Non-Woven Gas-Permeable Packaging for Produce Atmosphere Control
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Solution Overview
Problem
Current packaging systems for fresh produce and flowers fail to establish ideal oxygen and carbon dioxide levels simultaneously, leading to inadequate shelf life and vase life extension, as they often control ethylene levels without considering the need for simultaneous regulation of oxygen and carbon dioxide, resulting in anaerobic conditions and tissue damage.
Innovation Solution
A gas permeable non-woven fabric based film with a high selectivity ratio for oxygen to carbon dioxide is used, allowing for controlled permeability to create specific atmospheres within packaging, reducing oxygen levels and increasing carbon dioxide levels to delay ripening and reduce metabolic activity, thereby extending shelf life and preserving nutrients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional packaging systems with equal oxygen and carbon dioxide permeability are used, then the packaging structure is simple, but the ability to establish ideal oxygen and carbon dioxide atmosphere levels simultaneously is lost
Solution Approach 1:
The patent uses a composite packaging system combining a polyethylene bag with a gas permeable non-woven fabric insert. The fabric is composed of multiple fibers (polyester, rayon, and spandex) creating a composite structure that provides selective gas permeability. This composite approach enables differential control of oxygen and carbon dioxide transmission rates, allowing ideal atmosphere establishment without overly complex design
2Reliability
If polyethylene bags with low permeability are used, then the packaging provides good barrier properties, but anaerobic conditions develop when oxygen levels go below 1%
Solution Approach 1:
The patent incorporates a gas permeable non-woven fabric with controlled porosity that allows selective gas transmission. The porous structure of the fabric enables oxygen and carbon dioxide to pass through at different rates, preventing anaerobic conditions by maintaining adequate oxygen levels while allowing carbon dioxide accumulation within ideal ranges
3Reliability
If high carbon dioxide levels are maintained to control ethylene, then ripening is delayed, but tissue softening and fungal growth occur
Solution Approach 1:
The patent changes the permeability parameters of the packaging system by introducing a non-woven fabric with specific oxygen and carbon dioxide transmission rates. This parameter modification allows carbon dioxide levels to be elevated enough to delay ripening and reduce ethylene production, while oxygen levels are maintained at sufficient concentrations to prevent tissue softening and fungal growth
4Duration of action of stationary object
If reduced oxygen levels are used to extend shelf life, then metabolic activity increases, but shelf life is reduced
Solution Approach 1:
The patent optimizes the oxygen transmission rate parameter of the packaging system to maintain oxygen levels that slightly stimulate metabolic activity, which in turn stimulates produce to use stored energy reserves more efficiently. This parameter optimization extends shelf life by several weeks compared to conventional packaging
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
The film effectively extends the shelf life and vase life of produce by regulating respiration, reducing ethylene production, and preventing tissue softening and fungal growth, while maintaining high quality and preserving nutrients by establishing optimal gas concentrations.
Implementation Method 1
Gas Permeable Non-Woven Fabric based Film with high permeability towards oxygen and carbon dioxide
Implementation Method 2
Produce is a living tissue that derives energy primarily by exchanging gases with its surroundings through the process of respiration
Data Source
AI summary
Packaging using Gas Permeable Non-Woven Fabric based Film extends the shelf life of various fresh fruits and vegetables and vase life of fresh cut flowers by changing the atmosphere in which these living products are stored and respires. The high oxygen and carbon dioxide permeability of the Gas Permeable Non-Woven Fabric based Film establishes an ideal atmosphere for the specific perishable item, and therefore extends its shelf life. The establishment of lower oxygen and carbon dioxide atmospheres inside packages using Gas Permeable Non-Woven Fabric based film, also leads to reduction in the respiration rate of the perishable items. The reduction in the respiration rate prevents loss of moisture, production of metabolic heat, and yellowing, browning, reduction in production levels of ethylene. Thus the created atmosphere is able to extend shelf life, maintain high quality and preserve nutrients of fresh produce items by naturally regulating respiration of said produce/flower.