IV. DESARROLLO DEL TRABAJO
4.2. Metodología del trabajo ejecutado
4.2.11. Prueba de rendimiento
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CHAPTER THREE
FORMULATION OF AN ANTIMICROBIAL COATING CONTAINING NISAPLIN® INTENDED FOR LARGE SCALE PRODUCTION AND INHIBITION OF
SPOILAGE MICROORGANISMS
ABSTRACT
Antimicrobial food packaging could reduce food waste by extending shelf-life in addition to enhancing food safety. Utilization of the antimicrobial peptide Nisaplin®, which is an FDA GRAS approved additive, has the potential to be used in commercial antimicrobial food packaging applications, particularly, ready-to-eat meat products. The objective of this study was to produce a Nisaplin® containing coating formulated for large scale production equipment while maintaining antimicrobial efficacy. Differential scanning calorimetry (DSC) testing was conducted in order to determine a grade of polyvinyl alcohol (PVOH) and compatible plasticizer. Compatible plasticizers were determined based upon the plasticizers’ ability to lower the Tm (melt temperature) of the
PVOH. Percent solids (%) of liquid coatings and pH testing in additional to general observations were conducted. Dynamic contact angle tests and tape tests were conducted in order to determine whether a secondary base substrate would better suit the formulated coating for increased wettability and adhesion. Film on lawn testing was conducted on dry coated films against Micrococcus luteus, Listeria innocua and Listeria
monocytogenes. Control films did not contain Nisaplin. DSC testing revealed that
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(373.4°F) to 150.9°C (303.7°F), making the coating more suitable for sealing and less brittle. The pH of the antimicrobial coating solution was found to be 5.9. The average percent solids was 20.53 (%). Coated films also achieved inhibition against M. luteus,
L.innocua and L. monocytogenes. Based on the characteristics of the coating and efficacy,
it is possible to formulate a commercial grade antimicrobial product containing Nisaplin® that could extend the shelf-life of RTE food products.
INTRODUCTION
In 2012, 14.5% (36.4 million tons) of total municipal solid wastes generated in the United States of America was food waste. [8] Food spoilage is one of the major causes of food waste. Active packaging is a growing research area that can reduce food waste and the demand for active packaging is increasing. According to Food Production Daily [30], the active packaging sector is expected to grow to 3.5 billion dollars by 2017 in the United States and 17.3 billion dollars worldwide. According to the USDA ERS (United States Department of Agriculture Economic Research Service), the cost of food waste totaled approximately $161.6 billion in 2010. [5] Not only could active packaging decrease food waste, but it also has the potential to decrease foodborne illness outbreaks, death and an estimated economic loss of approximately 15.6 billion dollars per year. This estimate was based upon 15 major pathogens included in a study conducted by the
USDA. [33] This study showed total cost breakdowns including medical expenses and quality adjusted life expenses based upon any aftermath caused by pathogenic organisms. For example, Listeria monocytogenes, a contaminant associated with ready-to-eat foods
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exhibited a cost totaling nearly $3 billion out of $15.6 billion for all 15 pathogens in the study.
Ready-to-eat (RTE) food products are in high demand due to the convenience and a “fresh” product appeal. [4] They are food products that require little or no
cooking/preparation prior to consumption such as deli meats, cheeses and frankfurters. [14] RTE products are cooked and handled (i.e. cutting, dicing, packaging) after the cooking process which can lead to post process contamination. Because of this, these products are susceptible to pathogenic environment contaminants such as Listeria
monocytogenes in addition to natural microorganisms that cause spoilage. In order to
slow the growth of spoilage microorganisms, products such as preservatives, new packaging methods and additions of antimicrobials have been implemented.
Nisaplin® is a natural antimicrobial peptide that has been utilized in previous antimicrobial coating work for RTE food products. It has been shown to be effective, however, has not been produced in a commercial grade active packaging application. Work previously conducted by predecessors consisted of producing a coating solution with a 70/30 (w/w) base mixture of methylcellulose and hydroxypropyl methylcellulose (MC/HPMC). [Franklin et al 2004; Grower] Several hurdles were discovered when attempting to scale up to a large scale coating application method using the cellulose based formulation. The coated film was unable to be heat sealed due to the highly crystalline structure of the cellulose components. The liquid solution did not contain a high enough percent solids (~9.5%) to meet the properties needed for gravure or
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high degree of haze, which increased over time, potentially due to the precipitation of salts from the Nisaplin® product. Because of these characteristics of the cellulose based formulation, several objectives were determined for a new formulation. The new
formulation also needed to exhibit a low enough melt temperature in order to promote sealability and produce a sealable package. It also needed to be translucent or exhibit low to no haze for aesthetics in addition to containing the proper percent solids for
implementation onto large scale gravure and flexography coating application processes. The overall objective, however, was to formulate an antimicrobial coating intended for large scale production methods and reduction of a spoilage indicator microorganism.