METHODOLOGIES SUGGESTED FOR REDUCING DAMAGES OF THERMOFORM VACUUM PACKAGES AND IMPROVING METHODOLOGIES FOR THE ABOVE

Abstract

Thermoform vacuum packages of pre-cooked meatballs get non-vacuuming conditions in different stages from packaging to consumption. Due to the low resistance of packaging material for stress conditions, humidity, and temperature variations, damages occur during storage, transportation and handling. Because of that vacuum leakage problem arises.Meatball is a processed meat product, which is packed in a polythene polyamide lamination.The objectives of the study were to decrease the physical damage percentage of the thermoform vacuum packages and to find the correct combination of material layering to restrict air and water vapor migration between in and out.Randomly selected 250 thermoform vacuum packages were filled by using a special air pump and immersed In to water basket. Using this method, the damage areas of the thermoform vacuum packages were identified. Then the main factors, which caused the nonvacuuming conditions, were identified and listed out. After that non-vacuumed trade returns were analyzed by using Pareto analysis. The major cause was identified as the punctures of the bottom material. The available bottom material for Skinless chicken and meatball was laminated LDPE nylon. So the bottom material was changed and new material was used. That new material was co extruded LDPE nylon.Under the same condition, using both packaging materials, 500 packets of meatballs were produced Those packets were bundled in to 20 bundles. Those bundles were sent to out station area by using a company truck and received through the same vehicle without unloading. The number of non-vacuumed packets was listed out. Finally overall damage percentages of available material and the changed material were listed out. Those data were statistically analyzed. Then microbiological tests were carried out to check whether it was microbiologically accepted or not. Such tests were carried out to determine the presence of Staphylococcus aureus and Escherichia coli . And also Total Plate Count (TPC ) was determined.Staphylococcus aureus and Escherichia coli were not present at initially and after three weeks. The total plate count was initially 300 cfu/g and after three weeks 300 cfu/g. It is necessary to carry out further studies for microbiological tests. Finally it can be concluded that co extruded LDPE nylon packaging material has higher mechanical strength and resistivity than laminated LDPE nylon packaging material.