A recent report from food consultancy Campden BRI, titled ‘Maximising Shelf Life,’ offers valuable insights on the optimization of packaging and processes to reduce waste and increase shelf life. This is crucial for maintaining consumer confidence while also ensuring product safety and quality. The efficient management of these factors can have a significant impact on the global food system, as food wastage is proven to be a substantial contributor to greenhouse gas emissions. In fact, if food wastage is reduced by half, it could remove around one-quarter of total emissions from the food industry.
Studies conducted by climate-action NGO WRAP have shown that extending the shelf life of products can prevent up to 50% of consumer food waste. To put this into perspective, the World Health Organization estimates that the reversal of food waste globally could provide enough food to feed two billion people. Various preservation techniques, such as microbial profiling, super-chilling, heat pasteurization, and modified atmosphere packaging, can be adopted by food and beverage processors to achieve longer shelf lives. However, with numerous factors to consider, including quality, waste, sensory, taste, and production, finding the most sustainable option for each product can be a challenging task.
To address these complexities, Campden BRI’s report provides a step-by-step approach for food and beverage processors undertaking shelf-life extension projects. The report highlights the assistance that Campden BRI’s scientific processing and packaging experts can offer in uncovering, validating, reviewing, proving, and implementing a shelf-life strategy. Their guidance ensures alignment with individual product applications and compliance with HACCP and country-specific food safety legislation.
While sustainable packaging is a trend many FMCG brands are adopting, the report emphasizes the need to consider risks and unintended consequences. Simply switching to sustainable packaging, composite materials, or plant-based formulations does not guarantee increased shelf life. If the packaging material fails to protect against gases, moisture, light, and microbial contaminants, it can result in shorter shelf life and higher food waste, which ultimately increases the carbon footprint. Therefore, it is essential for manufacturers to ensure that packaging substrates are compatible with the specific requirements of each food and beverage product and suitable for storage conditions while protecting against contamination.
Campden BRI advocates rigorous testing of packaging over the entire shelf life of a product. By conducting comprehensive tests, manufacturers can mitigate the transfer of constituents, maintain pack and seal integrity, and test barrier properties against microorganisms. With the market constantly introducing new packaging materials, this testing is vital in determining compatibility over the product’s shelf life.
The challenge for food manufacturers lies in striking a balance between shelf-life extension and clean labeling. Extended shelf life often requires the use of preservatives and additives, which may deter consumers due to unfamiliar names. However, alternative options can be explored to meet both objectives. For instance, if microbial growth needs to be limited, pH levels can be reduced, a pasteurization step can be added, or natural antioxidants like extract of rosemary can be used. These strategies allow for longer shelf life without sacrificing clean labeling.
In addition to ingredient choices, manufacturers can employ various techniques to lengthen shelf life. For example, ‘superchilling,’ which is the point just before a product starts to freeze, can significantly slow down microbial and chemical spoilage development without affecting sensory attributes. This technique has proven successful for cooked prawn products, leading to longer shelf life and reduced water and electricity use.
Another method, high pressure processing (HPP), can eliminate microorganisms that limit the shelf life of certain products. Innocent Drinks partnered with Campden BRI to implement HPP and improve the shelf life of their beverages.
Furthermore, predictive modeling can be utilized to maintain the delicate balance between shelf life and clean labeling. It involves computer simulations to evaluate microbial growth in food and beverage products. This approach enables effective exploration of different scenarios when developing new products or reformulating existing ones, ensuring the extension of shelf life in a cost-effective manner.
In conclusion, food and beverage processors must optimize packaging and processes to enhance shelf life while reducing waste. With the guidance of Campden BRI’s experts, manufacturers can navigate the complexities associated with shelf-life extension and find sustainable solutions. By considering factors such as packaging compatibility, ingredient choices, and various preservation techniques, businesses can achieve longer shelf lives without compromising product safety or quality. Ultimately, this benefits both the environment and consumer satisfaction.
