Packaging

Department of Food Science and Technology University of Sri Jayawardenapura M.Sc. in Food Science and Technology

Export Packaging of fish to Europe

Name of the Student : W.D.M.S.Thilakarathne Student Number

: ( MFS/351

)

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Content 01. What is packaging ( History )………………………………………………… 3 02. The Role of Packaging…………………………………………………………. 3 03. Packaging Type ………………………………………………………………. 4-7 04. Packaging Materials …………………………………………………………… 8-11 05. Packaging For The Global Market…………………………………………… 11-13 06. Key products and varieties …………………………………………………… 13-14 07. Products that export from Sri lanka to Europe / Packaging materials for chilled fish 14-17 08. Packaging materials that Sri Lankan exporters used …………………… 17-23 09. Eu Rules and regulations for export fish to European countries ……… 23-24 10. Global supply and demand ………………………………………………… 24-25 11. Packaging methods that use other countries …………………………… 25-32 12. Reference ……………………………………………………………………… 32

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01. What is Packaging ( History ) The principal roles of food packaging are to protect food products from outside influences and damage, to contain the food, and to provide consumers with ingredient and nutritional information .Traceability, convenience, and tamper indication are secondary functions of increasing importance. The goal of food packaging is to contain food in a cost-effective way that satisfies industry requirements and consumer desires, maintains food safety, and minimizes environmental impact.

02. The Role of Packaging Quality assurance is essential in each technological process, and suitable packaging materials and methods are of great importance. If these requirements are not met all efforts made during processing could be of useless which could lead to serious economic losses. Packaging should protect the product from contamination and prevent it from spoilage, and at the same time it should: - extend the shelf life of a product - facilitate distribution and display - give the product greater consumer appeal - facilitate the display of information on the product

2.1 Fresh Fish And Seafood Quality Is Dependent Upon Condition of the fish and seafood depend up on the method of harvest and handling. Product handling that assures high quality should begin on the fishing vessel or at the fish farm. quality levels will also depend on natural factors including seasonal changes, particular harvest areas, feeding behavior, sex and spawning condition of the fish and seafood. Harvesting methods and onboard handling factor greatly in maintaining product quality and freshness. For example, the rough gloves used by harvesters can cause physical damage leading to bacterial infections with a significant reduction in harvest value. Holding tanks for live fish and seafood should be designed to avoid physical damage. Only fish and sea food in prime condition should be selected for live export. Some importers have specific requirements regarding product handling, pack styles and size grading. Check with the importer/buyer, prior to packing, to determine the particular requirements. This attention to detail may ensure the best possible price. 3

03. Packaging Types Food Packaging Techniques In the last decade, the most important additional function of the packaging method is to prolong the shelflife of the food product.      

Vacuum packaging Moderate vacuum packaging Active packaging Modified atmosphere packaging Aseptic packaging Edible coatings

3.1 Vacuum packaging Vacuum packaging is another way to increase the shelf life of food products. Here the product is placed in an air-tight pack, the air sucked out and the package sealed. By removing air from around the product, the levels of oxygen in the packaging are reduced, impeding the ability of oxygen-breathing microorganisms to grow and spoil the product. The lack of oxygen also reduces the amount of spoilage due to oxidation. Vacuum-skin packaging is becoming more common for packing smoked fish. In this process the wrapper is heated and wrapped over the product, the film moulding completely to the product shape and sealing the product completely, forming an extra skin. Vacuum packaging removes most of the air before packaging. For example for packaging seafood, the proportion of carbon dioxide and oxygen in the modified atmosphere can by varied depending on the type of fish: oily fish benefit from a different atmosphere compared with, for example, prawns .In vacuum packaging, as the pressure within the packaging is reduced the packaging material collapses and forms itself tightly around the product. For some products, such as fresh meat, this can distort the appearance of the product. Other products, such as shredded cheese, are not suitable for vacuum packaging because the pressure of the packaging material on the product would cause the product to deform and to lose important characteristics. 3.1.1 Advantages of Vacuum Packaging    

Eliminating Oxidization Preserving Delicate Flavors & Oils Preventing Freezer Burn Maintaining Natural Moisture

3.1.2 Disadvantages of vacuum packaging   

External Gases Can Increase Cost Proper Gas Levels and Oxygen Levels Must be Known to Increase Shelf Life Additional Sealer Attachments may be Required Based on Each Product 4

3.1.3 Systems For Gas Packaging

Type of Packaging

Type of foods used this method

This type of packaging system is mainly suitable for the retail packaging of meat, and semi-rigid packages poultry, fish, cooked meats, bakery products, cheese and nuts Horizontal and vertical form-fill-seal machines These kinds of packaging systems are mainly suitable for the retail packaging of bakery for flexible “pillow-pack” pouches products, snack foods, coffee, cheese, nuts, meats, fish, salads and fruits. These types of packaging systems are suitable Vacuum chamber machines for both retail and catering packaging of meat, fish, nuts, and prepared meals. The system can be applied to meat, poultry, fish, cooked meats, fruit, vegetables, cheese, Gemella packaging systems bakery products, salads and ready meals Horizontal form-fill-seal machines for rigid

3.2 Active Packaging Active packaging employs a packaging material that interacts with the internal gas environment to extend the shelf life of a food. Such new technologies continuously modify the gas environment (and may interact with the surface of the food) by removing gases from or adding gases to the headspace inside a package. fish, cheeses and strawberries are foods, which can benefit from packaging in a high carbon dioxide atmosphere . Active agents can be useful in a package, such as oxygen or carbon dioxide scavengers, moisture absorber and oxygen or carbon dioxide emitter.

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Active packaging systems have also been studied, in which specific bioactive substances are combined with the packaging material or within the package resulting in the retardation of the microbial growth and lipid oxidation. It was reported that the use of carbon dioxide emitters in fish can control the G/P ratio and volume reduction compared with traditional MAP. 3.2 Modified Atmosphere Packaging 

  

Defined as the enclosure of food products in gas–barrier materials, in which the gaseous environment has been changed, extend the shelf-life and retard the deterioration of seafood under refrigeration, Although an increasing choice of packaging materials is available to the MAP industry, most packs are still constructed from four basic polymers: polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyproylene (PP) and polyethylene (PE) Brown shrimp. The MAP products have to be stored at the temperatures lower than 3° C because of C. botulinum hazard. MAP packages consist of two kinds of foil. The bottom film is foil-rigid or semi-rigid. This foil is formed by, for example, extrusion and the resultant tray is moved to the packing section. Because of product drip it is placed on an absorbing board. The top web is drawn over the filled trays and sealed round the edges. The pack may be evacuated or gas-flushed before sealing. Oxygen Nitrogen Carbon dioxide

These three gases are used in different combination according to the product and the needs of manufacturer and consumer.

MAP for fish requires high barrier to Co2, O2, N2. The pre-determined gas mixture has to stay inside the package and remain the same mixture. Packaging films or layers with high gas barrier are applied. PVDC co-polymers . EVOH have the highest barrier to oxygen gas. Water Vapour Barrier Impermeability to water vapour is important for fish packages as its quality is adversely altered by dehydration. PVDC, coated OPP and HDPE are used. Other plastics like PA and PS have poor water vapour barrier and yet some other plastics like EVOH can be adversely affected by moisture. films must be laminated on both sides to protect it from contact with moisture.

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Heat Sealability A tight seal has to be formed between the tray and lidding material to prevent contamination and dehydration of fish. The strong fish odour should not be allowed to spread. LDPE, EVA and PP are widely used as a heat seal layer in laminates of fresh fish packaging. Mechanical Damage Fresh fish can be easily bruised. EPS (expanded polystyrene) tray is widely used to protect the sensitive product. To provide gas barrier and heat seal properties, EPS is used in combination with EVOH and LDPE to provide a suitable package. At times, rigid HDPE tray is also used. A sufficient head-space with puncture resistant films like polyamides completes the package. Oil Resistance For fatty fish, oil resistant films like polyamides, PVDC and PVC ( un-plasticised) may be considered. PET and OPP are also used as they provide excellent oil barrier. Transparency For fresh food, the visibility of the product is important to the consumer. PET and PP films have superior optical clarity and, therefore, are applied for fish packaging over-wraps and as lidding materials. The polymers may also be blended with antifogging agents in order to reduce condensation on the lidding film. The advantage of MAP       

Increased shelf life Reduction in retail waste Improved presentation-clear view of product and all round visibility Hygienic stackable pack, sealed and free from product drip and odor Little or no need of chemical preservatives Increased distribution area and reduced transport costs due to less frequent deliveries Reduction in production and storage costs due to better utilization of labor, space and equipment

Disadvantages of MAP a) Capital cost of gas packaging machinery; b) Cost of gases and packaging materials; c) Cost of analytical equipment to ensure that correct gas mixtures are being used; d) Cost of quality assurance systems to prevent the distribution of leakers, etc. e) Increased pack volume which will adversely affect transport costs and retail display space; f) Potential growth of food-borne pathogens due to temperature abuse by retailers and consumers; g) Benefits of MAP are lost once the pack is opened or leaks

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04. Packaging Materials In order to improve the barrier properties of packages laminates are used, for example polyester/polythene. Products which are particularly sensitive to oxygen are vacuum-packed. During the sealing operation, air is removed from the package. A laminate nylon/polythene is commonly used as packaging material. This type of packaging is used, for instance, for smoked trout which are arranged on a board with, for example, a coated texture. Numerous machines exist for vacuum-packing with single, double or continuous chambers. Vacuum-sealing machines can additionally be equipped with a modified atmosphere packing system (MAP). Immediately on removing the air from the package a mixture of gases is pumped in. Usually this mixture consists of 30% nitrogen, 40% carbon dioxide, and 30% oxygen. In the case of fat fish the oxygen is replaced by nitrogen. This method is increasingly used for packing fresh fish.

1. Expanded Polystyrene Boxes These boxes are produced from moulded polystyrene beads and they comprise 98% air by volume which makes them light and contributes to their insulation but makes them bulky to store when empty. The lid and box are manufactured in the same manner and are designed to interlock, creating a firm seal. They have very good insulation properties, but relatively poor impact strength. A fold flat polystyrene box is being developed which brings together insulation and volume reduction for storage and transport of the empty boxes. Lightweight EPS is effectively 98% air minimizing weight impacts in transportation Tough The 2% polystyrene cellular matrix gives outstanding impact resistance Insulating Unique insulation performance keeps fish safe and eradicates waste Hygienic & Safe EPS is non-toxic, chemically inert and fungi and bacteria cannot grow on it Waterproof EPS is insoluble and non-hygroscopic Low Carbon Impacts Clean manufacturing technologies mean minimal energy and water inputs with no production waste Economic Highly efficient manufacture and localised production units mean EPS is a low cost, proven solution

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Natural Styrene for EPS is a by-product of oil refining but is also abundant in natural products such as strawberries, coffee beans and wine Recyclable Most EPS packaging is easily recyclable where facilities exist. Life Cycle Advantages Independent studies show that no alternative offers better LCA performance than EPS for fish boxes

The superb insulating properties of EPS makes it perfect for frozen, chilled, fresh or pre-cooked food products. Packaging Range • Boxes • Trays • Drained • Leak Proof • Easy Fold • Manual Folding • Automatic Folding • Crayfish Separators • Interlayers • Absorbants And Gel Ice.

2.Solid Fibre board boxes These boxes are made from a water resistant board, lined with a low density polyethylene film. They are usually corner glued with water resistant glue. A typical grade of material will contain 85% Recycled fibre. Fibre-board boxes have good impact strength but poor insulation. They are Available fully erected or as a fold flat box for volume reduction during storage and transport of the empty boxes. These are constructed from marine ply board and lined with polyethylene film to enhance their water resistance. Their use has diminished and the have been replaced by EPS boxes. 9

This is mostly used for packaging of dry fish products. Ex: Smoked fish

3. Corrugated Plastic Boxes These boxes are made from extruded corrugated plastic (polypropylene) sheet comprising thin skins over a central corrugate to give a total thickness of about 3 mm. The sheets are cut to the desired shapes and the fold lines are made. Boxes are available erected or flat pack for manual erection. The original boxes have poor insulation and strength but an improved type is now available. Produced by a new process the new type has walls of about 7 mm total thickness and has sealed edges to the corrugate.

6. Returnable Plastic Boxes These are re-usable plastic (high density polyethylene) containers which can be folded flat for volume reduction during storage or transportation but when assembled make a rigid container. They are available in sizes to carry 5, 10 and 25 kg of fish with ice and they can be re-used 50 times or more. Returnable box systems are already operating on the Continent. The initial box cost is high and a collection and cleaning system is required. The boxes are used to transport whole fish, fillets, loins and portions

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7. LLDPE bags (linear low density polyethylene) This has an extremely high tensile strength and very high stretch with very good heat sealing characteristics. LLDPE is Use for heavy duty sacks and stretch wrap applications. It is used for incorporating into HDPE to reduce brittleness and increase tensile strength of carry bags. LLDPE is a well-recognized material for stretch cling film for lightweight secondary packaging Ex: frozen shrimp

05. Packaging For The Global Market 1. World Export market for Sri Lankan fish Seafood product sector plays an important role in Sri Lanka’s Social and economic life. The Sector contributes about 2.7% to country’s GDP. End of the civil unrest detained three decades in the country, fisheries sector has a significant scope to increase the level of contribution through exploiting high seas for tuna fishing & value addition. Our main markets are Germany , France , Italy , Belgium and Austria, Certifications that our Sea food exporters have HACCP, EU, FDA, ISO, HACCP

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Sri Lanka has emerged as a quality tuna exporter -predominantly yellow fin and big eye species to international markets. These include sashimi quality tuna, tuna loins, fresh tuna steaks, tuna topping and tuna saku blocks, to name a few. Other varieties of Sri Lankan seafood relished by the world are the ingredients to culinary seafood heaven; lobsters, crabs, squid, cuttle fish, shark fin, beche de-mer and fish maws are famous in the international seafood market due to their quality taste and texture. Value added shrimps such as nobashi, and butterfly cut are popular in the Japanese market, while head-on, headless, shell on, peeled and cooked shrimps are popular in the USA, Japan, and Asian markets such as Singapore. These highly sought-after products are all exported from Sri Lanka in significant quantities. The seafood sector has shown a growth rate of 5% within the last 5 years with key buyers from UK, France, Italy, Japan, Netherlands and the USA. With the opening up of the Northern and Eastern areas of the island nation, 65% of oceanic area is now free for fishing. A fishing fleet of 1700 boats operate around the island's waters and supply approximately to 75 medium and large scale export companies, 32 of which utilize the EU-approved processing plants. The sector has generated close to 2.4 million direct and indirect jobs. Under the government's Fisheries Sector development strategy, a modern and technically improved Vessel Monitoring System (VMS) is being established; this will be able to prevent national fishing vessels from drifting to other countries' territorial waters. Cold chain facilities as well as impressive harbour and road and highway infrastructure ensure a quick and safe supply chain. E-business has been deployed, taking the industry to the next level in reducing waste and time consumption and increasing cost-effectiveness. When it comes to product developments, processing and packaging techniques, Sri Lanka's traditional skills in manpower and advanced technology ensure the makings of a perfect, high quality and most importantly fresh seafood export range that is well packed and ready to ship.United Kingdom is the main market for Sri Lankan tuna followed by France, Italy, Netherlands, Germany etc. In recent years Sri Lanka has been steadily increasing its share in the international market. Annual exports of tuna increased from US$ Mn. 50 in 2000 to US$ Mn. 195.31 in 2011. The insulation value of the packaging is controlled by the demand for Sri Lankan Tuna fish in the global market has increased rapidly. Sri Lanka has emerged as a quality tuna exporter -predominantly yellow fin and big eye species to international markets. Yellow fin tuna (Thunnus albacore) and big eye tuna (Thunnus obesus ) are the principal varieties of finfish exported by Sri Lankan seafood companies. Export grade Sri Lankan tuna are long lined, gutted, gilled and chilled at sea. Key tuna products include whole fish, loins, toppings, saku blocks, steaks, belly and cubes. Sri Lankan tuna products are exported mainly fresh in open or vacuum packs. 12

Other finfish varieties exported include skip jack tuna (Katsuwonus pelamis), billfish (Istiophorous spp., Makariya spp., Xiphias spp.), dolphin fish (Coryphaena hippurus), spanish mackerel (Scomberomorus spp), trevally (Carangoides spp, caranx spp.) barracuda (Sphyraena spp.), groupers (Epinephelus spp.), snappers (Lutjanus spp.), white mullet (Liza spp., Mugil spp.), parrot fish (Scarus spp.) and ribbon fish (Chirocentrus spp) Other finfish products include whole fish, loins (billfish only), steaks and fillets. Finfish are also exported alive (grouper only), fresh (in open or vacuum packs), frozen or canned. The blue swimming crab (Portunus pelagius) accounted for the majority of Sri Lankan crab exports, both in terms of volume and value in 2011. Key Sri Lankan crab products include chilled and frozen fresh crab and pasteurized crab meat (canned). Mud crabs (Scylla serrata) are exported alive or as chilled fresh crab. Wild caught and cultured tiger prawns (Penaeus monodoon) and wild caught Indian white prawns (Penaeus indicus) and banana prawns (Penaeus merguiensis) are the main varieties of prawns exported by Sri Lankan seafood companies. Prawns are exported fresh or frozen. Value added shrimps such as nobashi, and butterfly cut are popular in the Japanese market, while head-on, headless, shell on, peeled and cooked shrimps are popular in the USA, Japan, and Asian markets such as Singapore. These highly sought-after products are all exported from Sri Lanka in significant quantities. With rapid technological advancements and increased shipping fleet capacity and the culturing of new inland species in Sri Lanka, the stage is set for significant expansion of the sector in the years to come. There are about 32 EU approved processing plants in Sri Lanka. The country successfully complies with the stringent regulations imposed by importing countries and adheres to HACCP, BRP, Friend of Sea and other food security environment friendly requirements.

06. Key products and varieties The main fishery export products include tuna, fresh chilled and frozen form ,shrimps and prawns ,crabs and lobsters .Other than the above shark fins ,fish maws, beche-de-mer , cuttle fish and squid ,sprats are also mostly exported to the Europe and Asian markets. Fresh Product: Fresh Chilled Yellow fin Tuna loin and H & G. Big eye tuna, sea cucumber, cuttle fish, Sword, Shrimps. we trade lobsters, mud crabs, shellfish, tiger prawns, red snapper, tuna, Live groupers and sea bass milk fish eels ,Swordfish loins ,Marlin loins, Grouper, Mullet ,Parrot fish , Sea Crabs , Anchovy ,Spanish, Emperor Fish, Seer Fish , Scad , White fis ,Barracuda ,Goat Fish, shark fins etc... Frozen Product: Yellowfin Tuna, Whole Round, Gilled & Gutted, Bullets- Mahi Mahi and other Rock Fishes including Crabs, Shrimps, Prawns ,oysters , jelly fish and lobsters W/R yellow fin tuna and Big Eye Tuna 13

Value Added Product: Yellow fin tuna (Thunnus albacares), Big eye tuna (Thunnus obesus), Sword fish (Xiphias gladius), Marlin (Makaira indika), Red snapper (Lutjanus spp), Grouper (Ephinephillus spp.), Mahi mahi (Coryphaena hippurus), Red mullets (Liza spp.), Barramundi (Lates calcarifer), Barracuda (Sphyracna spp.), Blue

Swimming Crab, Prawns, Squids, Cuttle fish, Parrot fish (Scarus spp.), Sardines, Skipjack tuna (Sarda chiliensis), Mackerels (Scomberomorus spp.), Trevally (Caranx hebiri), Emperor (Lethrinus spp.) and any other fresh fish product according to the customer requirement. Eg: whole fish /GG/H&G/fillets/loins/ saku/cubes.

07. Products that export from Sri lanka to Europe / Packaging materials for chilled fish The most useful materials for making small packages of chilled fish are the thin flexible films produced mainly from plastics. Plastics are mainly synthetic or naturally occurring polymers or resins. Polymers are large molecules built up by the repeated addition of small chemical units; when more than one type of unit is added the resulting molecules are called copolymers. Other packaging materials for wet fish are used in conjunction with flexible films; for example small trays of cardboard, pulpboard or expanded polystyrene are often used to support the product and improve presentation. 14

The following properties of flexible films for wrapping fish are of importance: Thickness or substance The thickness of single plastics films is measured in micrometres, µm, but cellulose film, and flexible laminates and their components, are described by substance, that is the weight of a given area, in g/m2 .Other properties are dependent on thickness, for example strength and opacity. Working temperature This is the range of temperature, in °C, in which the film can be worked without becoming too brittle or too limp. Heat sealing When a film is heated to a certain temperature which depends on the type of material, the molecules move out of position and start to slip; this property is used for sealing bags and pouches. A film that has good protective properties but forms a poor heat seal can often be improved by coating it or laminating it with a film that seals well. The heat sealing temperature of a film is the lowest temperature that will give an acceptable seal. Types of flexible films Some properties and uses of the more common flexible films used for packaging are briefly described. A single example of a proprietary name is given for each type, but this is in no way an endorsement of that particular make in preference to any other. i)Cellulose The effect of moisture can be reduced by coating it, usually with nitrocellulose, or by converting it to cellulose acetate which, however, has somewhat different properties from cellulose but can be used for packaging fish. Cellulose can also be coated with a polymer, usually polyvinylidene chloride, PVdC, to reduce the gas transmission rate. Example : Cellophane ii)Polyethylene The ethylene polymer is available in three main grades, low, medium and high density film. Polyethylene, PE, film is slightly opaque; the opacity increases with density but can be reduced by radiation treatment. PE film is waxy to the touch, and is a good moisture barrier. Low and medium density PE films are flexible even when cold. Low density PE film is a poor gas barrier, but resistance to gas transmission increases with density. Low and medium density PE films are not resistant to oils and fats, and high density film is only slightly resistant. PE is readily heat sealed. High density PE film is suitable for boil-in-the-bag packs, whereas low and medium density films are not. Example : Polythene 15

iii)Polypropylene Polypropylene, PP, is available either as an extruded film or as an orientated film, often designated polypropylene 0. The orientated film is usually stronger and more resistant to transmission of water vapour and gas.PP resembles polyethylene but is stronger, lighter and more rigid. It has a higher melting point than PE, but becomes brittle at about -10°C. It can be heat sealed, and the orientated film has slightly lower water vapour and gas transmission rates than a medium density PE. It is resistant to fats, acids and alkalis. PP is used as a single film, coated or uncoated, and in laminates. Example: Propathene iv) Aluminium foil Aluminium foil when free from pinholes is a complete barrier to water vapour and gases; foil more than 30 µm thick is generally regarded as being free from pinholes. Since foil is easily damaged, it is frequently used in conjunction with a supporting film. A coating of polyethylene or a heat sealing lacquer is usually necessary to provide a sealing facility. Aluminium is resistant to fats and oils, and can be used at any temperature likely to be encountered in packaging. It is opaque. The following tables compares the principal properties of some of the single films and laminates that have been used for prepacking chilled fish. Guide to films for prepacking chilled fish Material water vapour single films PE ld Md Hd PP Polyamide Cellulose coated single films cellulose/PVdC on one side both sides PP/PVdC on one side

barrier to oxygen

carbon dioxide

odour transfer

use with wet fish

good poor good poor very good moderate

Poor moderate Good

nil nil nil

very good moderate very good very good poor poor

moderate very good

nil nil

Overpouch Overpouch overpouch (opaque) Overwrap vacuum pouch

Poor

nil

Overwrap

good very good

Good very good

nil nil

Overwrap Overwrap

very good

nil

Overwrap

very good

good very good very good

Laminates 16

PE Id/PP PE md/PP PE Id/PP with PVdC coat PE md/PP with PVdC coat PE md/polyester

very good good very good good very good excellent very good excellent very good very good PE md/cellulose very good very good PE md/cellulose with PVdC coat one very good excellent side

Good Good excellent excellent very good

slight slight strong strong nil

Overpouch Overpouch vacuum pouch vacuum pouch vacuum pouch

very good

nil

Overpouch

excellent

slight

vacuum pouch

Notes on the table: 1. PE Polyethylene PP polypropylene PVdC polyvinylidene chloride Abbreviations: ld low density md medium density hd high density 2 Film PE 38 or 50 µm, PP 12·5 or 19 µm, polyester 12·5 µm. The equivalent thicknesses in the thickness: old imperial guage are given below.

08. Packaging materials that Sri Lankan exporters used Packaging is used to protect fish & fishery products from damage during handling and transport. Packaging of fishery products under modified atmosphere(MA)increases shelf life of the fish product compared to those packed under air. Fresh chilled tuna loins are packed in individual vacuum packed LLDPE bags. Vacuum pouches, Gel ice packs, Styrofoam boxes and Corrugated boxes are used as packaging materials for fresh and chilled products. Airlines, generally, recommend using polyethylene bags to pack fish and seafood. Polyethylene is superior to vinyl chloride in terms of cost savings, water tightness and strength. The major disadvantage is that it can be easily punctured by sharp objects. In all cases, bag thickness should be sufficient to retain liquids and resist punctures. Generally, shippers double-bag product. The package cannot improve the quality of the contents. The fish must be of high quality prior to packaging. A suitable fresh fish package must (1) Reduce fat oxidation (2) Reduce dehydration (3) Provide for less bacterial and chemical spoilage (4) Eliminate drip and prevent odour 17

A water absorbent material is recommended for inclusion in the packaging system to avoid leakage. This can be an absorbent pad that is impregnated with an organic gel agent, a simple absorbent pad, newspapers, wood shavings or shredded paper. Gel agents effectively trap water. By removing drip water from the product, bacterial growth can be slowed Seafood packaging is used for a wide range of seafood. Examples of usage are :Fish Fresh or Chilled, Frozen Fish, Other Edible Fish, Crabs, Swordfish, • Fresh filet and loin • Whole fish • Shrimp • Lobster • Clams and shellfish

1. Product Name: Tuna Lions

General Description: Tuna loins are prepared from sashimi grade raw material, Long-line caught, gilled. The loins are skinless, boneless, belly off, with all viscera and black meat removed. Steaks are individually vacuum packed in LLDPE bags. LLDPE offers the high Polyethylene Shrink Film stretch rate needed for stretch film. Many polyethylene bundling shrink films are made with Low-density polyethylene. The low-density polyethylene offers a low shrink temperature and excellent clarity 2. Product Name : Tuna Steak

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General Description : Tuna steaks are prepared from sashimi ,Long-line caught, gilled/ gutted. Steaks are cut from chilled loins that are skinless. Boneless ,belly off, with all viscera and black meat removed .Steaks are individually vacuum packed in LLDPE bags.

3.Product Name : Tuna Saku

General Description : Tuna saku is prepared from sashimi grade raw material ,Long –Line caught, gilled/gutted.Streaks are cut from chilled loins that are skinless, boneless, belly off with all viscera and black meat removed. Tuna saku is individually vaccum packed in LLDPE bags.

4. Product Name : Tuna Medallion

General Description : Tuna medallion is prepared from sashimi grade raw material , long-line caught ,gilled /gutted. The medallion is cut from fresh loins that are skinless, boneless ,belly off ,with all viscera and black meat removed .Tuna medallion is tray packed, ready for super market use.

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5. Shrimp/Lobsters/Live Crustaceans (Live Fish) Polystyrene foam container, inner and outer bag of polyethylene film (100µ) and outer CFB (in water 1:3 ratio in sealed bag flushed with oxygen). Pre-chilled sawdust, water-absorbing material, ice cubes in polyethylene bag, CFB boxes. Transportation by air.

6. Product name :IQF Cuttle Fish

7. Product name : Blue swimming crab

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This product comes in IQF or block form.

8 . Tuna Whole / GG

Packaging =2-3 fish in corrugated box in a polythene bag with gel & dry ice.

9. Tuna H&G Packaging= 2-3 fish in corrugated box in a polythene bag with gel & dry ice.

10. Tuna Loin Skin – ON Packaging vacuum Packed / wrapped in food touch paper

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11. Green Paper Wrapped Tuna Loins Packaging Individual Vacuum packed in LLDPE bags

12. Shrimps Packaging shrimp in plastic trays. These trays are sealed with a (transparent) lid foil. Waxed/poly coated printed duplex board cartons tuck-in-type, LDPE/HDPE liner/pouch to hold individual blocks.

13. Crabs Provide air holes in eskies/boxes (2 in winter or dry season, 4 in summer or wet season). If refrigerated transport is less than 15°C, reduce the number of air holes. using Styrofoam packing material for very rough situations. Plastic Crab Crate Durable Plastic Crab Crate with lid.

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14. Prawns Prawns packaging in thermoforming in flexible film, and in modified atmosphere (MAP) in rigid film. 15. Live Lobsters Stress and physical damage are the major factors influencing live lobster quality during transport. Live lobster shipment stress factors include: temperature shifts such as inadequate cooling in warm climates and insufficient warmth in cold climates; low humidity; low oxygen; overcrowding, and; rough handling. Lobsters are solitary animals and are easily stressed when placed in communal settings. Packaging coolants such as wet ice or gel packs that come in direct contact with live lobsters can cause stress and mortality. 16.Special Packaging for Live Finfish Double bagging is generally suggested. Spiny finfish should be placed in an inner container of hard plastic within a polyethylene bag separated from an outer polyethylene bag by several layers of paper. Only one species should be contained per bag. The inner bag should be filled with water to approximately one third of its capacity. Add water and then fish. To inject oxygen, hold the oxygen tube at the bottom of the bag. Press out air from inside of the bag and bubble oxygen through the water. Blow more oxygen in to inflate the bag. Twist the top of the bag, fold it over and secure with an elastic band. It is recommended that expanded polystyrene containers, sheets or other insulating material be used to maintain an appropriate temperature and to protect the fish from rough handling.

09. Eu Rules and regulations for export fish to European countries EU rules 1. Packaging must be carried out under satisfactory conditions of hygiene, to preclude contamination of the fishery products. 2. Packaging materials and products liable to enter into contact with fishery products must comply with all the rules of hygiene, and in particular - They must not be such as to impair the organoleptic characteristics of the fishery products; - They must not be capable of transmitting to the fishery products substances harmful to human health; - They must be strong enough to protect the fishery products adequately. 3. With the exception of certain containers made of impervious, smooth and corrosion-resistant material which are easy to clean and disinfect, which may be re-used after cleaning and disinfecting, packaging materials may not be re-used. Packaging materials used for fresh products held under ice must provide adequate drainage for melt water. 23

4. Unused packaging materials must be stored in premises away from the production area and be protected from dust and contamination.

10. Global supply and demand The world’s population is expected to increase by 36% in the years 2000 to 2030, from approximately 6.1 billion people to 8.3 billion. It is also expected that the estimated total seafood demand will be 183 million tons by 2030, but the estimated supply will be only 150 to 160 million tones. Thus, there is a sizable gap between demand and supply. However, global capture fisheries will be able to provide only 80-100 million tons of fish annually on a sustainable basis. The global seafood market is estimated at US$ 100 billion per annum. Also, the world demand for seafood increases by 3% each year. The world largest seafood consumption in the world is by Japan, followed by European Union. The top five consumed species are salmon, shrimp, tilapia, catfish and crab (major consumption in China and India. 6.1 Germany using methods to pack fish product What are the methods that other countries used for packaging Cellulose-based packaging represents a sustainable alternative to the existing rigid packaging solutions, based on e.g. expanded polystyrene. During the last years, PFI has thus been working extensively in the development of novel fibre-based water barrier packaging for transport of fresh fish and agricultural products. Trays used for packing are generally overwrapped with a protective film, often with PE wrapping which shrinks. The film shrinking is achieved by use of hot air or hot water. Stretch wrapping is often used for products which are heat-sensitive. The film is stretched over the product manually (very often in the supermarket) or by machine. Foils used as wrapping or bags for packing of trays with product must be puncture-proof, extensible and impervious to gases like oxygen. Hundreds of different films are used in the packaging industry. These can be broadly categorized into two groups: - basic films consisting of a single layer of film - laminate consisting of two or more basic films glued together or bonded together by heat or by adhesives Plastics such as polyethylene film or copolymer of ethylene and vinyl acetate are very often used for packing of frozen products. Polyethylene packs can be produced manually using pre-made bags. An impulse or bar sealer is used to seal the bags which are hand-filled.

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Japan :- Dried fish are typically packed onto white Styrofoam trays and covered with transparent vinyl wrapping in retail preparation rooms and then displayed in the stores. Occasionally, brown trays are used,

but these are not as common as the white variety. Tray size tends to vary. One to three pieces of dried fish are packed onto a tray (the so-called “in-store” pack). Packaging in plastic bags (“out-pack”) eliminates the need for “in-store” packing by the retailer Flexible thermoforming films.

11. Packaging methods that use other countries        

Pouch packs / cans Vacuum packed trays / pouches Modified atmosphere packaging Controlled atmosphere packaging Sous vide Boil-in pouches Retort pouching Other advanced packing system

Fresh pack Solutions produces both thermoforming formable films and lid films which are used for product packaging using thermoforming method. This packaging method makes it possible to achieve optimum shelf life of fish and seafood products. Benefits of use – distinguishing the goods, using custom package design; – High level of automation of the packaging process; – Simple and reliable packaging process. Key features – Excellent thermoforming properties; – A wide range of films (high and medium barrier properties); – Excellent clarity; – High tear and puncture resistance; – Preservation of mechanical properties of packages, even during the process of product freezing. 25

Lid films

Lid Films are ideally suited both as lid-films (for sealing rigid trays), and as top films in combination with films for thermoforming. Advantages – Easy-peel, antifog properties; – Can be used for sealing to a variety of materials such as - PE, PP, PET and aluminum; – Different barrier properties (high and medium barrier), as well as films with a high permeability. Characteristics: – can be used for MAP packaging; – A wide range of easy-peel films with different welding force; – Properties of the sealing layer are selected for a particular form of package depending on type of application; – Excellent optical properties. London design agency Postler Ferguson created a fresh fish pack concept intended for use at fresh fish counters. Constructed from a double layered polyethylene, they are airtight, resealable and can be filled with ice for transport to keep fish fresh.

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This fish packaging proposal helps put unpopular and abundant fish more attractive to the end consumer and on equal standing with their more recognized brethren by placing them in an attractive and highly recognizable packaging. SaucyFish Tesco challenged their fish supplier, Seachill, to come up with a sales-boosting product strategy.

The new Seachill’s Saucy Fish line of chilled ready-to-serve products, designed by Elmwood in London, features a range of seafood species offered with unique sauce combinations.Elmwood uncovered a wellknown, but still intriguing market insight. Not only is the fish category seriously devoid of innovation, but also consumers don’t feel confident about cooking and serving fish, while the sales outlet doesn’t give any inspirational hints.

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Saucy Fish Set out to overcome this resistance by packing portioned fish in easily merchandised skin packaging twinned with an appropriate sauce. Saucy Fish uses Sealed Air Darfresh skin packaging and for some products the Sira Cook cook-in bag from Sirane. With the skin packaging there are no liquids moving within the pack, there is no need for an absorber, and the consumer gains better bacteriological control.

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The packages are using paperboard sleeves or folding cartons printed by Paragon. They can be printed both sides to provide more consumer or product information. Hot and cold foil blocking can be incorporated to deliver a premium finish as well as combination varnish effects to deliver tactile, matte or gloss features. ParchmentBake For me one of the best packaging solutions for preparing/cooking fish by the unprofessional consumer is the Parchment Bake.

The ParchmentBake delicately bakes the pre-grilled, 100% whole-fillet tilapia in a sauce locking in the fish’s natural moisture and flavours. Cooking in parchment paper is a classic technique used in restaurants and by professional chefs. The consumer just places the parchment bags on a shallow baking tray and bake at 400oF (200oC) for twenty-two minutes.

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The consumer just places the parchment bags on a shallow baking tray and bake at 400oF (200oC) for twenty-two minutes The convenient ParchmentBake cooking process takes the guesswork out of preparing and serving seafood with no MSG (Monosodium glutamate), no artificial flavours, colours or preservatives.

The puffed parchment bags in the hot oven It isn’t only the preparing and cooking of fish. One of the main points in the supply of fresh fish to the consumer is the packaging that is shuffled around, sometimes roughly, in the supply chain.

High Liner frozen seafood North American High Liner Foods markets its frozen seafood to retailers under the Sea Cuisine and Fisher Boy brands. The company switched to a mineral-based coating technology from Smart Planet Technologies.

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High Liner’s decision to switch to Earth Coating for its retail packs, represents a staggering 26 million cartons/year and reduces plastic use by 40,000 lb/yr, according to a Life Cycle Analysis of the raw materials performed by Heritage Plastics.

Earth Coating from Smart Planet Technologies, is a relatively new technology that allows up to 60% of the LDPE in a barrier coating to be replaced with calcium carbonate (CaO3). The company claims that this is a very high-performance barrier coating that can be applied to just about any type of paper or folding carton material, using essentially all of the same equipment. The clear coating is said to provide up to a 60% greater Moisture Vapour Transmission Rate (MVTR) than 100% LDPE and offers comparable heat-seal performance. Super fresh Salmon Packaging Super fresh is a technology to package salmon under vacuum, after placing a CO2 emitting cushion that consists of, among others, citric acid and baking powder, in the packaging. After the pack is sealed, the cushion develops CO2 gas and it also has absorbent properties. This CO2 emitter has been adapted for the product, so that it does not change the fish’s pH value, and sensory tests have also shown that the fish often has a higher quality than with comparable packaging technologies. This way salmon can be kept fresh for up to 20 days at a consistently low temperature, or between 10 and 12 days at 4°C.

Nautical Foods Nautical Foods created a packaging for frozen, value-added seafood products, of which both the thermoformed tray and the flexible film lidding material is a key element. The Go-Green tray material, 30

supplied by Coextruded Plastic Technologies, is a five-layer co-extrusion of polypropylene/tie/ethyl vinyl alcohol/tie/PE. However it is more interesting to see the way in which the trays are thermoformed. In short, and in contrary to the general thermoforming systems using roll-feeding, these trays are cut in blanks and stacked the way flat carton blanks are stacked. Passing first through a pre-heat process said to be crucial to the overall tray making sequence, the blanks are fed into a proprietary thermoforming system.

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12. Reference http://www.fao.org/wairdocs/tan/x5928e/x5928e01.htm http://www.dilshara.lk/products

(2016.12.10)

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http://lk.kompass.com/a/fish-canned-bottled-and-otherwise-packaged/03400/ http://www.fao.org/docrep/w0495e/w0495E05.htm https://www.swisspack.co.in/fish-packaging

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https://bestinpackaging.com/2012/09/19/packaging-innovation-for-fish-and-seafood/ http://www.intracen.org/itc/exporters/packaging/

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http://wikieducator.org/Food_Packaging_Technology (2016.12.15) http://www.inspection.gc.ca/food/retail-food/information-bulletins/smokedfish/eng/1331662809395/1331662880980 (2016.12.15) http://www.coolseal.co.uk/pdf/seafood_processor_november_2007.pdf

(2016.12.16)

http://www.omafra.gov.on.ca/english/food/industry/food_proc_guide_html/chapter_7.htm (2016.12.17) https://sealedair.com/food-care/food-care-products/fish-seafood/cryovac-packaging-materials (2016.12.17) http://www.papiers-paviot.com/uk-produits-emballage-poisson.php http://www.seafoodpackaging.com/

(2016.12.18)

(2016.12.18)

http://www.packagingsrilanka.com/flexible.php# http://www.ilocis.org/documents/chpt67e.htm

(2016.12.18)

(2016.12.18)

https://archive.org/stream/productionofdrie034553mbp/productionofdrie034553mbp_djvu.txt (2016.12.18) http://www.seafish.org/media/Publications/SR226.pdf (2016.12.18) http://www.freightshop.com.au/air-freight- (2016.12.18) http://www.salazonesasensio.com/catalogo.pdf

(2016.12.18)

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