Dasar pengemasan pangan
Kuliah ITP
Pengemasan pangan • Modul ini akan memberikan gambaran mengenai pengemasan pangan hampir semua pangan dikemas. • Jenis dan mutu pengemas tergantung kepada: – – – – –
Jenis produk Umur simpan Biaya Segmen pasar: kaya /miskin, industri /rumah tangga Fungsi pengemas
• Modul ini akan memberikan overview tentang pengemasan pangan dan jenis pengemas yang saat ini ada serta fungsi pengemas. • Sekali-sekali, pelajarilah bermacam jenis pengemas yang ada di supermarket. Belilah beberapa produk dan pelajarilah di rumah • Jawablah pertanyaan : Mengapa jenis pengemas itu yang dipakai? • Ini akan menambah ketertarikan anda
Definisi pengemasan pangan • Australian Institute of Packaging – Packaging is 'The preparation of goods for shipment and marketing' – Pengemasan adalah penyiapan produk untuk pengiriman dan pemasaran
• Robertson, G. 'An Introduction to Packaging for Food Technologists' – 'Packaging is the protection of foods by means of containers designed to prevent damage to the foods by outside influence.‘ – Pengemasan adalah perlindungan terhadap makanan dlam arti wadah yang didesain untuk mencegah kerusakan karena pengaruh luar
• Mason, R.L. – 'Packaging is the Protection of Foods from Outside Influence and the Preparation of these Foods for Shipment and Marketing' – Pengemasan adalah perlindungan terhadap makanan dari pengaruh luar dan penyiapan produk untuk pengiriman dan pemasaran
Nilai penting pengemasan (Australia) • Pengemasan makanan penting karena: – Nilai industri $7.5 milyar – Pekerja 65 000 orang – Industri meliputi industri konverter, industri bahan mentah, yang mampu pula memproduksi pengemas untuk non makanan – 66% dari kemasan yang beredar adalah kemasan makanan
• Pengguna utama kemasan makanan: – – – – – –
Bir14% Softdrinks10% SUSU 9% Buah dan sayur 7.5% Aneka daging 4.5% roti 3.5%
• Hampir semua makanan dikemas
Fungsi pengemasan • • • • • •
Mengawetkan : kotak kemasan jus Melindungi : karton wadah telur Wadah : wadah cemplon Kenyamanan pengguna : teh celup Sarana komunikasi : label Mempermudah penanganan : karton wadah susu, kaleng Coba cari contoh yang lain!
1. Fungsi pengawetan • Pengemasan : komponen utama pengawetan makanan • Proses seperti pemanasan, pembekuan, dll takkan mampu mempertahankan sifat makanan tanpa pengemasan yang baik dan efektif • Pengemasan dapat dilakukan sebelum, saat dan atau setelah proses selesai • Jadi Preserve = Process + Package
Preservation
2. Fungsi Pelindung 2.1. Kerusakan fisik menyebabkan hilangnya produk dan mengurangi umur simpan 2.2. Kontaminasi menyebabkan timbulnya racun dan membawa resiko terhadap kesehatan 2.3. Perpindahan air menyebabkan hilangnya mutu produk dan meningkatnya masalah mikroorganisme 2.4. Perubahan kimia mempengaruhi mutu dan masa simpan
2.1 Kerusakan fisik menyebabkan hilangnya produk dan mengurangi umur simpan • 60 juta butir telur rusak di China tahun 2006 karena kurang baiknya pengemasan • Buah dan sayur rusak (mungkin hanya terbentur berubah warna) selama transportasi • In Japan, apples are sold in individual boxes to prevent damage • Kaleng yang rusak menyebabkan kebocoran pada seam • Transport is a major cause of physical damage due to: – Compression (tekanan) – Vibration (getaran) – Impact (benturan)
2.2 Kontaminasi menyebabkan timbulnya racun dan membawa resiko terhadap kesehatan
• Tanah, debu, serangga, tikus adalah sumbernya • Microorganisms cause spoilage and illness • 'Pilfer Evident' closures were developed to indicate tampering • Pengemas/seal yang tamper evident bisa menjadi indikator tamper (perubahan yang tidak dikehendaki)
Tamper evident • Tamper-evident describes a device or process that makes unauthorized access to the protected object easily detected. • Seals, markings or other techniques may be tamper indicating.
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Tamper-evident design is perhaps most visible in the area of product packaging and labelling, where it can be vital to know that the product has not been altered since it left the manufacturer. Cans of baby-food were among the first high-profile cases, where manufacturers were blackmailed by persons claiming to have added various poisons to baby-food, and replaced them on supermarket shelves. The amount of stock which needed to be destroyed (because it was impossible to tell if a given item had been tampered with) and the threat of public fear, meant that tamper-evident design principles had the potential to save a lot of money in future. Jars of food items soon started appearing with metal bubble-top lids commonly known as a "safety button" which popped out if the jar had ever been opened, and stayed flat if the jar was in pristine condition. Customers were advised to never buy a product with a popped lid. (These lids would also pop out if the jar was contaminated by gas-producing bacteria, which was an additional safety feature). Presumably the seal was achieved by packaging the jars in a low-pressure atmosphere, although companies were reluctant to divulge details. Soon after, the BBC demonstrated that such tamper-resistant jars could indeed be reclosed with their seals intact, and this spurred more robust designs.
• Newer jars of food tend to come with a plastic wrap around the edge of the lid, which is removed when opening, although the springy-cap designs are still in common use. • The Tylenol Crisis of 1982 involved over-the-counter medications. Due to FDA regulations, many manufacturers of food and medicine (as well as other products) now use induction sealing and other special means to help provide evidence of tampering. Break-away components which cannot be reattached are useful. Custom seals, tapes, labels, RFID tags, etc. are sometimes added. • Packaging that tears open raggedly or otherwise cannot be resealed is sometimes used to help indicate tampering. • Often multiple layers or redundant indicators are used because no single layer or device is "tamper-proof". Consider unique custom indicators (change regularly because these are subject to counterfeiting). • End-users and consumers need to be educated to watch for signs of tampering, both at the primary means of entrance and at secondary or "back door" locations on a package
2.3 Perpindahan air menyebabkan hilangnya mutu produk dan meningkatnya masalah mikroorganisme
2.4. Perubahan kimia mempengaruhi mutu dan masa simpan • Oxidation (rancidity) atau ketengikan disebabkan terpaparnya produk oleh: – – – –
H2O Cahaya O2 Temperatur
• Hilangnya volatile flavours melalui pengemas akan mengurangi kualitas • Off-flavours dan pencemar yang mampu melewati pengemas akan merusak produk
3. Sebagai wadah • Kemasan didesain untuk memberikan batas fisik yang menunjukkan jumlah/isi produk – Makanan terkemas (mestinya) menunjukkan volume atau berat produk – Hati2, Over packaging menyebabkan pemborosan dan sampah yang lebih banyak – Ingat, kemasan juga bisa menipu! Kelihatannya masih bagus padahal tidak
4. Kenyamanan pengguna • Masyarakat menghendaki kemasan yang memudahkan mereka menyiapkan dan menyantap makanan lebih cepat dan nyaman, misal: • Kemasan yang bisa dioven
• Aerosol untuk mengeluarkan krim, topping • Portion packs (teh, kopi) • Penutup yang mudah dibuka
5. Sarana komunikasi • Memberi info kepada konsumen – Ada yang wajib ada yang murni untuk marketing
• Info di kemasan: – Identitas produk
– Nama dan alamat pabrik – Kuantitas : berat atau ukuran – Harga (per unit atau per satuan berat) : di beberapa negara wajib – Ingredients (bahan) – Informasi nilai gizi – Kedaluwarsa – Label asal negara – Dll (klaim, peringatan, cara penggunaan dll)
Contoh • Ambil satu kemasan makanan, amati!
6. Kemudahan penanganan • Penanganan saat transportasi, display dan penanganan oleh konsumen • Kemasan harus memastikan kualitas produk bertahan sampai di tangan konsumen • Hal2 yang terkait dengan fungsi ini misal adalah penggunaan: – – – –
Wadah karton Shrink wrapping Palet Container untuk bulk transport
Hal2 yang wajib diingat dan diperhatikan • Kemasan bisa menipu (buruk terlihat bagus atau bagus terlihat buruk) • Over packaging: menggunaakan kemasan yang berlebihan baik ukuran maupun jenis • Isu lingkungan: CFC (utk aerosol), plastik, daur ulang dan penggunaan kembali kemasan • Biaya kemasan bisa sangat mahal • Interaksi kemasan dengan makanan
Interaksi kemasan dan makanan • Korosi kaleng tinplate : meningkatkan kadar logam menyebabkan kerusakan warna • Migrasi monomer plastik pada makanan
Tingkatan pengemas
Bahan Pengemas • Logam : kaleng tinplate, kaleng alumunium, wadah Al yang lain, baki Al, Al foil
• Kaca: gelas, jar, botol
• Kertas: kertas, karton, kardus, tetrapak (kombinasi karton, plastik dan Al)
Layer pada tetrapak
• Plastik : fleksibel (kantong dan laminate) dan semi rigid (botol, jar atau baki)
Kaca Advantages • Transparent .. allows the product to be seen which assists in marketing attractive products • Inert ..glass is completely inert to all food components so there is no chance of product tainting from contact with glass or container breakdown • Strong .. will resist puncture damage • Resealable .. glass closure enable the package to be resealed to protect the contents • Reusable ..glass bottles (beer and milk) can be washed and reused several times. However, this is largely been replaced by recycling as washing is too expensive. • Recyclable .. 30% of raw materials for glass manufacture is recycled glass or cullet. –
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http://www.gpi.org/recycling/
Retortable .. can be thermally processed as long as it is done under water. Easy to open .. in principle this is true but can be difficult with some closures Raw materials – –
abundant.. there's plenty of sand cheap. there's plenty of sand
Kaca Disadvantages • Easily broken .. this is a major disadvantage for glass especially with the trend to reduce weight to keep it cost competitive with the alternate light weight materials such as aluminium and plastic. • Manufacturing costs high ..sand is cheap but melting it at 1500oC is very expensive. • Heavy .. even light weight glass is heavy so transport costs are high and glass plants are not found outside capital cities so it usually must be transported long distances. For example the original glass Coke Bottle contained 185mL and weighed 366g while the new glass Coke Bottle contains 300mL and weighs only 220g. • Transparent ..while an advantage, it also allows light to enter and increase the incidence of oxidation (rancidity) which is why the glass milk bottle lost out to plastic and paperboard. • Thermal shock ..glass does not have good resistance to thermal shock unless treated so breakage is a problem if heated and cooled rapidly • Not biodegradable ..it is inert so it never biodegrades • Shape Limitations.. the glass making process is continuous so changing moulds for different shapes is not economical unless large volumes are produced such as beer bottles. That is why small manufacturers only have access to "generic shapes" eg juice bottles. • Must process under water to minimise thermal shock and breakage.
Plastik • • • • • • • •
Permeability to H20, O2, N2, CO2, Volatiles Dimensional stability as affected by temperature and RH Temperature range for use (freeze/boil) for cook /chill products Ability to seal. Some plastics cannot be heat sealed (eg nylon) so this makes them unsuitable for form-fill-seal applications unless the film is laminated to something that does such as PE. Resistance to migration of fats and oils. PVC is very good for this. Wet and dry strength. Some plastics change properties if wet Tear, puncture and crease resistance. Nylon and PET are very strong plastics but LDPE is not. Try to tear up a pair of "Nylon" stockings compared to a common plastic bag? Reaction to UV radiation. Some plastics decompose if exposed to UV radiation. PVC is a good example unless it is stabilised. That's why cheap plastic buckets crack if left outside.
Plastik •
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Free from odours and flavours. Tainting from plastic odours is a problem. Just think of the smell in a new car (PVC) and think what this would do to a food? Appearance and feel (clarity) varies between plastics. PET is clear like glass while HDPE is opaque. Printability of plastics varies from impossible to easy. Cost varies dramatically depending on properties. The cheaper the plastic the less positive properties. LDPE is the cheapest plastic but has little barrier against migration of water vapour or oxygen but it heat seal well. PET and Nylon have excellent barrier properties but are expensive and don't heat seal. Laminate two of these and you have a cheaper plastic with good barrier properties. Recyclability of plastics is increasing but most cannot be reused for food contact because all the fillers and additives may be exposed. Most get recycled into carpet and other plastic furniture. New processes are being developed to make recycled food grade plastics. Toxicity of plastics is an issue. Vinyl chloride from which PVC is made is a carcinogen. It was banned in the US for many years until residue levels were considered safe. FSANZ has limits on residual monomer units for plastics.
Kertas Paper Advantages • Many types and grades • Can be coated, and laminated to other papers, plastics and foil • Opaque which prevents light penetration and reduces oxidative changes • Light weight so transport costs are low • Transported as rolls or flat blanks which can be formed in packages on site • Good temperature stability • Recyclable see http://www.tappi.org/paperu/all_about_paper/earth_answers/Recycle1.htm • Cheap to produce so make an ideal substrate to laminate more expensive materials that have improved barrier properties • Many uses from simple paper bags to complex materials such as those used in aseptic packaging that have up to seven laminated layers. • Easily printed with high quality graphics
Kertas Paper Disadvantages • Lacks strength and can be easily torn and punctured • Lacks rigidity • High permeability to moisture, gases, odours and vapours • Pollution problems in manufacture due to large volumes of water used and chemicals.
Alumunium Advantages • Safe • Easy to fabricate - soft • Light weight/steel/glass • Good appearance/graphics • Corrosion resistant (except H+) • Recyclable (> 60%) • Does not stain • Many uses • Excellent barrier properties (O2, H2O, CO2) Disadvantages • Lacks strength • Cannot solder or weld (therefore need new equipment) • Bleaches some products • Must lacquer or laminate • Biaya transportasi kaleng kosong sangat mahal
