent
entry of undesired elements, such as microorganisms and filth, through the packaging
material and into the product. Certain foods must be protected from moisture and
oxygen that can encourage microbial and chemical changes leading to spoilage. In
some cases, the need is to provide packages that will allow selective entry of elements.
Fresh fruits and vegetables, for example, have to be packed in materials that will allow
passage of gases needed for respiration but not necessarily the entry of moisture.
A packaging material must be strong and dimensionally stable, meaning, it
should be able to maintain its form and integrity even when subjected to the stresses of
handling and transport. This is particularly true for packages of fruits, vegetables and
fresh eggs. In contrast, dressed chicken can be packed in flexible pouches because the
product is less susceptible to bruising. Some of the important types of material failure
that must be watched when considering the strength of packages are tearing, bursting
and creasing.
Another important property of a good food package is sealability. The package
must have a means of easily and effectively sealing off food from contamination during
handling, transport and storage. In the plastic film industry, heat sealability is an
important consideration for film selection. For the semi-rigid plastic packs, such as ice
cream and biscuit containers, the trend is to use snap-on lids.
With the growing popularity of supermarkets and shopping centers, the
packaging material is assuming a big role in the success of food products sold on the
shelves. Food packages must now be designed not only for their functionality but also
for their appeal to the consumer. Printability and attractive surface finish are important
characteristics of a package. Finally, the materials used for packaging must be cheap
and readily available.
Classes of Packaging Materials
A product may be contained in a structure of a single type of material, such as
paper bag, whose properties are mainly dependent on the characteristic of the parent
material. However, there are packages made of layers of different materials which may
include a basic substrate, adhesive protective coating and decorative coating (ink, etc.).
The overall characteristics of such packages result from the combination of the
individual properties of component materials. Some of the basic materials used for food
packaging, either as a single component or in combination with others, are discussed
below. Table below compares the properties of these different packaging materials.
A qualitative comparison of the properties of the different classes of packaging materials
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Material Barrier Mechanical Heat Appearance Cost
Paper sealable
Glass poor fair poor excellent good
Tin
Foil excellent good n.a. good poor
Film excellent excellent good poor
n.a.
excellent poor excellent fair
poor
good poor good excellent
good
Paper. Paper remains to be an important food packaging material in the Philippines.
In flexible packages, paper is an important component because it gives strength and
stiffness to the package and it is an excellent printing medium.
Paper is made from wood fibers, which are separated by either the sulfate or the
soda process, depending on the type of wood used, then re-grouped into more or less
random fashion to form a sheet of desired dimension and properties. The strength,
surface characteristics and moisture resistance of paper depend largely on the type of
wood from which the fibers were taken and the processing involved in their
manufacture.
Paper alone is not suited for wet products, such as meat, because of its poor
barrier properties. For such purpose, paper is normally used in conjunction with other
materials that can offer better protection to the food commodity. In some cases, paper is
waxed to improve its moisture barrier properties and, to some extent, its grease
resistance.
Glass. Next to paper, glass is perhaps one of the oldest forms of packaging material.
It is rigid and it has an excellent visual appeal. However, it is also more difficult to
handle and it is a costlier type of packaging material. Glass is made through heating
sand and silica together in a furnace. Measured amount of molten glass is either blown
in a mold of a specific shape or it may be pressed, and blown to obtain the desired form.
Glass containers may be re-melted and re-cycled in an almost unlimited number of
times. However, the cost of production, as well as the cost of collection and re-
distribution, sometimes becomes so prohibitive that many local food processors find it
cheaper to hire laborers to clean the containers over and over. Experience at the
Institute of Food Science and Technology, UPLB has revealed that bottles may be
cleaned and re-used as many as eight times.
Tin Cans. In packaging, tin is a general term used to describe a thin sheet of steel
coated with tin and formed into a can. The tin, which is applied to the steel base
material by either electrolytic or by a hot dip process, is used to protect the steel base
from reacting with the sometimes corrosive content. This is particularly true with acidic
fruit juices. Certain food products, such as asparagus, will react directly with the tin, that
is why a special type of enamel is generally used to coat the interior surfaces of the can.
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Tin cans are generally preferred to other types of packaging material because of
the almost complete protection it can provide for its content. Unless there are faults in
the can seams, a tin can is almost a perfect barrier against spoilage agents. Cans are
strong and rigid, thus, they can stand the high physical and thermal stresses of
commercial sterilization, as well as the mechanical stresses of handling and transport.
The major problem encountered with the use of tin cans particularly during handling and
transport is its heavy weight. Also, tin cans are generally more expensive than the other
forms of packaging materials.
Foil. Aluminum foil is probably the most popular flexible packaging material used to
maintain or preserve the quality of food. It is widely used due to its superior shielding
properties against both moisture and gases. Aside from its barrier properties, the foil
has been appreciated for its wide temperature application, formability, luster and
metallic sheen which, when colored, is highly appealing.
Foil is defined as a thinly rolled section of a metal with a thickness less than
0.0015 cm (0.6 mil). The thickness of commercially available foil may range from 0.0004
cm (0.17 mil) to 0.0145 cm (5.7 mils). As the thickness of the foil is decreased, its
controllability in terms of shape is reduced and the chance of getting “pinholes” is
greater. This is particularly critical in food applications since moisture and gases can
migrate through the holes. Saccharow and Griffin (1980) recommended foil thickness
greater than 0.0018 cm for food packaging. Pure aluminum foil is weak and needs other
types of metal, in an alloy, to improve its bursting strength. For flexible packaging of
foods, the 1100 and the 1145 foil types, which use iron, are often employed.
Aluminum foil may be combined with other materials, in the form of laminates, to
protect it from scratching, as well as to allow sealing with the use of heat. The most
common materials used with foil are paper for scratch protection and plastic films for
inertness to contents and heat sealability.
Film. A film is a thin flexible plastic sheet with a thickness of 0.0254 cm or less. The
plastic may be made from a single type of polymer compound or from a mixture of two
or three types of polymers. If the plastic is crystallized from the fluid state to form a
randomly arranged pack of molecules, an amorphous solid that is bulky and weak is
formed. However, under controlled conditions, polymers can be crystallized so that they
run parallel to one another to form an orderly, properly packed and dense structure. The
plastic material that is formed is strong and can be melted and re-formed using heat.
This plastic material is also thermoplastic. Certain polymer molecules, such as
polypropylene, have extensive side chains which interfere with the close packing of the
molecules and encourage side chain linking, thus producing a more heat stable, difficult
to re-melt and more difficult to heat seal film.
Films are made through melting and then extruding plastic resins through a die
that shapes the resins into a plastic sheet. During extrusion of the film, it may be
stretched or “oriented” under carefully controlled temperature condition to improve its
tensile and bursting strength. Orientation re-aligns the polymer into a more orderly and
dense structure that results in different, sometimes desirable, film properties. Molecules
in this arrangement are under some form of stress and, given proper conditions, will
tend to shrink and return to their more stable structure.
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Types of Films Used in Food Packaging
Several types of films have been used as packaging materials for various
industrial products. The films that will be described have found application in food
products. Tables below summarize the physical properties of these different films.
Cellophane. Cellophane is a film made from regenerated or hydrated cellulose. While it
is a good barrier to grease, cellophane cannot resist moisture. The film has an excellent
clarity and sparkle that make it a very attractive packaging material. Cellophane has
high tensile and impact strengths but it cannot withstand tearing.
Resistance of locally available packaging films to different chemicals (Adapted from
Modern Plastics Encyclopedia. 1978-79 Vol. 55 No 10A. McGraw-Hill, New York)
Film Material Resistance to
Acids Alkalies Greases Organic Water
and Oils Solvents
Cellophane
Plain poor poor Good good fair
NC coated poor poor good ctg attack. fair
PE coated good good fair - -
PVDC coated good good good
good good
Cellulose acetate poor poor good poor good
Polyamide
Nylon 6 poor good good good poor-good
Polyester good poor good good good
Polyethylene
Low Dens. Good good poor good good
(60º)
Med. Dens. good good good good good
Hi Dens. good good good good good
(80º)
Polypropylene
(cast) good good good good Good
(coated-oriented) good good good
ctg attack. good
Polystyrene good good poor-good poor-good good
good good
(oriented) good good fair-good poor-good good
Polyvinyl chloride-
acetate (plastic’d) good fair-good good
Polyvinylidene
chloride-vinyl
chloride
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Mechanical properties of locally available packaging films
Film material Tensile Tearing Bursting Heat sealing
strength 2 strength 2 (g strength range 2
(°C)
(Mpa) mil) 1 mil thick
(kPa) 93.3-148.8
107.2-176.6
Cellophane 110-48.81
Plain 72-128 ³ 275-426³ 379-4481 176.6-232.2
NC coated 48-103 2-10 276-345 5 204.4-232.24
Saran coated 48-89.6 2-15 345-586³ 135-204.4
Polyethylene coated 35 and over1 16-501 No burst
37-95.81 121.1-176.6
Cellulose acetate 95.2-117 4 2-25 115.5-176.6
Polyamide 50 4 135-176.6
Nylon 64 162.7-204.4
121.1-176.6
Polyester (Mylar 117-163 10-271 310-345 ³ 93.3-176.6
Scotchpak, Videne)
Polyethylene 9.3-17 150-350 331s 135-148.8
14-24 137.7-148.8
Low density 16.5-42 50-300 - 121.1-176.6
31-69
Medium density 55-82.7 15-300 -
High density 20.7-75.8 32-1750 1
20-30 very high 1
Polypropylene 30-14001 158.6-4141
Polystyrene (oriented) 172-276 5
Vinyl chloride
Vinylidene 41.4-82.71 15-201 -
Cryovac
Saran 55-138 10-1001 138-276 ³
Rubber hydrochloride 24-34.5 60-1600 stretches 2
(Pliofilm)
1 Source: Modern Plastic Encyclopedia Issue for 1962
2 Source: Modern Plastics, 1961 all values unless otherwise noted
3 Source: Stone and Reinhart (1954)
4 Source: Miller (1959)
5 Source: Modern Packaging Encyclopedia Issue 1960. Copyright 1959. Packaging
Catalog Corp., New York
A major disadvantage in using cellophane as a food packaging material is its
inability to heat seal. Also, the film is affected by hydrogen gas and it has a strong
tendency to crack when very dry. Foods wrapped in cellophane alone will not preserve
well but in a laminate, cellophane can be an excellent substrate.
Polyethylene. One of the most widely used plastic films is polyethylene (PE), over half
a billion kilograms of which are produced every year. It is estimated that about 50% of
this goes to food applications. Polyethylene is a polymer of ethylene with 100 to 1000
carbons in a chain. It has a barrier property that improves with the increasing thickness
of the film. PE films are typically classified according to their density. Low density PE
has a density range of 0.915 to 0.925 while medium and high density PE have 0.925 to
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0.935 and above 0.940, respectively. High density PE is structurally more rigid and less
stretchy while the medium density film is only fairly rigid and it is machineable. In
contrast, low density polyethylene generally lacks stiffness and it is stretchy, soft and
flexible.
Polyethylene is a very good moisture barrier even at low density but it is only
fairly resistant to gas. The resistance of PE to gas migration increases with increasing
film thickness. However, even heavier PE films will not resist oil and grease migration.
One of the problems with polyethylene is its poor optical property. As the density of the
film increases, the film becomes more opaque and unattractive as a food packaging
material.
Perhaps the most important characteristic of a PE film is its excellent heat
sealing property. PE will easily seal within 0.5 to 1.5 seconds at temperatures ranging
from 190 to 230°C.
Polypropylene. Unlike PE, polypropylene (PP) is a very good gas, grease and moisture
barrier. PP films are fairly strong with a tendency to be brittle. Film strength, particularly
impact strength, can be improved by orientation during manufacture, as well as by
addition of polyethylene before extrusion. For freezing and low temperature storage of
PP-wrapped foods, thinner films are generally used.
Polypropylene films have only a fair heat sealing characteristic that is explained
by the branches in the molecules which prevent good orientation. Generally, PP will
heat-seal at around 350°C but at thickness over 0.00508 cm, heat sealing is difficult.
Unlike PE, polypropylene has superior optical properties even at higher densities.
Cost-wise, polypropylene is more expensive than polyethylene.
Polyvinyl Chloride. Polyvinyl chloride (PVC), a polymer of vinyl chloride, is among the
lowest priced films. Aside from being a good gas barrier, it is fairly resistant to oils and
greases. Like PP, PVC is a good moisture shield. PVC is a normally rigid and strong
film. Pliability is achieved by adding plasticizer, such as tricresyi phosphate, which
sometimes can be as much as 50% of the formulation. Polyvinyl chloride has a good
heat sealing property although it tends to release HC1 that can corrode the heat sealing
filament. One of the most interesting properties of oriented PVC is its ability to shrink
even under low heats, hence, it is extensively used for shrink wraps. Like PP, PVC is
very clear and brilliant; however, it tends to turn yellow when heated and exposed to UV
light.
Saran. Saran is the popular name for the plastic film made from polyvinylidene chloride
(PVDC) polymer. It is considered to be the best of all films in terms of barrier properties
for it will resist most acids and alkalies. However, PVDC tends to cling, making it very
difficult to machine handle.
Polyvinylidene chloride is stiff when pure but when co-polymerized with vinyl
chloride and oriented, it becomes very soft and highly stretchable. It has a good impact
property but this characteristic gradually deteriorates at freezing temperatures. PVDC
has a good heat sealing property and excellent optical properties, such as transparency
and glossiness. Like PE, Saran has been with the food industry for quite sometime.
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Nylon. Nylon is made from long chains of polyamides. The most commonly used types
of nylon is Nylon 6/6 or simply Nylon 6. This film is very compatible with greases but it is
a poor moisture barrier as it tends to absorb water. Nylon is generally resistant to
alkalies and weak acids. The most important characteristic of nylon is its superior
impact and yield strength making it ideal for packaging foods that are subject to rough
handling and dropping. Nylon is a tough thermoplastic that has a strong tendency to
creep or to stretch with time.
A major disadvantage of nylon is its poor heat-sealing property. Also, it is
transparent only as a thin film and it becomes opaque, as it gets thicker. Unlike other
plastics, nylon can withstand fairly high temperatures but it is comparatively more
expensive.
Polyester. Polyester film is more popularly known by its trade name, Mylar. Like nylon,
it is a very strong packaging material with a very low gas transmission property.
However, the film cannot be heat sealed, so it is commonly used in laminates, together
with heat sealable films, such as polyethylene and polyvinyl chloride. Like nylon,
polyester is costly but the strength it can offer makes it an important component of food
packaging materials.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 17
June 2005 December 2005
Job Sheet # 1-1
Job Title : Packaging
Purpose : To enhance the learners ability in evaluating and comparing the
properties of the different packaging materials
Equipment, Tools and
Materials : Paper and pen
Precautions : Be careful in handling fragile objects.
PROCEDURE
1.Visit a well-stocked grocery or a supermarket and list the available canned sugar
concentrate products.
2.Evaluate and compare the properties of the different packaging materials
3.Packaging material that would be suitable for
a. Jams
b. Jellies
c. Marmalades
d. Fruit Concentrate
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 18
June 2005 December 2005
SELF-CHECK #1- 1
A. Answer the following question:
1. Define Packaging.
2. Why do we need packaging?
3. Enumerate the types of packaging materials and forms.
4. What are the modern concepts about packaging? Explain.
B.Fill in the blanks:
__________ 1. Is the art, science and technology of bringing goods from its sources to
places of consumption at minimum cost possible.
__________ 2. Bottles, jars, tumblers, vials, ampoules, carboys
__________ 3. Wrappers, labels, folding cartons, multipack carriers, corrugated boxes,
trays, molded pulps and pallets
__________ 4. The temperature required to produce glass.
C.Enumerate the following
1. Glass is ideal for use in food packaging because it is:
a)
b)
c)
d)
e)
f)
g)
h)
2. Six types of glass containers
a)
b)
c)
e)
f)
g)
D.Label the parts of two bottles illustrated below
(a)Shoulder
(b)Finish
(c)Bottom
(d)Body
(e)Sealing Surface
(f)Heel
(g)Neck
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 19
June 2005 December 2005
Answer Key # 1-1
A.
1. Packaging is the art, science and technology of bringing goods from its sources to
places of consumption at minimum cost possible.
2. Functional: Product containment and protection
Marketing: Enhancement of product sales appeal.
Cost Control: Helping keep production and distribution costs at minimum possible
levels.
3.
Glass
Plastics
Flexibles
Metal
Paper
Cushion materials, “kaings”, indigenous packaging materials, capseals, tags,
etc.
4.Modern concepts about packaging
More than just a container
The “silent salesman”.
Cost effective
Socially-oriented
Global character
Environmentally-responsible
B.
1. Packaging
2. Glass
3. Paper
4. 1,500ºC
C. 1. a) Chemically inert
b) Clear, transparent
c) Non-toxic
d) Re-usable
e) Impermeable to gas and liquid
f) Rigid
g) Resistant to internal pressure
h) Heat resistant
2. a) jar
b) bottle
c) tumbler
d) jug
e) vials / ampoules
f) wide mouth bottle
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 20
June 2005 December 2005
D. Various Bottle Parts Name
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 21
June 2005 December 2005
QUALIFICATION : Food Processing NC III
UNIT OF COMPETENCY : Process Food by Sugar Concentration
MODULE : Preparing the Packaging Materials
LEARNING OUTCOME #2 : Wash, sterilize and cool bottle glass and jar in
inverted position .
ASSESSMENT CRITERIA:
1.Glass bottle and jar are washed, sterilized and cooled in inverted position.
RESOURCES:
Equipment and Facilities Tools and Instruments Supplies and Materials
None Stainless enameled Glass bottle
Plastic casserole Jars
Plastic trays Tin cans
REFERENCES:
1. Carpio, E. V. 2000. Engineering for Food Technologist. University of the
2. Philippines:
3. De Leon, S.Y. and Guzman M.P. 1998. Preservation of Philippine Foods, A Manual
of Principles and Procedures.
4. Gonzales, Olympia N., et.al. 1982. Philippine Handbook on Canned Low Acid
Foods. A project of NSDB-NIST and No. 7801. National Institute of Science and
Technology Authority.
5. Hayter, R. 2000. Food Preparation and Cooking. Singapore: Thompson Learning.
6. Introduction to Agricultural Products and Processing. 1990. Oklahoma: Department.
Of Vocational and Technical Education Curriculum and Materials Center.
7. Institute of Science and Technology, national Science and Technology Authority.
8. Larousse, J. and Bruce E. Brown. 1997. Food Canning Technology.
9. McSwane, D. N. Rue and R. Linton. 2002. Essentials of Food Safety and Sanitation.
3rd ed. Singapore: Pearson Education South Asia Pte Ltd.
10. Packaging and Labeling for Processed Foods. 1999. Philippine Trade and Training
Center, Philippines:
11. Philippine Trade and Training Center. 2003. Philippines : Current Good
Manufacturing Practices for the Food Industry/ Establishment.
12. ServSafe Serving Safe Food Course Book. 1999. Food Safety Institute Foundation,
Inc.
.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 22
June 2005 December 2005
Learning Experiences Wash, sterilize and cool bottle glass and jar in
Learning Outcome #2: inverted position .
LEARNING ACTIVITIES SPECIAL INSTRUCTIONS
1. Read: Information Sheet #2-1 Information Sheet #2-1
a. Canned Fruit Drinks a. Canned Fruit Drinks
b. Hot Filling Juices and Juice Drinks in b. Hot Filling Juices and Juice Drinks in
Glass Containers
c. Commercially Sterile Cold Filling of Glass Containers
Citrus Juice in Glass Container c. Commercially Sterile Cold Filling of
d. Glass Packaging Jellies and
Preserves Citrus Juice in Glass Container
d. Glass Packaging Jellies and
Preserves
2. View: Power Point Presentation: Power Point Presentation: Cooling
Cooling Finished Product Finished Product
3. Perform Job Sheet #2-1 “Cooling Job Sheet #2-1 “Cooling Finished
Finished Product” Product”
4. Perform Self Check # 2-1 Self Check # 2-1
Answer Key # 2-1
4. Check your answers using the Answer
Key # 2-1
5. Go back to items in the self-check
section that you failed to answer. You can
go back and study more the information
sheets.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 23
June 2005 December 2005
INFORMATION SHEET # 2-1
A. CANNED FRUIT DRINKS
Several specific canned food drinks are covered by FDA Standards of Identity
and label statements of optional ingredients.
The subject of labeling requirements for canned drinks has been a point of much
controversy for the past several years. Federal (FDA) regulations are being developed.
On a State basis, there is considerable variation on requirements.
CANS
For drinks containing FD&C Food Colors, a double enameled can is recommended.
This can is used for minimizing any potential corrosion problems. Since some FD&C
Food Colors are subject to fading by the presence of metal ions, this type of can should
always be used. Food colors also contribute to can corrosion, it is generally
recommended to keep the azo dye content in the drink less than 40 ppm. Glass
containers may be used.
For beverages such as Pineapple-Grapefruit, or drinks containing no FD&C Food
Coloring, a 100-25 tin plate can is satisfactory. The amount of tin, body, and end weight,
can vary according to what is best suited for the particular drink. Due to the tin lining,
the can has the additional advantage of bleaching the fruit juice. This retards the
darkening of the product without appreciably affecting the flavor. For more specific
requirements a can supplier should always be consulted.
The Canning Operation
Fundamentally, the operation involved in the manufacture of 46 ounce canned
drinks is relatively simple. It is basically a mixing and blending process of various juices,
nutritive carbohydrate sweeteners, acidulants, and flavors.
The product is then flash pasteurized in a plate heat exchanger, filled in cans, and
immediately closed in an atmospheric sealer. The closing temperature should be
between 185° and 195°F. After closing, the cans should be inverted and held or rolled
for one minute to sterilize the top end before being cooled. Water cooling should
immediately follow to bring the cans as rapidly as possible to a temperature of 95°-
105°F.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 24
June 2005 December 2005
B. HOT FILLING JUICES AND JUICE DRINKS IN GLASS CONTAINERS
The preparation of the juices and the juice drinks will be the same as is outlined for
the canned products. However, in the case of tomato juice, if salt is added, the salt is
normally added to the tank ahead of the filler rather than as a tablet as is indicated in
the case of cans.
The basic packaging operations are the same as with other hot fill glass packaging
operations, such as ketchup, but with several variations as follows.
Cleaning
The bottles should pass through an inverting type cleaner prior to filling. Either air
or hot water can be used for the cleaning operation.
Preheating
Preheating the bottles is necessary to avoid excessive temperature differentials
when the hot juices or drinks are filled into the bottles. This also serves to prevent the
colder bottle from cooling the hot liquid below the desirable sterilizing level before it is
sealed. The pre-heater is essentially a tunnel with a sloping roof placed over the
conveyor between the bottle cleaner and the filler. Perforated steam pipes are placed
along the sides of the conveyor in the tunnel with the perforations directed downward so
that steam surrounds the bottle without striking them directly. A similar perforated steam
pipe, with the holes directed laterally, may also be added under the conveyor.
Glass containers with a capacity up to one-half gallon should be preheated to a
temperature within 60° F of the product filling temperature. Glass containers one- half
gallon and larger should be preheated to within 50° F of the product filling temperature.
Filling
The hot juices and drinks should be filled into the properly preheated containers at
a temperature of 190°F to 195°F. Gravity fillers and vacuum-gravity fillers are normally
used for these products.
Sealing
The filled containers should be sealed immediately with a positive hermetic seal.
Plastisol lined lug caps or conventional style crown closures are most generally used for
these products today.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 25
June 2005 December 2005
Holding
The properly sealed containers are given a holding period of three minutes prior to
starting the cool. This three-minute holding period is required to complete the
sterilization of the cap and the headspace area prior to the first cooling section. If a
standard crown closure is used, provision should be made for spraying the inside of the
crown with a suitable sterilizing agent prior to the capping operation, or the sealed
package must be handled in such a way as to bring the hot liquid in contact with the
inside surface of the crown.
The holding period is normally accomplished at the in feed of the cooler by
eliminating sprays in the front end to provide this three-minute period.
Cooling
Following the holding section discussed above, the first section of the spray cooler
will have either tempered water sprays or extremely fine sprays of cold water which
produce a mist or fog. Where tempered water sprays are used, the water temperature in
this first five-minute section should be within 50° of the filling temperature for containers
of one-half gallon size or larger, or within 60° of the filling temperature with containers
smaller than one-half gallon.
In the second section of the cooler, successively heavier sprays of cold water can
be used, again maintaining the 50° or 60° temperature differential from the first section
as previously discussed. This second section again should provide a five-minute cooling
period.
With all juices and juice drinks other than pure citrus juices, the water temperature
down the balance of the cooler will be at the normal plant water temperature and
consists of heavy sprays.
Most orange and grapefruit juice packaged in glass today is stored and sold under
refrigeration. When packaging these juices in glass then, it is desirable to get the
temperature of the juice in the range of 35°F to 40"F prior to casing and warehousing.
This can be accomplished by using refrigerated water at 35°F in the final sections of the
cooler, and in some instances a refrigerated brine solution at temperatures below 32°F
is used. If brine is used, a provision to wash the brine off the jars prior to casing will
have to be made.
Other glass packed juices and drinks are normally cooled to a point where the
shake temperature is approximately 100°F.
In either case, an air dryer is usually incorporated at the discharge end of the cooler
to remove excessive water prior to placing the containers in the cases, and air jets may
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 26
June 2005 December 2005
also be installed along the conveyor between the cooler and the labeling or casing
area to blow air under the closure and remove the water from this area.
C. COMMERCIALLY STERILE COLD FILLING OF CITRUS JUICE IN GLASS
CONTAINERS
At the outset, it should be understood that packaging citrus juices using any
commercially sterile cold fill operation involves a calculated risk. The glass containers
themselves must be cleaned and sterilized to eliminate all micro-organisms capable of
growing in the juice. The juice itself must be similarly sterilized. The closures used must
be similarly sterilized. Then the three components—the container, the product, and the
closure—must be assembled without recontamination of the interior of the container or
closure, or the product itself, by spoilage organisms.
The importance of the maintenance of the highest degree of sanitation and quality
control in the operation of a commercially sterile cold fill system cannot be over-
emphasized. At the same time, it is absolutely necessary to provide packaging
equipment and a physical set up which will keep sanitation and quality control problems
to a minimum. It is not implied that a high degree of sanitation is not required in a hot fill
procedure, but it is far more critical in the cold fill operation.
The packaging system discussed here reduces the "calculated risk" to a minimum
consistent with modern high-speed packaging operations.
Such a system is not intended to produce an absolutely sterile packaged product,
but rather to eliminate those microorganisms capable of spoiling the citrus product
under its normal storage conditions. This operation then is a commercially sterile
process rather than an aseptic process.
This discussion does not cover in detail the preparation of the citrus juice itself.
Juice Processing
Through the point of sterilization, the actual product preparation procedures will be
similar to those for a normal hot pack line. Following extraction, de-oiling, deaeration,
etc., a heat exchanger is used to heat the product to 190°F to 230° F for periods of 2 to
15 seconds, depending upon the product temperature used. The juice is then
immediately cooled to approximately 35° F or below. From this point on, every
precaution must be taken to be certain the juice does not become recontaminated.
Product handling lines must be thoroughly sterilized and all joints, pumps, etc.,
must be carefully checked to be certain they cannot pull air into the systems and, thus,
possibly recontaminate the product.
A qualified microbiologist must definitely be on the Quality Control staff and must
have all necessary authority to see that his decisions are enforced. Every phase of the
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 27
June 2005 December 2005
product preparation and the three critical packaging areas which will be discussed
here must be under his surveillance and control.
While specific quality control and microbiological test procedures will vary from
plant to plant and may change as experience is gained with the operation, there can be
no let down in sanitary precautions at any time.
Bottle Sterilizer
There is a distinct possibility that bottles going into the commercially sterile cold fill
system may not always be completely clean, due to storage conditions, shipping
conditions, and possible reuse of containers within a plant. Therefore, the proper
procedure in such an operation is first to thoroughly clean the bottles. The cleaning
operation may also be used to sterilize the bottles or a separate sterilizing rinse can be
used after cleaning.
Both soaker-washers and chemical rinsers can be used for the sterilizing
operation.
Soaker-Washer
The best piece of equipment available for cleaning and sterilizing glass
containers at relatively low cost is a soaker-washer unit which utilizes hot caustic soda
to clean the bottles. By completely separating the entrance and discharge sections and
enclosing the discharge conveyor, such a unit could be close coupled to a sterile filling
room to provide clean, commercially sterile bottles.
A total immersion type unit is preferred. A caustic concentration of at least three
percent should be maintained. An immersion time of three minutes at 140° F, or higher,
is adequate for complete sterilization at this concentration. All water for final rinsing
should be pre-sterilized, either by heating in a heat exchanger or by using chlorine or
iodine compounds in concentrations recommended by the manufacturer of these
compounds, for the particular water in question.
Before coming in contact with the hot caustic, the bottles should be preheated both
internally and externally with tempered water sprays at about 90° F to prevent thermal
shock breakage. Likewise, as the bottles come out of the hot caustic, tempered warm
water rinsing sprays should be used.
Sterilizing Rinsers
If adequate inspection, or prior cleaning of the bottles by the packer, ensures that
only bottles free of foreign material will be used in the process, then it is possible to use
chemical sterilization on these bottles. This fundamentally involves a chemical rinse with
sufficient dwell time to provide the holding period recommended by the manufacturer of
the iodophor or chlorine compound, at the concentration recommended by the
manufacturer of the compound.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 28
June 2005 December 2005
Sterile Filling Room
A sterile filling room and a very clean capping area are absolutely essential to
successfully produce a commercially sterile product. The size of such a room will vary
with individual packer's desires.
The size of air-conditioning unit required to supply the necessary dehumidified
sterile air will be determined by the size of the filling room. Such a unit should allow
pressurization of the room to 0.15 to 0.25 inches of water to prevent possible airborne
contamination from outside the room during operation of the line. As with the bottle
sterilizer, suitable covers for blocking off all openings in the room should be provided so
that when the line is not operating, it can be completely sealed.
The room should be constructed of suitable materials and must be scrupulously
cleaned and sterilized at frequent intervals. Suitable materials will have smooth, hard,
impervious surfaces that will not deteriorate under the rigorous operating conditions and
the corrosive actions of the juice itself, caustic cleaning solutions, a constantly humid
atmosphere, and possible severe abrasion.
Normal illuminating lights should be flush mounted and sealed into the ceiling with
provisions to change them from above, outside the room. If stainless steel is not used in
the construction of the room, it is strongly urged that all internal surfaces of the room,
including the floor, be epoxy coated.
The floor of the room should be sloped from all sides to a drain outside the filler
floor space. In addition, the floor should be covered to the side walls and corners, as
should be the ceiling. It is essential to eliminate all cracks, crevices, sharp corners,
butted joints, etc., from the inside of the room. Elimination of such areas is necessary in
cleaning and sterilizing the room. After the line has been installed and final adjustments
have been made, it would even be advisable to cover the legs of the filler, and
conveyors with epoxy to eliminate the possibility of juice lodging in these areas.
Sterile Filling
A liquid gravity-vacuum filler which can be easily sterilized and maintained in a
sterile condition is required. It should be so constructed that all crevices, joints, threads,
etc., are eliminated from the product alone. All stainless steel construction is mandatory
for areas which can come in contact with the product. The filler bowl should be covered
to prevent airborne contamination. The most critical area in fillers from a bacteriological
standpoint is the filling heads themselves.
It is also necessary that the vent tubes which exhaust air from the containers, as
well as excess foam and a small amount of juice, be vented outside the filler bowl. This
juice should be collected so that it may be returned for reprocessing, and thus, any
organisms which might be present in the bottles or on the filler heads will not be
returned directly to contaminate the filler.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 29
June 2005 December 2005
Sterilizing Procedures
Prior to starting the line, all equipment must be thoroughly cleaned and sterilized.
This will include the conveyor from the bottle sterilizer into the filling room, including its
housing, the filling room itself, the filler, the discharge conveyor from the filling room to
the capper conveyor, the exterior of the capper, cap chute, and cap conveyor.
Further, the entire product zone from the hot end of the heat exchanger through the
filler bowl and filling heads must be cleaned with a suitable mild detergent of alkali
solution and then thoroughly flushed with fresh cold water. Following the cold water
rinse, a chemical sanitizer, such as an iodophor solution or similar agent, must be run
through the product line. The length of time will be determined by the concentration of
the solution and should be recommended by the sanitizing agent manufacturer.
Following the use of the sanitizing solution, hot water at as high a temperature as
possible (200° F or above) must be pumped through the entire product system for a
minimum of 15 minutes and preferably 30 minutes. The filler bowl must be filled to
overflowing during this period. To ensure internal sterilization of the filling heads, the
machine should be run at normal speed and stainless steel spacers should be run
through the filler to open the valves and make sure that hot water contacts all parts of
the filler heads, both inside and outside.
The filler must be run continuously during this period. This can be accomplished by
temporarily removing the center bottle guide so that the sleeves remain on the
pedestals while the machine is rotated.
Cleaning and sterilizing of the conveyor systems, the sterile filling room itself, and
the capper can be accomplished by a similar procedure. That is, they should be
thoroughly washed down with a suitable mild detergent, flushed with fresh water,
sprayed with sanitizing solution, and then thoroughly rinsed with fresh water chlorinated
to a level of 5 to 10 parts per million.
This sterilizing procedure must be performed immediately prior to each startup and
again immediately after each shutdown. If the line is not run continuously, the filler bowl
must be filled with suitable sanitizing solution. For overnight or weekend shutdown,
covers must be placed over all openings in the room and the bottle sterilizer, to
completely seal the entire system. The filling system must be kept full of a sanitizing
solution.
The sterilizing procedures will obviously introduce a great deal of moisture into the
room and condensate will be visible on the walls, ceiling, floor, and just about
everywhere. This condensate must be removed before product is run. The air
conditioner must, therefore, be turned on in advance and adjusted for maximum
moisture removal and minimum recirculation. As the room must be thoroughly well
sealed to begin with, the air-conditioning unit will have to be run about 30 minutes to
one hour before all of the moisture is removed.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 30
June 2005 December 2005
D. GLASS PACKAGING JELLIES AND PRESERVES
The filling and capping operations for preserves and jellies are so closely related
that they will be treated as one subject. Filling requires that the proper weight of finished
product be placed in the container and that the material so placed in the container shall
be truly representative of the batch. Where there is a tendency for the fruit to float due
to large size pieces or the wholeness of the fruit such as berries in the finished
preserves, it is customary to use rapid set pectin, which, because of its rapid setting
characteristics, gives a thickening action soon after the cook is completed and tends to
hold the fruit uniformly distributed. However, in the case of open kettle cooked
strawberries, cherries and large slices of peaches, it is necessary and highly desirable
that the preserves be cooled in a jacketed cooling pan prior to the time they go to the
filling equipment. Otherwise, they will be filled so hot that floating of the fruit is likely to
occur. Without cooling the floating can only be controlled by the use of an excessive
amount of pectin which results in too firm a preserve upon setting. Therefore, the
cooling operation is considered essential. Normally, the preserve is cooled down to
around 160°F and sometimes to as low as 140°F prior to filling. In the case of preserves
which tend to separate into syrup and fruit in the hopper or holding tank of the filling
equipment, even though partially cooled, it is well to have an operator at this point
maintaining agitation with a gentle stirring motion or to use a slow mechanical stirrer. In
this way a uniform portion of the finished cooked batch is placed in each container.
These remarks apply to hand filling also.
In connection with the filling machine operation, it is well to watch constantly the net
weight of the finished packages as they come from the filling machine. Due to the higher
density of preserves and jellies, usually about 1.33 times as heavy as water, it
frequently occurs that a greater weight of finished product is placed in a given container
than the label is intended to declare. For example, a tumbler holding 8 avoirdupois
ounces of jelly as declared on the label may easily hold 9 avoirdupois ounces unless the
filling operation is checked and kept under careful control. It is the usual practice to give
some small amount of overweight in preserves and jellies to avoid the danger of being
cited by the authorities for short-weight packages. Machines are available on the market
which have a high degree of accuracy of fill so that, on any given size package, the
over-weight which is desired can be accurately obtained and it is usually in the order of
1/8 ounce avoirdupois per package. A short calculation will show how easily a large loss
can result from giving excessive overweight.
Cleaning the Containers
The glass containers should be cleaned using an inverting type air cleaner prior to
filling.
Preheating the Containers
To prevent the colder container from reducing the filling temperature below safe
levels and also to reduce the possibility of the hot product subjecting the colder
container to excessive temperature differences, the containers should be preheated
prior to filling. For glass containers up to one-half gallon capacity, they should be
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 31
June 2005 December 2005
preheated so that the maximum temperature differential between the container and
the hot product is not more than 60°F. For containers of one-half gallon size and larger,
the maximum temperature differential should not be more than 50°F.
The preheater consists essentially of a tunnel placed over the conveyor leading to
the filler in which perforated steam pipes run along the sides of the tunnel at
approximately the shoulder height of the containers. The perforations are directed
downward so that the bottles are subjected to an atmosphere of steam without the
steam jet striking the bottles directly. A similar perforated pipe, with the perforations
directed laterally, may also be placed under the conveyor. The length of such a
preheater will depend upon the speed of the line.
Filling
Piston fillers are generally used for both jellies and preserves and the filling
temperature may also vary with the type of product being filled. In those products where
floating of the fruit is not a problem, the preserves should be filled into the preheated
containers at a high enough temperature to ensure a sealing temperature of 175°-
185°F.
In those preserves where floating is a problem, producers sometimes fill at a
temperature in the neighborhood of 135°F. With this low filling temperature, it is
necessary to pasteurize the containers after sealing for a sufficient length of time to give
a temperature of 180°F at the coldest spot in the container. Pasteurization in the
neighborhood of 195°F is necessary.
Unlike preserves, which go into a holding pan for cooling and checking before
filling, jellies should not be cooled after cooking but should be run directly from the
cooking kettles to the filler where they are filled at 180°-190°F.
Holding or Pasteurizing
With products filled at a satisfactory sterilizing temperature (185°F or above), further
pasteurization is not necessary but a holding period prior to cooling will be necessary.
With the top-side seal closures and lug closures, which are applied with a steam
vacuum sealing machine, it is suggested that the containers be held for a period of
three to five minutes after sealing and prior to cooling. This is to provide sufficient time
for sterilization of the upper surface of the product and other exposed surfaces in the
headspace.
If a plastisol lined screw cap (without a steam vacuum seal) is used, the sealed
containers should be held inverted for three to five minutes after sealing or should be
subjected to steam or hot water sprays or a hot water bath at 195°F or above for a
period of three to five minutes for cap sterilization purposes.
Preserves that are filled at temperatures below 185°F should be pasteurized after
hermetic sealing. Pasteurization may be accomplished by immersion in a water bath, or
by hot water sprays, or by a steam atmosphere. As previously mentioned, the
pasteurizer temperature is normally held at 195°F and the jars are in the unit for a
sufficient length of time to bring the cold spot in the container to a temperature of 180°F.
The separate holding period is obviously not required where pasteurization is done.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 32
June 2005 December 2005
Normally the pasteurizer, when used, is part of a continuous pasteurizer-cooler
unit.
Cooling
Following the holding or pasteurization period, the containers should be cooled as
rapidly as possible in order to maintain the maximum color and flavor in the product.
For cooling purposes, either a spray or immersion type cooler can be used. In
spray coolers it is possible to use a very fine mist or fog of cold water in the first section
of the cooler (five minutes travel time) with successively coarser sprays down the
balance of the cooler; or, tempered water at approximately 135°F can be used in this
first section with successively colder water down the balance of the unit.
In immersion cooling, the front end of the cooler should be held at 135° to 145°F,
again with successively colder water down the balance of the unit.
Regardless of the type of cooling method used, the jellies and preserves should be
cooled to a temperature of approximately 100°F or slightly below before they are
labeled and sealed into the cartons.
Cooling finished products
Cool canned and bottled fruits after processing.
Fruits Cooling Process
Immediately after processing:
1. Apple The cans should be water cooled until the average
temperature of the contents reaches 95º to 105º F.
Casing canned apple slices at high temperatures
may result in softening, loss of normal color or
darkening or pink discoloration of the product.
(stack burn).
2. Blackberries The can should be well cooled in water before
stacking or casing.
3. Pears It is important that the cans be immediately and
thoroughly cooled after processing to an average
can center temperatures between 95º to 105ºF. If
the cooling is not complete, the edges of the pieces
may become too soft or frayed and a general dull
appearance may result.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 33
June 2005 December 2005
4. Pineapple The cans should cooled in cold water after
processing. When using the rotating cooker, the
cans pass from the cooker to a rotating cooler.
Some canners pass the cans through a lacquering
bath after coming from the cooker. This is done
previous to their passing to the cooler. The
lacquering is used to protect the cans from rusting.
THE COOLING PROCESS OF JUICE DRINKS IN GLASS CONTAINERS
The first section of the spray cooler will have either tempered water sprays or
extremely fine sprays of cold water which produce a mist or fog. Where tempered
sprays are used, the water temperature in this first five-minute section should be within
50º of the filling temperature for containers of one-half gallon size or larger, or within 60º
of the filling temperature with containers smaller than one-half gallon.
In the second section of the cooler, successively heavier sprays of cold water
can be used, again maintaining 50º or 60º temperature differential from the first section
as previously discussed. This second section again should provide a five-minute
cooling period.
With all juices and juice drinks other than pure citrus juices, the water
temperature down the balance of the cooler will be at the normal plant water
temperature and consists of heavy sprays.
Most orange and grapefruit juice packaged in glass today is stored and sold
under refrigeration. When packaging these juices in glass then, it is desirable to get the
temperature of the juice in the range of 35º to 40ºF in the final sections of the cooler,
and in some instances a refrigerated brine solution at temperatures below 32º is used.
If brine is used, a provision to wash the brine off the jars prior to casing will have to be
made.
Other glass packed juices and drinks are normally cooled to a point where the
shake temperature is approximately 100ºF.
In either case, an air dryer is usually incorporated at the discharge end of the
cooler to remove excessive water prior to placing the containers in the cases, and air
jets may also be installed along the conveyor between the cooler and the labeling or
casing area to blow air under the closure and remove the water from this area.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 34
June 2005 December 2005
Job Sheet # 2-1
Job Title : Cooling Finished Product.
Purpose : To cool the containers as rapidly as possible in order to
maintain the maximum color and flavor in the product
Equipment, Tools and
Materials : paper and pen
Precautions : Strictly observe company rules and regulations.
PROCEDURE
1. Visit a fruit processing plant.
2. Observe the cooling process of different canned processed fruits.
a. Jams
b. Jellies
c. Marmalades
d. Fruit Concentrate
3. Evaluate and compare the cooling process of different finished product. How
canned and bottled fruits cooled after processing?
4. Submit all data.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 35
June 2005 December 2005
SELF-CHECK #2-1
A. Enumeration:
1. Name two methods of cooling processed food products.
in tin cans
a.
b.
2. Name the methods of cooling processed food products in glass jars.
a.
b.
c.
B. Explain the cooling process after processing of the following product:
a. Canned apple
b. Canned pineapple
c. Juice drinks in glass container
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 36
June 2005 December 2005
ANSWER KEY #2-1
A. 1. a. air cooling
b. water cooling
2. a. air cooling
b. external water sprays
c. water under pressure
B. Cooling Finished product.
Fruits Cooling Process
Immediately after processing:
a. Apple The cans should be water cooled until the average
temperature of the contents reaches 95º to 105º F.
Casing canned apple slices at high temperatures
may result in softening, loss of normal color or
darkening or pink discoloration of the product.
(stack burn).
b. Pineapple The cans should cooled in cold water after
processing. When using the rotating cooker, the
cans pass from the cooker to a rotating cooler.
c. Juice drinks in glass Some canners pass the cans through a lacquering
containers bath after coming from the cooker. This is done
previous to their passing to the cooler. The
lacquering is used to protect the cans from rusting.
The first section of the spray cooler will have either
tempered water sprays or extremely fine sprays of
cold water which produce a mist or fog. Where
tempered sprays are used, the water temperature
in this first five-minute section should be within 50º
of the filling temperature for containers of one-half
gallon size or larger, or within 60º of the filling
temperature with containers smaller than one-half
gallon. In the second section of the cooler,
successively heavier sprays of cold water can be
used, again maintaining 50º or 60º temperature
differential from the first section as previously
discussed. This second section again should
provide a five-minute cooling period.
With all juices and juice drinks other than
pure citrus juices, the water temperature down the
balance of the cooler will be at the normal plant
water temperature and consists of heavy sprays.
Most orange and grapefruit juice packaged in glass
today is stored and sold under refrigeration. When
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 37
June 2005 December 2005
packaging these juices in glass then, it is desirable
to get the temperature of the juice in the range of
35º to 40ºF in the final sections of the cooler, and in
some instances a refrigerated brine solution at
temperatures below 32º is used. If brine is used, a
provision to wash the brine off the jars prior to
casing will have to be made.
Other glass packed juices and drinks are normally
cooled to a point where the shake temperature is
approximately 100ºF.
In either case, an air dryer is usually incorporated
at the discharge end of the cooler to remove
excessive water prior to placing the containers in
the cases, and air jets may also be installed along
the conveyor between the cooler and the labeling
or casing area to blow air under the closure and
remove the water from this area.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 38
June 2005 December 2005
QUALIFICATION : Food Processing NC III
UNIT OF COMPETENCY : Process Food by Sugar Concentration
MODULE : Preparing the Packaging Materials
LEARNING OUTCOME #3: Wash, sterilize and cool new caps (PVC and plastic).
ASSESSMENT CRITERIA:
1.New caps (PVC and plastic) are washed, sterilized and cooled.
RESOURCES: Tools and Instruments Supplies and Materials
Equipment and Facilities Utility tray
Food tray
Stove / burner Wire basket
Vat
kettle
REFERENCES:
1. Carpio, E. V. 2000. Engineering for Food Technologist. University of the
Philippines:
3. De Leon, S.Y. and Guzman M.P. 1998. Preservation of Philippine Foods, A
Manual of Principles and Procedures.
4. Gonzales, Olympia N., et.al. 1982. Philippine Handbook on Canned Low Acid
Foods. A project of NSDB-NIST and No. 7801. National Institute of Science and
Technology Authority.
5. Hayter, R. 2000. Food Preparation and Cooking. Singapore: Thompson
Learning.
6. Introduction to Agricultural Products and Processing. 1990. Oklahoma:
Department. Of Vocational and Technical Education Curriculum and Materials
Center.
7. Institute of Science and Technology, national Science and Technology Authority.
8. Larousse, J. and Bruce E. Brown. 1997. Food Canning Technology.
9. McSwane, D. N. Rue and R. Linton. 2002. Essentials of Food Safety and
Sanitation. 3rd ed. Singapore: Pearson Education South Asia Pte Ltd.
10. Packaging and Labeling for Processed Foods. 1999. Philippine Trade and
Training Center, Philippines:
11. Philippine Trade and Training Center. 2003. Philippines : Current Good
Manufacturing Practices for the Food Industry/ Establishment.
12. ServSafe Serving Safe Food Course Book. 1999. Food Safety Institute
Foundation, Inc.
.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 39
June 2005 December 2005
Learning Experiences Wash, sterilize and cool new caps (PVC and Plastic)
Learning Outcome #3:
LEARNING ACTIVITIES SPECIAL INSTRUCTIONS
1. Read Information Sheet # 3-1 or View - Information Sheet # 2-1 or Power Point
Power Point Presentation: Presentation:
“Metal Closures” “ Metal Closures”
- Cross Section of - Cross Section of
Lithographed Sheet Lithographed Sheet
- Manufacture - Manufacture
- Resealable Caps - Resealable Caps
- Factors to Consider in - Factors to Consider in
Closure Selection Closure Selection
2. Read Information Sheet #3-2:”Capping - Information Sheet #3-2:”Capping
Operations ( For Juice Processing)” Operations ( For Juice Processing)”
3. Perform Job Sheet #3-1 - Job Sheet #3-1
“Capping Operation” “Capping Operation”
4. Perform: Self-Check #3-1 - Self-Check #3-1
5. Check your answer: Answer Key #3-1 - Answer Key#3-1
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 40
June 2005 December 2005
INFORMATION SHEET #3-1
METAL CLOSURES
Provides security and integrity on the contents of the glass package
Completes the glass package
Enhances the appearance of the package by its design
Types Commonly Manufactured
1.Crowns
2.Resealable caps
TSROPP (Top Side Roll-on Pilfer-Proof)
3.Metal Caps
Continuous Thread (CT) caps
Lug Caps
Pilfer-Proof (PP) caps
Raw Materials/Components
Raw Material (Component) Types Quality Parameters
Metal Sheets Tinplate (TP)* Thickness
Tin-Free Steel (TFS) Hardness
Aluminum Tin Coating*
Coatings External Coating System IR Profile
Internal Coating System GPC Profile
Physical Properties
Performance
Liners/Gaskets Plastics Physical Properties
Opening Torque
Sealing
Adhesion
Inks Physical Properties
Performance
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 41
June 2005 December 2005
CROSS SECTION OF LITOGRAPHED SHEETS
CROWN External Coatings
Operation Tin Coating
Litho Sheets Metal Substrate
Tin Coating
Blanking/Forming Internal Coatings
Lining Quality
Packing Crown Height
Crown Diameter
Flange Angle
Corrosion Resistance
Gasket Weight
Leak Pressure
Sampling
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 42
June 2005 December 2005
MANUFACTURE Quality
LITHOGRAPHY
Operation
Coating Viscosity
Printing DFW
Coating Oven Temperature
Lithographed Sheets
Color
Registration
Oven Temperature
Viscosity
DFW
Oven Temperature
Fabrication Test
Performance
Crown Research Cap Metal Cap
CROWN
Operation Quality
Litho Sheets Crown Height
Crown Diameter
Blanking/Forming Flange Angle
Corrosion Resistance
Lining
Gasket Height
Curing
Temperature
Leak Pressure
Specific Gravity
Tumbling Loss
Sampling
Packing
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 43
June 2005 December 2005
RESEALABLE CAP Blank Height
Operation Blank Diameter
Litho Sheets
Rolled Height
Blanking/Forming
Temperature
Rolling Removal Torque
PAT
Lining/Adhering
Sampling
Packing
METAL CAPS Quality
Operations
Continuous Lug Caps Pilper-Proof
Litho Sheets Thread (CT)
Dimensions Dimensions
Blanking Dimensions Visual Visual
Rolling/Lugging Visual CuSO4 Test
CuSO4 Test Dimensions
Lining Dimensions Visual
Dimensions Visual Opening Torque
Packing Visual CuSO4 Test
CuSO4 Test Visual
Visual Air/ H2O Leak
Visual Capping Test
Capping Test Ethyl Acetate Test
Air/ H2O Leak
Test Sampling
Test Sterilization Inspection
Hot-Fill Test
Sampling
Inspection Sampling
Inspection
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 44
June 2005 December 2005
QUALITY SPECIFICATIONS
I. Composition
Type of Base Metal
Type of Coating
Type of Gasket/Line
II. Design/Type of Closure
Base on Glass Finish
Base on Product
III. Chemical Properties
Product Contact
Processing Conditions
IV. Application Performance
Handling
Processing
Delivery
Customers Use
V. Special Features
Safety
Tamper-Evident
FACTORS TO CONSIDER IN CLOSURE SELECTION
Compatibility with glass container
Compatibility with product
Compatibility with customers operations and end-used
Tamper-evident/Safety Features
Product Image
Availability
Cost
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 45
June 2005 December 2005
COMPARISON BETWEEN COMMON TYPES
Base Metal Continuous Lug Type Roll-on Crown
External Thread Tinplate Pilper-Proof Tinplate, TFS
Coat 2-3 Aluminum 2-3
Internal Coat Tinplate 2-3 1-2
Plastic 2-3 Plastic
Liner 2-3 Material Material
1-2
Glass Finish 1-2 Vacuum Beverage
Lug Pulp Board, Crown
Capping Pulp Board, Plastic
Plastic Material
Type of Seal Material
Made Roll-on
Continuous
Common Thread
Application
Complete Simple Require Require
360 Quarter mechanical crimping
deg. turn. (90 deg.) turn. rollers to machine to
Can be Can be press shell force the
manually or manually or against entire closure
mechanically mechanically contour of against the
applied applied. glass finish. projecting
ring on the
Normal Vacuum Seal Normal and glass finish
Pressure Pressure
Seal Vacuum Seal Pressure
sealing, heat Seal
Dry powders, pasteurized Pmarma-
Liquid foods, and sterilized ceutical Beverages,
Creams, products. beverages, TSP
pastes, chemicals
Viscous
foods, etc.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 46
June 2005 December 2005
INFORMATION SHEET #3-2
Capping Operations ( For Juice Processing)
The steam vacuum capper should be installed in a separate room adjacent to the
sterile filling room. This room need not be sterile but must be kept clean and sanitary.
To protect the sterility of the filled unsealed bottles between the filling and capping
operations, the filler discharge conveyor and the capper in feed conveyor must be
thoroughly shrouded and the conveyor housing must be sealed to the filling room. This
ensures this area will be under a positive pressure of sterile air from the sterile filling
room.
In addition, the capper conveyor must pass through a sanitizing solution to avoid
the possibility of transferring any contamination from this conveyor to the filler conveyor
at the point where they overlap.
A positive hermetic seal is required for the citrus juice, and plastisol lined lug
closures are currently satisfactorily performing this operation. This type of closure can
be successfully sterilized by the use of high-pressure steam. Cap sterilization can also
be achieved by chemical means, although the use of the steam is much simpler.
Provision must also be made for exhausting the excess steam from the capping
operation.
All possible protection must be given the caps themselves to prevent
contamination. They should be supplied to the citrus plant in polyethylene bags in the
shipping cartons. They must be stored in a clean, dry area. Caps should not be left in
the hopper or in the cap chute during periods when the line is down. They must be
removed and stored in polyethylene bags.
The capper must be thoroughly cleaned and sterilized each time the filling room,
filler, and the rest of the equipment are being cleaned and sterilized. It is essential that
the capper be supplied with clean dry steam in order to achieve maximum performance.
Sterility of the cap application area in the capper during operation is maintained by this
steam.
SEALING ( For Glass Packaging Jellies and Preserves )
Immediately after filling, the containers should be sealed with a positive hermetic
seal, which can be a top-side seal closure (normally used on certain types of tumblers),
a lug cap with a plastisol gasket, or a screw cap with a plastisol gasket.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 47
June 2005 December 2005
The top seal or side seal closures, and the lug caps, are normally applied in steam
vacuum sealing equipment. Some producers operate the steam vacuum sealing
equipment at a level to produce a minimum vacuum in the jars at the time of sealing to
minimize possible separation in preserves and also to minimize the size of "bubbles"
which may appear in jellies. Others prefer to operate at higher vacuums to maintain a
better surface color. The capping equipment manufacturers should be consulted for
recommendations in this area.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 48
June 2005 December 2005
JOB SHEET #3-1
Job Title : Capping Operation
Purpose : To understand the methods of capping different bottles and
cans in accordance with manufacturer’s specification
Conditions or
Situations for the Job : Food Processing Plant producing jams, jellies, preserves and
fruit juices.
Equipment, Tools and
Materials : Paper and Pen, Processed Fruit Jellies, Bottles and Caps
Precautions : Observe company policy strictly.
PROCEDURE :
1. Your instructor will provide a list of suppliers/manufacturers of sugar
concentrates like jam, jellies, preserves and fruit juices.
2. From this list select at least three companies and arrange a visit to their
food processing plant.
3. Your instructor or guide will tour the group to the Food Processing Plant.
Please observe company policy strictly. Write down your observations.
4. Check the types of packaging materials these companies are using and the
capping operation.
5. What are the specification of their packaging materials regarding:
a. Washing, sanitizing and sterilization
b. Storage conditions
6. After the industry tour, perform the capping operations with your bottled
processed jellies.
Code No. Preparing the Packaging Materials Date: Developed Date: Revised Page 49
June 2005 December 2005
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