Fraunhofer Institute for Process Engineering and Packaging

Functional papers with a minimum weight proportion of barrier and heat‐seal coating are one alternative to difficult‐to‐recycle plastic‐based multilayer composite films. Due to the low amount of thermoplastic polymer coating compared to the base paper material, the meltable material alone is not sufficient to close the channel leak at the transition between cross and fin seals when producing pouch packaging. Therefore, this paper focuses on the influence of the thermomechanical material properties of the seal coating, the paper layer structure and process parameters of the heat‐sealing process to reduce the channel leak at the layer transition area. Regarding the technologically based measures, the focus of the study is on the application of a deformable layer on the sealing jaws and the localization of sealing pressure by profiled sealing jaws. It is shown that the amount of thermoplastic material flowing into the channel leak highly depends on the thickness of seal coating and the melting behaviour of the applied coating. For the selection of suitable heat‐sealing parameters, sealing pressure on the paper material and temperature of the jaws must be considered. By applying a deformable material layer on one side of the sealing jaws, the closure of the channel leak at layer transition area is significantly reduced. Finally, with the use of certain deformable materials, a complete closing of the channel leak at the layer transition area is achieved on a laboratory scale.

Chocolate bars with whole nuts are a popular type of chocolate. However, their shelf life is limited by the roasted hazelnuts, which can become rancid or cause fat bloom, a whitish layer on the chocolate surface. Both are thought to be related to the nut oil that rises to the surface. Surface oil is prone to rancidity due to contact with oxygen. In addition, when the nuts are used in chocolate, the surface oil can be washed off by the chocolate during mixing or can migrate into and through the chocolate to become visible as fat bloom. Although fat bloom tends to occur on only a few nuts in a bar, the presence of fat bloom on just one nut is enough to reduce enjoyment because consumers associate it with mold. In this study, the influence of origin and roasting conditions on both quality changes was investigated. Hazelnuts of caliber 11–13 mm harvested from two different regions of Turkey, namely, Akçakoca and Ordu, were subjected to four different roasting conditions. The roasting process was performed either at low temperature for a long time (at 142°C for 30 or 50 min) or at high temperature for a short time (at 200°C for 7 or 9.5 min) in an industrial scale roaster (capacity of 50 kg per batch). Assessment of oxygen consumption and hexanal headspace measurement, both indicative of rancidity, showed increased oxidative stability for nuts roasted at the lower temperature. Roasted nuts from all roasting trials were used to produce various nut chocolate bars for storage tests. During these storage tests, the development of fat bloom was quantified using the DigiEye colorimetric measurement system, which is a box with defined lighting conditions and a fixed and calibrated digital camera. Images taken with this system were used to evaluate the whiteness index, an indicator of fat bloom. The migration of oil from the roasted hazelnuts into liquid cocoa butter was studied in a model system. Higher oxygen consumption and hexanal formation could be clearly related to the higher roasting temperature of 200°C. Oil migration in the model system as well as in the chocolate bars was independent from the roasting conditions, but hazelnuts from Ordu showed a higher oil release than those from Akçakoca. Fat bloom formation was clearly related to the storage temperature of the chocolate bars but independent of the origin of the hazelnuts and the roasting conditions. However, in individual bars with the same production processes, hazelnuts of the same origin and roasting conditions showed fat bloom only on some nuts and not on all, indicating that there are additional factors affecting fat bloom formation.

This paper outlines the current design trends in food packaging, its main environmentally friendly material alternatives, and industrial processing technologies. In this respect, this important product has undergone several evolutions throughout history. Initially acting as a containment device, it has later evolved into a source of information and even a marketing platform for food companies, always with a view to extending shelf life. However, these functionalities are highly dependent on the materials used and their properties. In this respect, plastics have conquered the food packaging market due to their affordability and flexibility. Nevertheless, environmental concerns have arisen due to their impact on the environment, in addition to the introduction of stricter industry regulations and increased consumer environmental awareness. Therefore, this work found that the current design trends in food packaging are toward sustainability, reducing packaging complexity, with easier recycling, and material selection that combines both sustainability and functionality. In the case of bioplastics as a sustainable alternative, there is still room for improvement in their production, with careful consideration of their raw materials. In addition, their technical performance is generally lower, with challenges in barrier properties and processability, which could be addressed with the adoption of Industry 4.0.

High‐gradient magnetic separation (HGMS) has traditionally been used in mineral processing, with many effective models developed for typically employed rod‐wire shaped matrices. However, its potential in bioprocessing, especially for high‐value products, introduces new demands on plant and matrix design. This study presents a multi‐scale model for HGMS that simulates new complex geometries, which enhance particle recovery. We have developed microscopic models to accurately simulate the trajectories of magnetic particles within the fluid flow and magnetic fields of HGMS systems. A pivotal aspect of our work is the effective translation of microscopic relationships into macroscopic transport models. The model is validated experimentally using a rotor‐stator HGMS system tailored for bioprocessing, with magnetic particle concentration measurements showing strong alignment with the model's predictions. The model's flexibility enables its application across various matrix shapes, overcoming the limitations of traditional rod‐wire models, and providing a robust framework for improved HGMS in‐silico process understanding and optimization.

Women’s health is related to several factors that include physical, mental, and reproductive health. Additionally, the vaginal microbiota modulation performs a fundamental role in the regulation of physiological homeostasis and dysbiosis, which provides us a potential overview of the use of different biotic agents and their implications for female health. The objective of this work was propitiated insights and conception about the influence of probiotics, prebiotics, synbiotics, and postbiotics as adjuvants for prevention/treatment on the main infections that can affect women’s health. Therefore, seventy-one studies published in the Web of Science Core Collection database from 1999 to 2024 were evaluated and performed to a bibliometric analysis employing the VOSviewer software for scientific mapping and network analysis. Our results suggest that administration of biotic agents as adjuvants are relevant for the prevention and/or treatment of the main diseases that affect female health, since they contribute to a healthy vaginal microbiota through anti-inflammatory and antimicrobial activities. Most clinical studies have demonstrated the effectiveness of intervention using probiotics to the detriment of other biotic agents in women’s health, being bacterial vaginosis, polycystic ovary syndrome, and vulvovaginal candidiasis, the main diseases evaluated. However, preclinical studies have emphasized that the inhibition of pathogens responsible for the process of vaginal dysbiosis may be due to the formation of biofilm and the synthesis of compounds that could prevent the adhesion of these microorganisms. Future perspectives point to the beneficial modulation of the vaginal microbiota by biotic agents as a promising adjuvant approach to improve women’s health.

To make different packages with various filling quantities better comparable for their packaging material use, in this study the packaging material use efficiency was defined as the ratio of fill good amount to the packaging weight. Several hundred rigid packages (tubes, bottles, cans, and carton packages) for liquid and higher-viscous fast-moving consumer goods, e.g., beverages and personal care products, were analyzed (weight) and more than >1000 data sets were taken from packaging suppliers of glass and PET packaging. As expected, glass packaging is heavier than PET packaging by a factor of around 10, and with a higher filling volume less packaging per amount of food is required. The material use efficiency of glass and PET bottles can differ by up to a factor of 3 within one filling quantity. The results are relevant for calculating life cycle assessments (LCAs) and selection of material efficient packaging.

Erythritol – a new zero caloric sweetener – shows high potential for developing new sugar reduced or sugar free food formulations. Since the crystallization behavior of erythritol was not investigated so far, this study focused on factors influencing erythritol crystallization in aqueous solutions using a simple gravimetric method. The general features of the course of crystallization are a linear increase until a period of 2.5 h of storage followed by a decelerating phase and a phase which represents equilibrium. Additionally, different influencing factors (supersaturation level, storage temperature, storage period and cooling rate) on the crystallization process of erythritol were investigated. It was shown that crystallization value increased with increasing supersaturation level and the progress of crystallization was almost linear from the initial induction period until equilibrium. Therefore, a first-order kinetic for erythritol crystallization was proposed, because only supersaturation level correlated to the erythritol concentration in the solution influenced the course of crystallization. Calculated crystallization rate constants increased considerably with increasing supersaturation levels. Furthermore, at the same supersaturation levels crystallization of erythritol was independent from the storage temperature. Cooling rate influenced only crystal shapes and sizes, but not the crystallization values.

Aroma compositions are usually complex mixtures of odor-active compounds exhibiting diverse molecular structures. Due to chemical interactions of these compounds in the olfactory system, assessing or even predicting the olfactory quality of such mixtures is a difficult task, not only for statistical models, but even for trained assessors. Here, we combine fast automated analytical assessment tools with human sensory data of 11 experienced panelists and machine learning algorithms. Using 16 previously analyzed whisky samples (American or Scotch origin), we apply the linear classifier OWSum to distinguish the samples based on their detected molecules and to gain insights into the key molecular structure characteristics and odor descriptors for sample type. Moreover, we use OWSum and a Convolutional Neural Network (CNN) architecture to classify the five most relevant odor attributes of each sample and predict their sensory scores with promising accuracies (up to F1: 0.71, MCC: 0.68, ROCAUC: 0.78). The predictions outperform the inter-panelist agreement and thus demonstrate previously impossible data-driven sensory assessment in mixtures.

Hazelnuts are frequently involved in IgE-mediated reactions and are the main cause of nut allergies in Europe. Most food products are processed before human consumption. Food processing can modify the structure, properties, and function of proteins, and as a result, the IgE-binding capacity of allergens can be affected. In this study, we aimed to investigate epitope changes caused by the roasting of hazelnuts using epitope fingerprinting. Rabbit sera were raised against hazelnut proteins, and their epitopes were characterized. Immunoassays using specific polyclonal antibodies from rabbits targeting the main allergens in hazelnuts revealed marked reductions in the levels of Cor a 1 (PR-10), Cor a 11 (7S globulin), and Cor a 14 (2S albumin). However, rabbit antibodies can recognize different epitopes. Using antibodies that are different and characterized could help establish reliable methods for estimating the effects of treatments on the allergenicity of foods. In this work, we provide the first practical application that could lead to sets of peptide epitopes to compare and standardize immune diagnostics, even for complex protein preparations.

Consumer interest in meat and dairy alternatives drives demand for plant-based protein ingredients. While soy and gluten dominate the market, there is a trend to explore alternative crops for functional ingredient production. The multitude of ingredients poses challenges for food manufacturers in selecting the right protein. We investigated 61 commercially available protein ingredients from various sources, categorizing them based on their protein content into protein-rich flours (protein content less than 50%), protein concentrates (protein content between 50% and 80%), and protein isolates (protein content higher than 80%). Methionine, cysteine, and lysine were decisive for the amino acid score, which even varied between ingredients produced from the same raw material. Such differences were also observed in the protein solubility profiles, characterized by their raw material–specific protein pattern. By focusing on soy, pea, and fava bean ingredients, the broad spectra of emulsifying and foaming properties were illustrated. These ranged from non–emulsifying and non–foaming to high emulsifying capacities of 737 mL/g ingredient and foaming activities of 2,278%, accompanied by a foam stability of 100%. Additionally, we demonstrated that the functionality of ingredients obtained from different batches could vary by up to 24% relative SD. Protein solubility, powder wettability, color, and particle size were determined as key properties for the differentiation of soy, pea, and fava bean protein ingredients by principal component analysis. In our study conclusion, we propose essential measures for overcoming challenges in protein ingredient production and utilization to realize their full potential in fostering sustainable and innovative plant-based food production.

In response to the need to employ recyclable materials for food packaging, the resurgence of paper as a primary flexible packaging material is driven by consumer trust in paper and its renewable wood fibre composition, strengthened by a well-established recycling infrastructure. A diverse range of coated papers and coatings has become accessible in the market, specifically tailored for applications in horizontal and vertical form-fill sealing. Within the framework of the CORNET-TETRA project HBC.2021.0288 REPAC 2 , a careful selection of 16 food-grade coated papers and/or coatings, slated for introduction to the market either presently or within the next 2 years, has been undertaken. This study focused on evaluating the processing window for superior hot tack and cooled seal performance of coated papers, in relation with the composition of paper coatings as identified using Fourier transform infrared (FTIR) measurements, and their thermal softening or melting characteristics as identified through differential scanning calorimetry (DSC). Thermal behaviour in DSC thermograms is used to categorize the commercial coated papers into distinct classes. Class I papers, mainly with acrylic-based coatings, exhibit high hot tack strengths (0.2-0.7 N/mm) and a glass transition temperature (T g) close to the seal initiation temperature but do not considerably gain strength with further cooling. Class II papers are thermally inert in DSC with minimal thermoplastics, leading to weak seals. In contrast, classes III and IV, including wax-based and polyolefin-based or polyvinylalcohol-based (PVOH) coatings, respectively, show low initial hot tack strengths that considerably increase upon adequate cooling. Particularly, the Class IV papers with polyolefin-based coatings have well-performing seals. Despite having relatively low hot tack strengths after cool times of 0.1 s, below 0.3 N/mm, high strengths can be obtained after adequate cooling with outliers reaching 0.74 and 1.14 N/mm. Additionally, the influences of seal parameters on seal performance were evaluated. The study reveals that cool time, seal pressure and, to a lesser extent, seal time significantly impact hot tack strength, consistent with prior research. The critical role of jaw temperature in heat conductive sealing is affirmed, as it dictates the efficacy of other seal parameters. Seal initiation occurs at 75°C for four papers, and nine others necessitate temperatures equal to or exceeding 100°C, with one paper only displaying seal initiation at 195°C. This variation highlights the requisite for tailored temperature windows for effective sealing of these papers. As such, deeper insights into the intricate interplay between coating composition, thermal properties and seal performance are obtained in order to support advances in sustainable packaging technology. This is an open access article under the terms of the Creative Commons Attribution-NonCommercial License, which permits use, distribution and reproduction in any medium, provided the original work is properly cited and is not used for commercial purposes.

Aims UV-C based air cleaners may reduce the transmission of infectious diseases. However, microbiological validation is necessary to quantify their efficiency. In this study, the stability of aerosolized bacteriophages for validation purposes was investigated in a test room, before an UV-C based air cleaner was exemplarily evaluated regarding the inactivation of airborne bacteriophages. Methods and Results The bacteriophage Phi6 was selected as virus surrogate and aerosolized in a room of 30 m³ volume. The recovery of infectious bacteriophages was first analyzed under variation of the relative humidity (20–55% RH) and sampling time. The aerosol studies showed that a low humidity between 20% RH and 30% RH provides a high and stable recovery of bacteriophages Phi6 over 1 h. However, with increasing humidity, the number of infectious airborne bacteriophages Phi6 decreased significantly. At 50% RH, the recovery of Phi6 was 4 orders of magnitude lower compared to 20% RH. The validation of an UV-C based air cleaner was then demonstrated in the test room whereat the decline of infectious airborne bacteriophages was recorded over time. The non-enveloped bacteriophage MS2 was used as a reference. The validation results were significantly different for Phi6 when the humidity in the test room was either 40% RH or 30% RH whereas comparable results were obtained for MS2 at both humidities. Conclusion A rising humidity in the test room caused a significant decline in the recovery of infectious airborne bacteriophages Phi6. The result of a quantitative validation of UV-C based air cleaners may therefore be affected by the respective humidity.

Reduced appetite with ageing is a key factor that may increase risk of undernutrition. The objective of this study is to determine the impact of innovative plant protein fibre (PPF) products within a personalised optimised diet (PD), a physical activity (PA) programme, and their combination on appetite, and other nutritional, functional and clinical outcomes in community-dwelling older adults in a multi-country randomised controlled intervention trial. One hundred and eighty community-dwelling adults (approximately sixty per trial centre in Germany, Ireland and Italy) aged 65 years and over will be recruited to participate in a 12-week, parallel-group, controlled trial. Participants will be randomised into one of four groups: 1, PD (incorporating two PPF products): 2, PA; 3, PD + PA; and 4, no intervention (control). The primary outcome is appetite measured by visual analogue scales and energy intake from an ad libitum test meal. Secondary outcomes include fasting and postprandial appetite-related gut hormones, Simplified Nutritional Appetite Questionnaire score, body composition, cardiorespiratory fitness, muscle strength, physical function and PA. In addition, self-efficacy, cognitive status, dietary restraint, depressive symptoms and compliance and acceptability of the intervention will be assessed. Metabolomic profiles, RMR, muscle motor unit properties and gut microbiome will also be assessed to explore potential underlying mechanisms. This multi-centre randomised controlled trial will advance knowledge on how PD (incorporating PPF products), PA and their combination influence appetite, nutritional status and related health outcomes in community-dwelling older adults and contribute to the prevention of undernutrition. Trial registration: Clinical Trials.gov Registry NCT05608707 (registered on 2 November 2022). Protocol Version: NCT05608707 Version 4 (registered on 29 September 2023).

The conching process plays a key role in determining the sensory and rheological properties of dark chocolate. To further understand this process, changes in the chocolate mass during plastic conching were investigated on a time-resolved basis with varying conching temperature, shear direction, and with or without the presence of residue from previous trials (pre-charge) on the conche vessel wall. Six selected odorants (acetic acid, benzaldehyde, linalool, 2,3,5,6-tetramethylpyrazine, 2-phenylethanol, 2-phenylethyl acetate) were quantified in fat and particle phases of chocolate masses. Particularly at elevated conching temperature, the odorant concentrations were found to decrease (up to 78.0% in the fat phase). The highest concentrations of desired odorants were determined mostly after conching without pre-charge. During conching, odorants were observed to accumulate increasingly in the fat phase (up to 91.7%) with decreasing odorant polarity. Similarly, it was found that conching temperature and the absence of pre-charge had the highest impact on the rheological properties of the chocolate mass, resulting in lowest and highest complex viscosity, respectively. In conclusion, some positive outcomes of conching, namely the retention of desired odorants and the reduction of viscosity, were inversely related at elevated temperature or in the absence of pre-charge, necessitating compromises to achieve optimal flow properties and flavor. Our results contribute to a deeper understanding of the influence of conching on the quality of dark chocolate by providing insights into the complexity of aroma migration and rheological changes during conching.

The rapid growth of product sectors for plant‐based meat and dairy alternatives has raised significant scientific interest in their nutritional and ecological benefits. Here, it outlines the fractionation of plant‐based raw materials and describes the technologies applied in the production of meat and dairy substitutes. Moreover, the study describes the effects of these new products on human nutrient supply and metabolic responses. Examples of meat‐like products produced by extrusion technology and dairy alternatives are provided, addressing production challenges and the effects of processing on nutrient digestibility and bioavailability. In contrast to animal‐based products, plant‐based protein ingredients can contain many compounds produced by plants for defense or symbiotic interactions, such as lectins, phytates, and a wide range of secondary metabolites. The intake of these compounds as part of a plant‐based diet can influence the digestion, bioaccessibility, and bioavailability of essential nutrients such as minerals and trace elements but also of amino acids. This is a critical factor, especially in regions with limited plant species for human consumption and inadequate technologies to eliminate these compounds. To fully understand these impacts and ensure that plant‐based diets meet human nutritional needs, well‐controlled human studies are needed.

Tin oxide nanoparticles are well‐established materials with a wide range of applications, including optoelectronic devices and solid‐state gas sensors. Conventional synthesis methods of these systems are often based on batch processes. In this study, we compare batch and continuous synthesis methods for tin dioxide nanoparticles using precipitation and sol‐gel processes. For the continuous processes we applied the so called microjet reactor method. The nanoparticles were characterized by TEM, elemental analysis and XRD and exhibited particle sizes of 1.7‐3.0 nm and crystallite sizes of 1.7‐2.3 nm, consisting of tetragonal (P42/mnm) and orthorhombic (Pbcn) phases. We have evaluated different post‐synthesis purification methods to remove impurities such as chlorides and carbon‐hydrogen species. Each purification method exhibited unique advantages and side effects, providing insight into selecting the most appropriate method for specific applications. We also demonstrated the potential of these SnO2 nanoparticles as ethanol gas sensing materials and compared their performance with a commercial sensor.

In an online survey, 154 decision-makers from the food industry were asked about resilience management, coping with disruptions, resilience characteristics, resilience dimensions and investment needs in their companies. This article analyses the survey, presents methods for assessing resilience and identifies potential for improvement. 84% of those surveyed responded that their companies had not yet implemented a resilience management system. Of the resilience dimensions, the impact of technology on ensuring the safety, quality and quantity of their products was rated highest, followed by finance. All respondents plan to invest in technology and digitalisation to increase resilience.