Development of a Laminated Antimicrobial Film and an Evaluation of Pilot-Scale Processing

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- Author:
- Bedford, Brittani
- Graduate Program:
- Food Science
- Degree:
- Doctor of Philosophy
- Document Type:
- Dissertation
- Date of Defense:
- October 02, 2024
- Committee Members:
- Gamini Mendis, Outside Unit & Field Member
Ramaswamy Anantheswaran, Major Field Member
Catherine Cutter, Chair & Dissertation Advisor
Greg Ziegler, Major Field Member
Jennifer Wagner, Minor Field Member
Robert Roberts, Program Head/Chair - Keywords:
- Pullulan
Antimicrobial Food Packaging
Biopolymer coatings
Ethyl Lauroyl Arginate
Meat and Poultry
Food Safety
Food Spoilage
Pilot-scale Processing
Scale-up
Multilayer film
Factorial design - Abstract:
- A laminated antimicrobial film (LAF) was developed to extend the shelf life and improve the safety of fresh and ready-to-eat meat and poultry products. Initially, LAFs were developed through the casting of a pullulan-based biopolymer coating containing gelatin, xanthan gum, glycerol, and lauric arginate (LAE), onto a polyamide-polyethylene (PA-PE) film. LAE is a broad-spectrum antimicrobial approved for use as a food additive at levels up to 200 ppm by the Food and Drug Administration (FDA). Currently, the production of biopolymer laminated multilayer food packaging materials has remained at the laboratory scale. To evaluate the commercial applicability of the laboratory-developed technology, small or pilot-scale processing was performed to establish a baseline of knowledge. Prior to pilot-scale processing, the effect of the concentration of individual components of the pullulan coating was evaluated to determine the rheological, mechanical, and physical properties of LAF. The main findings determined that the anionic polysaccharide, xanthan gum and cationic LAE form complexes with LAE resulting in the reduction of antimicrobial activity. This finding led to the investigation of the incorporation of xanthan gum on the antimicrobial activity of the LAF through a series of in vitro and in situ experiments. The findings from the study revealed that the presence of xanthan gum significantly reduced the antimicrobial activity of the LAFs within in vitro analyses compared to the LAF developed without xanthan gum, but the results do not translate to in situ analyses. To assess its commercial potential, the film was adapted for use with BOPEEVOH (biaxially-oriented polypropylene-ethyl vinyl alcohol). Initial pilot-scale processing revealed sagging of the pullulan coating under gravity, which hindered drying iii and slowed production. To address these issues, eleven film-forming solutions (FFS) were designed using response surface methodology to reduce sagging, improve wetting on the packaging material, cut drying time, and retain antimicrobial properties. The FFS were tested for viscosity at 30°C, 50°C, and 70°C, contact angle, and drying times at 50°C, 60°C, and 70°C. Antimicrobial efficacy against Escherichia coli O111, Salmonella Typhimurium, and Listeria monocytogenes J1-003 was evaluated through plate overlay assays. FFS with higher gelatin content showed better pathogen inhibition. The optimized formulation contained 14.84% pullulan, 3.65% gelatin, and 74.0% water. Despite experimental values of viscosity, contact angle, and drying time being higher as well as the antimicrobial activity lower than predicted values, the production of the film was improved using infrared heating at 50°C and an air flow of 12 m/s. This combination reduced drying time to 7.22 minutes. Ultra-high pressure liquid chromatography with tandem mass spectrometry (UPLC-MS/MS) revealed that LAE releases from the LAF followed a twophase pattern: an initial burst followed by sustained release. This release profile is promising for enhancing the film's antimicrobial efficacy, although further research is needed to assess the stability of LAE within the coating and explore the use of costeffective materials.
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