Anti-microbial Food Packaging via Two-Step Spraying
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Solution Overview
Problem
Current anti-microbial packaging methods for high water activity foods (>0.7) rely heavily on preservatives, which are undesirable due to consumer demand for preservative-free products and regulatory restrictions, and existing technologies face issues with compatibility, effectiveness, and environmental impact.
Innovation Solution
A two-step spraying technology is used to apply a nano-silver added calcium phosphate based anti-microbial material onto the inner surface of packaging materials, ensuring effective anti-bacterial and anti-fungal properties without compromising barrier properties, using a urethane-based binder solution and ethyl acetate solvent system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If preservatives are used to extend shelf-life of high water activity foods, then microbial growth is inhibited and quality is maintained, but consumer acceptance decreases due to preservative-free demands and regulatory restrictions
Solution Approach 1:
The patent introduces anti-microbial packaging materials as an intermediary between the food and the environment. These materials contain anti-microbial agents that are released slowly to inhibit microbial growth without requiring preservatives in the food itself, thus maintaining consumer acceptance while achieving microbial protection
Solution Approach 2:
The patent replaces the chemical preservation system (preservatives added to food) with a physical packaging system that has integrated anti-microbial properties. The packaging material itself becomes the active agent against microorganisms through controlled release of anti-microbial substances
2Reliability
If anti-microbial materials are applied to packaging surfaces, then anti-bacterial and anti-fungal properties are achieved, but the complexity of the production process increases
Solution Approach 1:
The patent combines the anti-microbial function with the packaging material itself by applying anti-microbial coatings or incorporating anti-microbial agents during the packaging production process. This integration eliminates the need for separate preservation systems while maintaining production efficiency
Solution Approach 2:
The patent modifies the surface properties of the packaging material by changing parameters such as surface energy, porosity, or chemical composition to enable anti-microbial activity. This can be achieved through surface treatments, coatings, or incorporating anti-microbial particles into the packaging matrix
3Manufacturing precision
If nano-silver added calcium phosphate based anti-microbial material is applied by two-step spraying, then uniform coating and effective anti-microbial properties are achieved, but the manufacturing time and process complexity increase
Solution Approach 1:
The patent divides the coating process into two sequential spraying steps: first applying a binder coating, then applying the anti-microbial material coating. This segmentation ensures uniform adhesion and distribution of the anti-microbial particles while maintaining process efficiency through continuous operation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method provides extended shelf-life for high water activity foods by reducing microbial growth, eliminating the need for preservatives, and ensuring the anti-microbial agents remain effective while maintaining the packaging's barrier properties, with silver concentrations of 170-740 ppm achieving significant anti-bacterial and antifungal results.
Implementation Method 1
nano-silver added calcium phosphate based anti-microbial material
Implementation Method 2
render anti-microbial (anti-bacterial and anti-fungal) properties
Implementation Method 3
two-step spraying technology using nano-silver added calcium phosphate based anti-microbial material
Implementation Method 4
ethyl acetate solvent system
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
Production method for anti-microbial food packaging The present invention relates to an anti-microbial (anti-bacterial and antifungal) property given food packaging (P) production method to be used in the food sector, especially in packaging of food products with high water activity (aw ≥ 0.7), to reduce or to completely eliminate preservative use in food products. In this method, a binder solution (N) is sprayed onto the inner surface (C) of the packaging material (A) at the last stage of the production process of the packaging material (A) by two-step spraying system, after the binder solution (N) is applied, an anti-microbial solution (O) is sprayed onto the inner surface (C) of the packaging material (A) and then it is dried and made into a roll.