Latest trends in packaging of livestock products

Latest trends in packaging of livestock products

 Preeti Pragalva Mohapatra and Annada Das*

Institute of Veterinary Science and Animal Husbandry, Siksha ‘O’ Anusandhan University, Bhubaneswar-751030, Odisha

*Corresponding author e-mail id: dasannada.555@gmail.com

1. Introduction

Packaging is not merely a wrapper, but the gateway through which products enter the lives of the consumers. Packaging extends the shelf life of livestock products, safeguarding them against microbial and chemical contaminants. It enhances consumer appeal, preserves freshness, and facilitates hygienic marketing and transportation. As the final link in the production-consumption chain for livestock products like meat, milk, eggs, and wool, packaging ensures that these products reach consumers in a safe, nourishing, and high-quality form. As the world transitions into an innovative and scientific era, the expertise and enthusiasm of professionals are also advancing to remarkable heights, paving the way for a more reliable, enduring, and promising future trends in packaging of livestock products. Consumers today prefer food packaging with fewer synthetic additives, opting for safer and environmentally friendly materials. Nano-composite films, blended solutions of packaging biomaterials, and non-toxic active packaging materials are considered great alternatives to synthetic plastic films due to their comparable or lower cost, availability, and biodegradability. Advancements in food packaging have incorporated nanotechnology, significantly improving the barrier and mechanical properties of the films, enhancing antimicrobial and antioxidant properties, including sensors, improving biodegradability, and expanding functionalities. Packaging materials with improved properties like flexibility, water and gas barrier, mechanical structure and thermal properties, active and intelligent packaging with antimicrobial or oxygen-scavenging particles, biosensors for microbial and biochemical changes, antioxidant release and flavouring to extend shelf life, and biodegradable polymer composites with inorganic particles like clay in the biopolymeric matrix are the latest methods of livestock products’ packaging. Bio-nanocompostites (polysaccharide, lipid or protein-based) have good mechanical, thermal, biodegradable, chemical resistance, antimicrobial and gas barrier properties and are biodegradable and low-cost, attracting food scientists. Novel techniques and improvements expand nanotechnology science and functionality, helping to design packaging that detects spoilage or contamination, informs consumers, studies opportunities and problems, and predicts market trends. Sustainable or bio-based packaging has become the talk of the town in the recent past due to environmental and health concerns. The food packaging industry has shifted from conventional to functional, active, intelligent/smart, sustainable and tech-enabled solutions. It provides reliable and trustworthy packaging solutions to consumers.

The various conventional and novel packaging methods utilized for different livestock products are given in Figure 1.Figure 1. Different packaging methods for livestock products.

2. Traditional packaging methods

• Aerobic packaging

Aerobic packaging involves wrapping the product, often on a tray, with a plastic film that allows for the exchange of oxygen and other gases with the surrounding atmosphere. Aerobic packaging, specifically designed for raw meat, is encased in stretch film on polystyrene (PS) foam trays. The film materials employed in aerobic packaging encompass cellophane, polyethylene, and synthetic polymers. This packaging is permeable to gases, thereby providing hygienic protection without compromising the shelf-life, and maintains the visual appeal of the product due to formation of the bright red oxymyoglobin pigment or ‘bloom’. The refrigerated shelf-life of the aerobically packaged meat is approximately 5 to 7 days.

2.2. Vacuum packaging:

Vacuum packaging (VP) is a preservation technique that eliminates air from the package environment. The process entails placing the product in a vacuum chamber equipped with a vacuum pump to extract air. Although the equipment cannot completely remove air, it can practically eliminate 75-85% or a maximum of 90%. VP offers several advantages, including an extended shelf life, protection against external hazards, and improved handling. Skin-type vacuum packaging, as used in ‘Cryovac’ bags, adheres the plastic material to the product, ensuring a complete seal. VP is employed for a diverse range of products, while Cryovac is primarily utilized for Vienna sausages, cotechino, and cooked ham. Advanced vacuum skin packaging heats an upper film prior to applying it to the meat’s surface, thereby inactivating bacteria and extending the shelf life. Close contact with the surface prevents the accumulation of air and wrinkles, further extending the shelf life and inhibiting bacterial growth. Lactobacillus spp. is the major cause of spoilage of VP meat.

 2.3. Modified Atmospheric Packaging (MAP)

Modified atmosphere packaging (MAP) is the practice of modifying the composition of the internal atmosphere of a package in order to improve the shelf life. Gases such as carbon dioxide (to reduce microbial spoilage), nitrogen (as an inert filler), and oxygen (for maintaining the bright red colour or bloom)) are utilized. These gases play a crucial role in controlling oxidative rancidity, preventing product spoilage, reducing freezer burn defects in meat and meat products, and extending the shelf life of the product. Notably, this process extends the shelf life of cheese and ready-to-eat items up to 45 days. Nitrogen and Carbon dioxide gases are used in the ratio 50:50 or 60:40 in the MAP of poultry meat. Nitrogen, Carbon dioxide, and Oxygen are used in the ratio of 70:20:10 in the MAP of pork and red meats like beef and mutton. Lactobacillus spp. causes a spoilage called “green cores” in MAP meat on prolonged storage.

           Controlled atmospheric packaging (CAP) is implemented under continuous monitoring and adjustment of gas levels, making it an ideal solution for bulk storage. CAP entails intentionally controlling the package atmosphere after air evacuation (<1%O2 level) to maintain a consistent level during the product’s lifespan. Shelf life of cured meat under CAP is 3 months. Unlike Modified Atmosphere Packaging (MAP), which creates a single, static atmosphere, CAP systems actively regulate the gas composition, often with the help of special packaging films and sensors that enable real-time control and adjustments. This leads to a significantly longer storage life and maintains the raw meat’s color, flavor, and eating quality. 

• Limitations of conventional packaging methods

Traditional packaging, primarily designed as containers, presents limitations in contemporary food safety, preservation, and sustainability requirements as given below:

1. Short shelf life:Conventional packaging expedites spoilage due to oxygen permeation, moisture absorption and release, and light penetration.
2. Passive protection:Traditional packaging is deficient in antimicrobial, antioxidant, or freshness-retaining properties, making perishables vulnerable to contamination.

• Limited intelligence and communication:In contrast to intelligent packaging, conventional systems lack the capability to communicate freshness, detect temperature deviations, or provide traceability. They solely rely on expiry dates that may not accurately reflect the product’s actual quality.

1. Weak barrier properties:Materials such as low-density plastics or coated papers are ineffective in preventing microbial invasion, odour emission, and UV radiation, leading to accelerated deterioration and loss of nutritional and sensory qualities.
2. Bulky and fragile:Glass and tin are heavy, fragile, and expensive to transport, reducing their practicality in the contemporary fast-paced food supply chain.
3. Environmental burden:Conventional plastics and foils exhibit resistance to degradation, contributing to pollution levels. Eco-conscious consumers and industries increasingly perceive them as unsustainable.

• Hygiene concerns:Reusable glass bottles or tin cans can harbour contamination if not properly sterilized, and chemical leaching from low-grade plastics into milk or meat raises safety concerns.
• Outdated consumer appeal:Simple bottles, cans, or bags lack contemporary features such as tamper-evidence, transparency, limited labelling space, and limited marketing value, failing to engage consumers who seek convenience and assurance.

3. Novel and functional packaging methods

 3.1. Active Packaging (AP)

It involves a process of adding additives to the packaging films that interact with the product to enhance it’s shelf life and keeping quality by combatting deterioration of the product. On a gross scale, it is divided into 3 classes: absorbing AP, releasing AP, and other AP.

Absorbing AP is sub-classified as oxygen absorbers, carbon dioxide absorbers, ethylene absorbers, humidity absorbers, absorbers of any off flavours, lactose and cholesterol removers. Releasing AP is classified as carbon dioxide emitters, ethanol emitters, anti-microbial releasers and antioxidant release.

Others include self-heating aluminium or steel cans.

3.1.1. Oxygen absorbers: Oxygen absorbers are employed to eliminate oxygen from the internal environment of packaged products. The materials commonly used in their production include iron, sulphites, boron, photosensitive dyes, and enzymes.When glucose oxidase is incorporated into probiotic yoghurt, it maintains a low level of dissolved oxygen and preserves cell viability until the 21st day of refrigeration. Notably, commercially available oxygen absorbers include Ageless, Fresilizer, Bioka, and Vitalon, etc.

3.1.2. Carbon dioxide absorbers/scavengers: They reduce the amount of carbon dioxide in the package (if not, may burst it under storage conditions). Materials used are CaOH, NaOH, KOH, CaO and silica. It is practically used in battered goods, cheese and coffee.

3.1.3. Ethylene absorbers: Ethylene is prime gas causing for early ripening and reducing shelf life of the product. To combat this, ethylene absorbers are used. Materials like potassium permanganate, activated carbon, zeolites and metal catalysts are used for this purpose. It extends shelf life of cheese up to 36 days.

3.1.4. Moisture absorbers/Hygroscopic agents: Deliquescent salts, salts of silica gel, natural clay, molecular sieves, humectants, modified starch, CaO and calcium chloride are employed.

3.1.5. Off-flavour absorption: Cellulose, triacetate, acetylated paper, ferrous salts, activated carbon clays, zeolites, and citric acid are utilized for any off-flavour absorption.

3.1.6. Lactose and cholesterol removal: For lactose-intolerant individuals, active packaging materials such as the incorporation of beta-galactosidase with LDPE films prove beneficial. Immobilized cholesterol reductase is used to reduce the cholesterol content.

3.1.7. Carbon dioxide emitters: Carbon dioxide emitters are extensively utilized in muscle food products that contain high carbon dioxide levels, ranging from approximately 10% to 80%. Their mechanism of action is based on the interaction of these products with ferrous carbonate, ascorbic acid, or sodium hydrogen carbonate. Notably, commercially available carbon dioxide emitters include Ageless and FreshFox, manufactured by Mitsubishi Gas Chemical Co. in Japan.

3.1.8. Ethanol emitters: Ethanol emitters, such as Ethicap, are widely used in the food industry. Ethanol denatures the proteins of molds and yeast at higher temperatures, inhibiting their growth and development. Additionally, ethanol possesses antimicrobial and anti-fungal properties, making it an effective preservative. Commercially, Ethicap is extensively used in the production of cakes and breads, extending their shelf life to up to 24 days.

 3.2. Intelligent Packaging

 This packaging type utilizes various indicators, such as freshness, leak, temperature, and radio frequency identification (RFID) tags, as well as biosensors, to convey product quality information. Its primary objectives are to enhance product safety, improve its shelf life, and provide timely warnings about potential issues.

3.2.1. Oxygen indicators visually represent variations in oxygen levels by undergoing a colour change, primarily as a result of chemical or enzymatic reactions.

3.2.2. Freshness indicators quantify the extent of deterioration or loss of freshness in packaged goods. Their measurement solely relies on the spoilage compounds, such as sulphides, amides, and volatile basic nitrogen, produced by the sample. In commercial settings, diacetyl amine, carbon dioxide, ammonia, and hydrogen sulphide are commonly employed as freshness indicators. Notably, the freshness of the renowned Korean fermented dish, Kimchi, is assessed using bromocresol purple or methyl red.  Nowadays, E-noses have a widespread application in these developing industries, as they sense the presence of trimethylamine in the raw food. Curcumin and carrageenan can be employed to accurately determine the freshness of food products. The freshness of fish products is detected using cresol red in conjunction with bromocresol purple. Carbon nanotubes have been developed to ascertain the presence of carbon dioxide, amines, and volatile sulphides within packaged food.

3.2.3. Time temperature indicators are also known as TTIs, they show irreversible change in physical/chemical/enzymatic/or microbial changes with respect to the preset temperatures. TTIs inform the consumer if the product is maintained at required temperature throughout the transport and storage. It detects pH changes, polymerization changes and acid base reactions. Commercially available TTIs are Monitor Mark™by 3M (USA), Fresh-Check® by Lifelines Technologies Inc.(USA), CoolVu™,OnVu™ by Freshpoint (Switzerland), Checkpoint® by Vitsab International AB (Sweden), etc. Microwave doneness indicators are employed in ready-to-serve food products, particularly poultry products.

3.2.4. pH indicators undergo alterations in response to the acidity or alkalinity of the environment. pH-sensitive chitosan has been developed using dyes extracted from Bauhinia Blakeana Dunn flower. When chitosan and polyvinyl alcohol are infused with anthocyanin extracted from red cabbage and sweet potato, they function as pH indicators for pork belly slices. Alizarin infused with chitosan detects fish deterioration. Jamun extract and nutmeg oil, when infused with polyvinyl alcohol films, detect pH changes in meat cut parts. Titanium oxide nanoparticles act as pH indicators for salmon meat.

3.2.5. Biosensors offer a promising and innovative technology for the development of future intelligent packaging systems. Their versatility stems from their ability to measure a wide spectrum of physical and chemical parameters associated with food. The primary components of biosensors include biological compounds such as enzymes, antibodies, antigens, phages, and nucleic acids. These components enable sensors to detect parameters such as light, pH, temperature, mechanical force, electric field, metabolites, or solvent composition. The hydrophilic and hydrophobic states of the materials employed by these sensors facilitate this detection process. Nanomaterials consisting of titanium oxide, silicon oxide, graphene, and nanocellusose exhibit high catalytic activity and conductivity, making them excellent biosensors. Graphene nanofibres are particularly flexible detectors of ethanol. Commercially available biosensors include ToxinGuard by Toxin Alert & Food Sentinel System.

3.2.6. Radio frequency identification (RFID) tags utilize radio waves to track items wirelessly, ensuring the product’s quality and freshness. However, this method is highly cost-effective and is operated by expert personnel as it is solely based on data and computerized.

Bio-based, bio-degradable and edible films:

Ecofriendly packaging includes biodegradable packaging materials such as starch, protein, polylactic acid plastic, cellulose, methyl cellulose, carboxymethylcellulose, etc. Biopolymers refer to packaging films derived from plant sources. Sustainable biopolymers such as chitosan, guar gum, and starch have been experimented as compatible and safe alternatives for synthetic packaging food materials.  Edible coatings are composed of hydrocolloids derived from plant or animal proteins, polysaccharides, lipids, or synthetic polymers.

Chitosan is obtained from the exoskeleton of crustaceans. Polylactic acid (PLA) is derived from the catalyzed polymerization of lactic acid monomers. It has been discovered that fresh chicken meat’s shelf life in refrigerators can be significantly extended for a period of 12 days by employing an edible film composed of chitosan. Chitosan edible film has also demonstrated inhibitory effects on the growth of Listeria monocytogenes and Escherichia coli on the surface of meat. Furthermore, incorporating chitosan into the production of edible films at concentrations between 0.5 and 1.5% results in meat products that do not exhibit any unpleasant odours even after a prolonged storage period of 9 days at temperatures between 4 and 7 degrees Celsius. Quercetin is a bio-flavonoid abundantly prevalent in onion, broccoli, and grapes. Combining all as Quercetin entrapped in PLA enhances the bioactivity and stability of the product. Edible films made of soy protein can reduce sausage weight loss. These films have denser characteristics, preserving evaporated water during storage. The protective action of a soy protein coating preserves the attractive red colour of hog meat. Japanese meat industries utilized collagen-based films for meat packaging. During processing, these coatings dissolve and integrate with the meat, resulting in a remarkable positive impact on texture. Additionally, they reduce weight loss and ensure high yields. Biodegradable packaging materials are also healthier, eco-friendly and sustainable alternatives to synthetic packaging,

Antimicrobial and Antioxidant packaging:

Antimicrobial releasing systems operate based on the principle of extending the lag phase and thereby reducing the log phase of microorganisms. Agents such as anhydrides, antibiotics, bactericides, and polysaccharides are employed in their implementation. Notably, commercially available antimicrobial systems include AgIONTM, Zeomic, and MicroGard TM. Antioxidant-releasing systems inhibit the initiation and propagation of chain reactions or suppress the formation of free radicals. In the food industry, polyphenols, ascorbic acid, tocopherol, BHA, BHT, and aromatic plants are utilised as antioxidant-releasing systems.

Science never renounces its traditional foundations; packaging has progressed by incorporating plant-based bioactive materials into polymers. Notably, essential oils have garnered significant attention. In the meat industry, antimicrobial and antioxidant-releasing systems employ essential oils, alpha-tocopherol, vitamins, phenolic compounds, nisin, curcumin, plant extracts, BHA, BHT, and organic acids. Thymol, extracted from thyme oil, is renowned for its high volatility and hydrophobic properties. When encapsulated with gelatine nanofibres in packaging, thymol exhibited a remarkable reduction in the growth of aerobic bacterial counts, nitrogen load, TBA, and trimethylamine content in poultry meat. Cinnamaldehyde (3-phenyl-2-propenal), extracted from cinnamon oil, exhibits bactericidal properties against Staphylococcus aureus PTCC 1337 and Escherichia coli O157:H7 when incorporated into Zein nano-fibre packaging. Tea tree oil extract incorporated with nano fibres packaging for chicken meat has caused inhibition of growth of Salmonella spp upto 99.99%. Pomegranate peel extract when electrospunned with chitosan for packaging of beef has delayed lipid oxidation activity. Rosemary extract when employed with LDPE of pork patties delay the lipid oxidation.

Application of Nanotechnology in packaging of livestock products:

Nanotechnology, the precise control of matter at the molecular level, enables the creation of tailored packaging materials. Nano composites and nano films have profoundly transformed the marketing landscape. Nanosensors have revolutionized the detection of pathogens. Sweden’s ‘BIOETT’ optical sensor provides highly accurate temperature measurements of products. Canada’s Flex Alert optical sensor detects toxins in packaged food products. Nanotechnology utilizes materials ranging from 1 nanometre to 100 nanometres in size. A common preservation technique involves enriching the oxygen barrier within nanolaminates or nanocomposites of liquid nanocrystal-enriched polymer films. These particles effectively block oxygen, moisture, and carbon dioxide, thereby mitigating adverse effects on dairy and meat products. Consequently, they enhance the shelf life of these products, reduce their weight, and improve their heat retention capabilities. Silver-based nanoparticles, endowed with antimicrobial, self-sterilizing, and bactericidal properties, are incorporated into polymer mixtures for moulding into plastic packaging components. These nanoparticles extend the shelf life of milk by 30 days at room temperature. Nanocoatings consist of multiple chemically and physically bound layers with nanometric dimensions and various advantageous properties.

Nanotechnology in meat packaging presents promising advancements in mechanical properties and novel roles, including antimicrobial, biodegradable, and thermal processing resistance. In the retail meat industry, absorbent pads are commonly employed to preserve freshness and prevent unsanitary juices. Additionally, silver, titanium dioxide (TiO2), tungsten trioxide (WO3), and zinc oxide (ZnO) are utilized for packaging purposes. Nanoclay, specifically montmorillonite (MMT), is an affordable and versatile material characterized by a translucent clay polymer structure.

Electrospinning is a versatile nanotechnology that enables the production of non-woven nano-fibre films. This method offers several notable advantages, including an increased surface-area-volume ratio, enhanced porosity, reduced inter-fibrous pore size, and decreased gas permeability. Zein-based coatings are particularly well-suited for packaging applications. Curcumin-loaded nanofibres possess the capability to monitor chicken spoilage within the packaging environment. This technique holds significant promise in the field of functional food products and active packaging.

Ecofriendly packaging includes biodegradable packaging materials such as starch, protein, polylactic acid plastic, cellulose, methyl cellulose, carboxymethylcellulose, etc.

Future Perspectives

Packaging has transformed from a passive tool to a dynamic component, ensuring the safety, quality, traceability, and sustainability of livestock products. Technological advancements and veterinary science will drive innovative, environmentally conscious, and consumer-centric approaches. Emerging technologies such as biosensors, RFID tags, and QR-enabled labels will monitor freshness, microbial load, and storage conditions, thereby ensuring product authenticity, tracking supply chains, and fostering consumer confidence. Future packaging systems will incorporate antimicrobial films, oxygen absorbers, and enzyme-based preservatives to mitigate spoilage and zoonotic pathogens, minimizing chemical additives and upholding enhanced food safety standards. Sustainability will drive the adoption of bioplastics, edible coatings, and biodegradable films derived from agricultural and animal by-products, aligning with circular bio-economy principles and reducing environmental pollution associated with conventional plastics. Nano-engineered packaging films with superior barrier properties, controlled-release antimicrobial agents, and nano-sensors will revolutionize meat, milk, egg, and fish preservation. Future packaging will function as a digital identity card for livestock products, with blockchain-linked QR codes verifying veterinary certifications, disease-free status, and cold-chain integrity from farm to fork, thereby enhancing transparency and accountability. Temperature-sensitive indicators and phase-change material-based packaging will enhance cold-chain logistics, ensuring the storage of veterinary-recommended conditions for perishable products such as meat and milk, thereby reducing post-harvest losses. Future packaging will prioritize food safety and convenience, incorporating portion-controlled packs, resealable pouches, and nutrient-labelled smart displays that support the “One Health” approach.

Conclusion

The integration of advanced technology and food packaging presents a transformative potential, revolutionizing our perception, interaction, and consumption of food. This transformation offers benefits to both industrialists and consumers.

Advancements in packaging materials improve functionality, extend shelf life, and ensure product safety.

Various technologies, including nanotechnology, antimicrobial, and antioxidant-active packaging, have been employed to ensure food microbial safety, reduce oxidation, and extend shelf life. However, nanotechnology, a relatively novel and modernized term and practice, requires further exploration and understanding, especially on consumer safety aspects

Certain technologies aim to create environmentally friendly packaging options, such as biodegradable and compostable materials.

The latest trends in livestock products’ packaging are steadily moving towards sustainability, safety, and smart technologies, ensuring longer shelf life and consumer trust. With innovations like nanotechnology, active and intelligent packaging, and Internet of Things (IoT)-enabled traceability, the future of packaging will not only protect products but also empower consumers with greater transparency and confidence.

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