Sensor Trends in Beverages Packaging

SENSOR TRENDS IN BEVERAGES PACKAGING

10

Bambang Kuswandi⁎, Mehran Moradi† ⁎

Chemo and Biosensors Group, Faculty of Pharmacy, University of Jember, Jember, Indonesia, †Department of Food Hygiene and Quality Control, Faculty of Veterinary Medicine, Urmia University, Urmia, Iran

10.1 Introduction Nowadays, the era of the Internet of things (IoT) is revolutionizing not only our lifestyle but also many functions and operations in various industries. This new “smart era” is signed by operating on adaptive intelligence filled with the various information and communication technologies (ICT), such as near field communications (NFC), radiofrequency identification (RFID), mobile, wireless, and sensor devices (Xu et  al., 2014). Sensors, in particular, might seem like one tiny aspect of IoT, but they have the potential to change how certain industries work (Gubbi et al., 2013). The application of sensors in various fields, including packaging, has endorsed them in many industries. Surprisingly, the sensor market is expected to reach a fantastic project value of $60 billion by the year 2022 (Fathima, 2017). This projection shows the massive impact of the sensor on the industry. Various industries are now integrating sensors in product packaging, including packaging machinery. Equipped and tagged with sensors that can recognize and sense the temperature, pressure, position, motion, and touch, these technologies are sifting the products management, such as packaged products, stored, distributed, and marketed (Biji et  al., 2015). Companies have realized that the use of such sensors in product packaging can be an integral part of complete operational improvement. Particularly, the application of sensors in product packaging has given great benefits for both producers and customers, when they are deployed in pharmaceutical and food and beverage packaging. Beverage companies, for instance, are using smart packaging for their finished goods and products. The smart packaging works in cooperation with sensor technology and packaging materials that are integrated with various smart technologies. For example, on-package sensors help significantly in controlling and monitoring various Trends in Beverage Packaging. https://doi.org/10.1016/B978-0-12-816683-3.00010-4 © 2019 Elsevier Inc. All rights reserved.

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aspects of foodstuff and beverage, such as temperature, moisture, and gas, mainly oxygen and carbon dioxides (Adley, 2014; Kuswandi, 2017). Sensors for beverage packaging are not always the electronic devices; they could also be in the form of an indicator showing a color change when beverage condition change (Arvanitoyannis and Stratakos, 2012). In this regard, sensors not only allow monitoring and controlling over beverages, but they also enable easy tracking of the beverage via the supply chain as shown in Fig. 10.1. This method significantly increases an efficiently controlled and well-monitored beverage supply chain, wherein both good and damaged beverage products can be monitored easily (Biji et  al., 2015; Kuswandi et  al., 2011). In addition, the application of RFID technology in the beverage packaging would help to keep a track on the movement of beverage supplies in logistics, distribution, and marketing (Sarac et  al., 2010; Ramos et al., 2015). Currently, there is a research on developing a sensor capable of detecting the expiry and deterioration of beverage and alerting the suppliers before they can cause a severe effect on customers, such as poisoning. Overall, the smart packaging market will be significantly increased simultaneously with an increase in the need for food quality and safety in the coming year (Kuswandi, 2017). Globally, smart packaging market in various beverage products will grow considerably. Since, employing sensors or indicators to sense, monitor, and control the degree of temperature, pressure, moisture, Polymer matrix

Sensors/indicators

External protection layer

Beverage

Oxygen barrier layer

Diffussion

Oxygen scavenging layer

PET inner layer

Gas or vapor molecules

Adsorption Desorption

Fig. 10.1  Scheme for the general mechanism of gas permeation through a multilayer beverage packaging system including sensor/indicator for quality and safety monitoring.

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oxidation, and motion has assisted several manufacturers to present their products in the best condition (Ramos et al., 2015). All parts of the emerging smart packaging technologies in beverage including the use of sensors or indicators, either physical, chemical, and biosensor are composed to mark a revolutionary change in the way how beverages are intelligently packed. Therefore, this chapter aims to reveal recent developments in sensor applications on beverage packaging, packaging lines, storage, distribution, and retail. Sensors or indicators integrated into smart packaging are categorized as direct/internal and indirect/external sensors or indicators, including RFID. Some of the sensors and indicators as well as labels that are mainly used in beverage packaging, including signs of product quality and safety, tamperproof, package strength, integrity, tracing, and antitheft detecting devices as well as product originality or genuineness (being anticounterfeit) are listed in Table 10.1. In addition, recent advances in beverage packaging technologies, including technology-driven inspection used to monitor both the quality and safety of beverage in packaging lines to avoid product losses and unnecessary quality decay within packaging lines are highlighted and discussed, such as leak and gas detection, X-ray and metal detection, machine vision, and other inspection devices.

10.2  Smart Packaging Smart sensor or indicator-integrated packaging provides information on the condition, integrity, and the time-temperature history of the food package, helpful in assuring the freshness, quality, and safety of the packaged food products (Ahvenainen, 2003; Kerry et al., 2006),

Table 10.1  Some of the Sensors and Indicators, as Well as Labels That Can be Applied in Beverage Packaging, are Listed as Follows Signs of product quality and safety Tamper-proof, package strength, and integrity Tracing and antitheft detecting devices Product originality or genuine (anticounterfeit)

Time-temperature indicator and regulators, gas detecting devices, microbial detection, pathogen growth biosensing Infringement of packed items Radio-frequency identification (RFID) chips, label, logos, stamps Holographic contents, tags, label, concealed print layout aspects, RFID for automatic identification and data capture

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including beverage (Kuswandi et  al., 2011; Kuswandi, 2017). Thus, while protecting and preserving food as the food packaging principal roles (Robertson, 2006), it also communicates and gives information on food quality, such as freshness, traceability, tamper indication, or safety via its sensors or indicators. Thus, smart or intelligent packing is the packaging technologies in foodstuff and beverage to deliver fresh, quality, and safer food products from the producers to the customers. Therefore, the first important function performed by smart packaging is to monitor both internal and external conditions via recording changes occurring both outside and inside the packaging. The latter function of smart packaging is assessing the quality of the product directly within the package which involves intimate association with the headspace or product, necessitating the use of sensors or indicators for the safety and quality of packaged food and beverage item. In smart packaging, the sensor or indicator is employed, where it can be defined as a tool or device used to determine, detect, or quantify matter or energy giving a response or signal for the determination or measurement of a chemical or physical characteristic to which the device gives response (Kress-Rogers, 1998; Kerry et al., 2006). These sensors have been considered as the most promising and game-changing technology for future smart packaging systems. Sensors give signals as the output, where the most of them consist of two main elements; they are a receptor and a transducer. Another common term used is an indicator which can be defined as a material or substance indicating the absence, presence, or concentration of another substance as a marker or the reaction degree between two or more substance by means of a property change, such as color/energy or mass (Hogan and Kerry, 2008). So, these two terms are commonly changeable when it is used in the smart packaging, but mostly indicator refers to colorimetric sensor either the chemical sensor or biosensors. Typical chemical sensors can be used to determine ethanol and glycerol, products of alcoholic fermentation. Enzymatic biosensors can also be produced for determining the concentration of these products as well as the content of sulfite ion in wine. A chemical sensor is defined as a chemically-sensitive film or a membrane that is capable of detecting the presence, composition, activity, and concentration of target chemical or gas through surface adsorption and diffusion. Then, the detected target chemicals are converted into measurable signals by the transducer, passive or active depends on the electrical power used for measurement (Vanderroost et al., 2014). A current advance in chemical sensors is the use of optical transducers that do not require the electrical power and can be read out from a distance by using a light of UV, visible, NIR, IR, or even the nude eye. Optical transducers based on silicon devices are composed of optical circuits integrated into silicon semiconductor materials

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(Yebo et al., 2012). Similarly, biosensors also consist of two main functional elements; bioreceptors and transducers (Kuswandi et al., 2001; Alocilja and Radke, 2003). Biosensors are defined as tools or devices used to determine, detect, and transduce its biochemical reactions into information regarding the target analyte (Kuswandi et al., 2001; Yam et al., 2005). Here, the bioreceptor detects the target analyte, then converts biochemical signals by the transducer into the measurable response (Kuswandi et  al., 2001; Yam et  al., 2005). The bioreceptors may be either biological or organic material, such as enzyme, antigen, nucleic acid, hormone, microbes, etc. The transducers could be optical, electrochemical, or mechanical. Such packaging systems contain sensors capable of sensing and providing information regarding the properties and functions of the packaged beverages. These types of sensors can be categorized into three groups; the first type is direct or internal sensors (inside the packs), the second type is indirect or external sensors (attached to outside of packages), and the third type is sensor that increases the efficiency and effectiveness of information flow and communication between product and the consumer (Han et al., 2005). Examples of internal sensor and external sensors and their working principles used in smart packaging are shown in Table 10.2. Here, smart packaging can play a critical role in facilitating the flow of both materials and information in the cycle of the beverage supply chain. In this regards, for practical packaging systems, they should be easy to use, capable of handling multiple tasks, and cost-effective.

Table 10.2  Examples of Internal and External Sensors or Indicators Used in Smart Packaging Sensors/Indicators

Principles/Reagents

Information Given

Application

Oxygen indicators (internal) Microbial indicators (internal) Freshness indicators (internal) Time-temperatures indicators (external) Temperatures indicators (external)

Redox dyes, pH dyes, enzymes pH dyes, all dyes reacting with certain metabolites pH dyes, all dyes reacting with freshness marker Mechanical, chemical, enzymatic Mechanical, chemical, enzymatic

Package conditions package leak Microbial quality of beverage (i.e., spoilage) Freshness quality of beverage Storage conditions

Water, beverages, and oil

Storage conditions

Milk and juices Milk, juices, and coffee Beverage stored under chilled conditions Beverage served under hot and cold conditions

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For instance, the freshness sensor for beverage packaging consists of a sensor that monitors the freshness condition of the beverage inside the packaging to give information associated with the quality and safety of the beverage during transportation, distribution, storage, and display (Kuswandi et al., 2011). This sensor technology can result in a variety of sensor designs suitable for real-time monitoring of food and beverage quality and safety, such as freshness, oxygen, temperature, and time-temperature, and even microbial or pathogen detections. These freshness sensors are proposed to meet the increasing need for freshness, quality, and safety of beverage products with longer shelf life. The market needs for sensor or indicator in the beverage packaging systems are predicted to have a promising future, thanks to their integration into packaging systems or materials. This is due to the fact that the growing needs for beverage information on packaging increase as consumers increasingly need to know what ingredients or components are in the product and how the product should be stored and used, will also means there has to be a step change in providing this information, and this will drive the need for sensor or indicator in future of beverage packaging. Furthermore, quality sensors will be capable of communicating directly to the customer via sensor film or label devices providing visual information on the quality and safety of the beverage product. Thus, the sensors in beverage packaging serve as active shelf life labeling devices and coupled with the “used-by-date” labeling or can be employed to optimize control of distribution, the management system of stock rotation, and reducing beverage waste as the most important.

10.3  Internal Sensors/Indicators The internal sensors or indicators directly sense or detect a target marker or compounds as an indication of beverage quality and safety. In this regards, various internal sensors have been developed for good quality monitoring of the beverage products, such as oxygen indicator, contaminant indicator, and others. Even in the beverage packaging, internal sensors have been applied less than external sensors, where the sensors were mainly in the form of a color indicator for easy detection by the naked eye. Here, the rate of color change in the indicator correlated well with the degradation of the beverage product in respect to temperature variation and time during transportation, distribution, storage, and display.

10.3.1 Oxygen Sensors Gas sensors, such as oxygen sensors, are devices that response reversely and quantitatively to the oxygen presence level by changing the physical parameters of the sensor, and are monitored by an

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external device (Kerry and Butler, 2008). For instance, the OxyDot (OxySense Inc., Las Vegas, EE.UU.) is a light-sensitive and noninvasive oxygen sensor placed inside a package or bottle before filling and sealing. The oxygen measurements are performed with a fiber-optic reader pen from outside the bottle or package (http://www.oxysense. com/how-oxysense-works.html). Herein, the measurement of oxygen is based on the quenching of the fluorescence of a metal organic fluorescent dye that immobilized in a gas-permeable hydrophobic polymer membrane. The light absorbs by the dye in the blue region and then fluoresces in the red region of the spectrum. The oxygen presence quenches the fluorescent light from the dye as its lifetime. Similarly, the UPM label (UPM Finland) “Shelf Life Guard” turns to blue from transparent; giving information on the consumer that air within the package has replaced by the modified atmosphere gases (http://www. upm.com). Generally, the commercially available oxygen-sensitive indicators have the main application to ensure the proper functioning of oxygen absorption. For example, Mitsubishi Gas Chemical Company (Japan) commercialized their oxygen-absorbing sachets under the trade name “Ageless” (http://www.mgc.co.jp/eng/products/abc/ ageless/eye.html). The indicator is activated at the time of consumption, the seal is broken when a timer goes off, and a color change is progressed over time (Realini and Marcos, 2014). In beverage, the indicators must be in direct contact with the gaseous environment surrounding the beverage packaging. The presence of oxygen in beverage packaging may indicate that the package has been tampered with or improperly sealed. The synthesis and manufacture of a nontoxic surface coating activated by exposure to molecular oxygen of a substrate via the irreversible formation of colored spots have been described in the literature (Shillingford et  al., 2016). Currently, EMCO packaging has developed OxyFresh, an irreversible oxygen indicator label (http://www.emcopackaging.com/index.php/products/oxygenindicator-labels). FreshPoint Lab has provided O2Sense as a luminescence oxygen indicator label for packaging of foodstuff and beverage (http://www.freshpoint-tti.com/technology/default.aspx).

10.3.2 Contaminant Sensors Development of smart packaging for beverages has led to the application of nanosensors for the detection of beverage contaminants, such as allergens, adulterants, or even food-borne pathogens in complex food matrices (Kuswandi, 2017). The most commonly used of the assays in nanosensors are based on colorimetric method, where the color changes occur to nanosensor in the presence of the analyte. For instance, gold nanoparticles (AuNPs) and crown-ether-modified ­thiols

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were employed to detect an adulterant content, such as melamine, in raw milk and infant formula. The surface of AuNPs bonded by the melamine causes a color change from red to blue. This method allows real-time and on-site detection of melamine without the need for any advanced instrumentation (Ai et al., 2009). Another efficiently ­fluorescence-based assay for cyanide in drinking water was developed using the quenching of fluorescence of gold nanoclusters (Liu et  al., 2010). A nanosensor based on nanoscale liposome-based fluorescence was also reported for the detection of pesticides in drinking water (Vamvakaki and Chaniotakis, 2007). Magnetic nanoparticles were used to isolate Mycobacterium avium spp. paratuberculosis from contaminated whole milk to measure the concentration of bacteria by observing conjugation effects of induced magnetic nanoparticle agglomeration on the spin-spin relaxation times of nearby water protons (Kaittanis et al., 2007). Electrochemical immunosensor operated by selective binding with antibodies to a conductive nanomaterial, and then monitor the conductivity changes of the nanosensor-linked antibody when the target analyte binds to them. Electrochemical detection may be more useful compared to optical methods (colorimetric or fluorimetric) for foodstuff and beverage matrices because the problem of light scattering and absorption from the various food components can be avoided (Duncan, 2011). AuNPs immobilized with pyranose oxidase can be used to determine glucose concentrations in commercial beverages (Ozdemir et al., 2010). An immunosensor based on piezoelectric AuNP has also been reported to determine the ­aflatoxin-B17 presence in contaminated milk samples (Jin et  al., 2009). Furthermore, Microcystin-LR, a toxin produced by cyanobacteria makes conduction changes occur when binds to the surface of ­anti-MCLR-coated single-walled carbon nanotubes that are proposed as a platform for nanobiosensing detection for toxin in drinking water (Wang et al., 2009).

10.4  External Sensors/Indicators External or indirect sensors or indicators respond based on indirect detection of a quality marker of beverage, where they are expected to mimic the change of a certain quality parameter of the beverage product that undergoing the same exposure to temperature as the sensor placed outside packaging. In order to be applied as beverage quality monitoring devices, the rate of change of the sensor or indicator must correlate well with the rate of degradation of the beverage according to the temperature variation over time during transportation distribution, storage, and display. Similar to internal sensors, the external sensors will change color when it is exposed

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to a higher t­ emperature than a recommended temperature for storage and will also change as the product reaches the end of its shelf life. Recently, the sensors or indicators that can be considered as the external sensor are temperature indicator (TI), time-temperature indicators (TTIs), and RFID that employ commercially for beverage packaging as given in Table 10.1.

10.4.1  Temperature Indicator Adding a self-heating or self-cooling container to a sensor to tell the consumer that it is at the right temperature will make the package “smart” (such packaging is currently commercially available). The most commonly used TI is a thermochromic ink dot, it is used to indicate the product is at the correct serving temperature after following by refrigeration or microwave heating. The plastic containers of pouring syrup for pancakes that can be purchased in the United Kingdom or United States are labeled with a thermochromic ink dot to indicate when the syrup is at the correct temperature after following by microwave heating. Other examples can be found with orange juice pack labels on supermarket shelves that incorporate ­thermochromic-based designs to give information on the consumer when a refrigerated orange juice is cold enough to be drunk (www. tetrapak.com). Another example of TI is the bottle of Coors Light, where a thermochromic ink is used to inform that the beverage has reached right and desired temperature for consumption (www.coorslight.com). Furthermore, Smart Lid Systems, (Sydney, Australia) (www.smartlidsystems.com) has also developed a TI technology. The smart lid is infused with a color-changing additive allowing it to color change from a coffee bean brown to a bright red color when it is exposed to an increase in temperature. The color change starts at 38°C and reaches intensity fully at 45°C. The red color appears instantly to indicate consumers that the coffee in the cup is too hot to be drunk comfortably. Here, the brown color will not be distributed evenly, if the lid is locked and not positioned correctly. It is showing that a potential for spillage exists. This color-changing additive is safe on food contact surfaces since it meets the requirements of the US regulations related to direct food contact materials additives (www. smartlidsystems.com). This technology has also been integrated into beverage machinery. Herein, the Curtis ALP3GT Brewing Systems use an innovative method to keep decanters ready to serve brewed coffee freshly using FreshTrac technology (www.vendingmarketwatch.com). FreshTrac includes a visual indicator that can be detected easily by the naked eye to indicate the coffee freshness which can range from 10 to 120 min.

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10.4.2  Time-Temperature Indicators Temperature fluctuations are one of the important factors that affects the beverage products quality. Even though a product is processed, packed, and shipped at the right temperature for prolonged shelf life, however, its quality may be lost due to temperature fluctuations during shipment and storage prior to retail sale. TTIs on packages can provide consumers with an assurance and a sense of the product’s quality to ensure that temperature abuse does not occur. They are small measuring devices capable of showing a time-temperature- dependent relationship as an irreversible color change (De Jong et al., 2005). Commercially available TTIs are given in Table 10.3.

Table 10.3  Commercially Available Extrinsic Sensor for Beverage Monitoring Trade Name

Company

Type

Shelf Life Guard Ageless Eye OxyFresh O2Sense Novas Best-by Smart lid Timestrip PLUS Duo Thermochromic ink Timestrip Complete MonitorMark Fresh-Check Onvu

UPM Mitsubishi Gas Chemical Inc. EMCO FreshPoint Lab. Insignia Technologies Ltd. FreshPoint Lab. Smart Lid Systems Timestrip UK Ltd. Tetrapak Ltd. Timestrip UK Ltd. 3M, Minnesota Temptime Corp Ciba Specialty Chemicals And Freshpoint Vitsab Pymah Corp Color Therm Thermographic Measurements Ltd. CAEN RFID Srl Mondi Plc Convergence Systems Ltd. Temptrip LLC

Oxygen indicator Oxygen indicator Oxygen indicator Oxygen indicator Integrity indicator Integrity indicator Temperature indicator Temperature indicator Temperature indicator Time-temperature indicators Time-temperature indicators Time-temperature indicators Time-temperature indicators

Checkpoint Cook-Chex Color-Therm Thermax Easy2log Intelligent Box CS8304 Temptrip

Time-temperature indicators Time-temperature indicators Time-temperature indicators Time-temperature indicators RFID RFID RFID RFID

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TTIs from 3M (http:solutions.3m.com) called MonitorMark has two versions; one intended for monitoring distribution, the threshold indicator for the industry, and other intended for consumer information, the smart label. In the smart label, they are used as an abuse ­indicator, which means that it yields no response unless a predetermined temperature has been exceeded. It works based on a special substance having a selected melting point and blue dye. A filmstrip separates the wick from the reservoir removed at the activation stage. At this point, the porous wick, white in color, is shown in the window. On exposure to a temperature exceeding the critical temperature, the substance melts and begins to diffuse through the porous wick, causing a blue color to appear as shown in Fig. 10.2A. There are available indicators with different critical temperatures from −15°C to 26°C. The consumer label is a partial-history indicator that changes color when exposed to higher than recommended storage temperature and will also change as the product reaches the end of its shelf life. The work based on the melting and diffusion of the blue dye as described previously. Timestrips (www.timestrip.com) are smart labels that can be used to monitor how long a foodstuff and beverage have been open or how long they have been in use. They can detect elapsed time from minutes up to over a year, in the freezer, chiller, at normal ambient, or even at elevated temperatures. Inside the Timestrip is a special porous membrane through which a food-grade liquid diffuses in a consistent and repeatable way. They are activated by squeezing a start button which moves the liquid into direct contact with the membrane. Then the liquid diffuses through the membrane by the physical laws. On the top surface of the Timestrip, the markers have been printed that

Fig. 10.2  (A) MonitorMark TTIs product from 3M (solutions.3m.com) and (B) Freshtag® TTIs product from Vitsab (www.vitsab.com).

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i­ nform the all-important time since activation, and space for branding as well as other graphics. As most applications require the Timestrip to adhere to a package or a product, they can be chosen from a wide range of adhesive tapes on the underside to fit the specific needs of the customer. Fresh-Check (www.lifelinestechnology.com) is a smart label for a fresh indicator that supplied as self-adhesive labels, which can be applied to packages of perishable products including beverage, such as milk, juice, etc. to ensure consumers either at point-of-purchase or at home where the product is still fresh. The active center circle of the Fresh-Check darkens irreversibly, faster at higher temperatures and slower at lower temperatures. Thus, it is easy to see when to use or not use the product within the product date codes. As the active center is exposed to temperature over time, it gradually changes color to show the freshness of the foodstuff and beverage product. The working mechanism of this full history indicator is based on the color change of a polymer formulated from diacetylene monomers. It consists of a small circle of polymer surrounded by a printed ring for color reference. The colored polymer, which starts lightly colored, gradually darken depends on the color that tends to reflect the cumulative exposure to temperature. The polymer changes color at a rate proportional to the rate of food degradation till quality loss. Thus, the higher the temperature, the faster the color of the polymer changes. CheckPoint (www.vitsab.com) is also a simple adhesive label attached to food or beverage cartons to check for temperature abuse. It monitors a carton or beverage package from the food processor to the retailer, staying with the package until the point of retail sale. These labels react to time and temperature in the same way, where the beverage product reacts and thus give a signal about the freshness state and remaining shelf life. This signal is an easyto-read color dot as shown in Fig. 10.2B. This is a full history indicator that works based on enzymatic reaction. It consists of a bubble-like dot containing two compartments; one for the enzyme solution, lipase plus a pH indicating dye and the other for the substrate, consisting primarily of triglycerides. The dot is activated at the beginning of the monitoring period by pressing on the plastic bubble that breaks the seal between compartments. The ingredients inside are mixed and, as the reaction precedes, a pH change results in a color change. The dot, initially green in color, becomes progressively red as the product approaches the end of shelf-life. They work like a stop light: Start green, near the end of their calibration they will change to yellow then red. The reaction is irreversible and will proceed faster as the temperature is increased and slower as the temperature is reduced.

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10.4.3  Traceability With RFID RFID does not really fall into either sensor or indicator classification but rather represents a separate electronic information that used on smart packaging (Kerry et al., 2006). RFID is an identification technology based on wireless sensors to identify and track the items and gather data automatically. It is used with tags and readers that programmed with unique information and attached to the product for identification and tracking purposes (Tajima, 2007; Hong et al., 2011). The tags store certain kind of identification number that the reader can retrieve information associated with the identification number from a database and act accordingly upon it, such as location, product name, product code, and expiration dates (Han et al., 2005; Todorovic et al., 2014) as given in Fig. 10.3. Depending on the power supply for communication and other functions, RFID tags are classified into three categories of passive, semipassive, and active. Passive tags have no internal battery;

Fig. 10.3  Schematic representation of the RFID system.

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t­herefore, they are not able to communicate until the emission of RFID reader is activated. The radio-frequency field produced by the reader provides enough power enabling integrated circuit of the label to reflect energy to the reader. Semipassive tags use a battery to maintain its memory or power the electronics inside the tag to modulate the radio-frequency field emitted by the antenna of the reader. Active tags powered by an internal battery are used to run the microchip’s circuitry and to produce a signal to the reader (Vanderroost et  al., 2014). RFID has been applied successfully to traceability control and supply chain management processes due to its ability to detect, identify, categorize, and manage the flow of foodstuff and beverage (Jones et al., 2004; Sarac et al., 2010; Ruiz-Garcia and Lunadei, 2011). RFID tags can be of great use when products are to be recalled. Traceability of products can be addressed when using RFID tags which are better than the barcode system for food traceability (Jedermann et al., 2009). Nowadays, RFID provides visibility of supply chain enables rapidly automated processes at the chain for rapid and automated processes at the levels of the supply chain such as exception management and sharing of information (Tajima, 2007). In the case of a product recall due to food poisoning, this technology can make more efficient and effectively when RFID used. Thus, it can create the ability to trace and recall, if necessary, not only the products but also its ingredients and packaging materials. The use of passive RFID sensors for monitoring the freshness of milk using RFID tags from Texas Instruments (Plano, TX, United States) has been reported (Potyrailo et  al., 2012). In this system, changes in the milk dielectric properties were detected with these RFID that had an adhesive backing attached to the sidewall of the milk cartons. RFID tags can be also employed to help combat counterfeit liquor sales, for example, whiskey, by reading the tag on the bottle using the dongle, which transfers the unique verification number of each product to the server of the National Tax Service via wireless Internet (Yam and Lee, 2012). Beverage Metrics Company has been used active RFID tags to provide a complete solution to trace and tract liquor bottles (Swedber, 2016). Herein, a bar’s manager can measure how much liquor a bartender pours per drink, based on a tilt sensor in the RFID tag. Furthermore, this system can also be used by the customer to receive an alert when a liquor bottle or wine disappears from the system, such as if they have been stolen (Swedber, 2016). The most benefit of the employment of RFID is the integration of time-temperature sensors to RFID devices attached to boxes or pallets during transport, allowing tracking of food temperature during the whole chain of food and beverage. This causes an improvement in efficiency of supply chain management (Realini and Marcos, 2014). In this context, an advanced technology is applied to fine wines in order to authenticate

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and track from producer to consumer, monitoring and recording the storage temperature by using eProvenance Fine Wine Cold Chain Systems, which are a combination of passive and semipassive RFID tags (www.epc-rfid.info/rfid_tags). Currently, a sensor employing RFID with tags are commercially available to detect and monitor the relative humidity, temperature, light exposure, pressure, and pH of the foodstuff and beverage products. These tags identify the possible interruptions of the cold chain harmful to the product safety and quality (Vanderroost et  al., 2014). Nowadays, many advantages have been made in RFID, such as the development of a pH sensor embedded in a passive RFID tag, the tags used for the real-time evaluation system of freshness of the packaged milk during distribution, marketing, and sales (Potyrailo et al., 2012), RFID tag with an optical oxygen indicator for use in MAP (MartínezOlmos et al., 2013), and the tag along with CO2 and oxygen sensor for the freshness monitoring of vegetables and juices (Eom et al., 2014). Thus, various companies have various RFID solutions on the market depending on the consumer demand and need as shown in Table 10.3.

10.4.4 Authenticity, Antitheft Devices, and Tamper Evidence Even though counter fitting and theft are not too common in the beverage industry, they do pose a huge economic burden in other industries. Usually, electronic article surveillance (EAS) is used to deter the theft of high priced products. Commonly, such devices are found in beverage retailers, where expensive items such as beer, wine, etc. can be seen fitted with EAS devices. Another global issue is tampering, for which more sophisticated antitampering devices or packages with responsive technology are necessary to control and minimize these problems (Han et  al., 2005). For instance, the use of thermochromic materials can provide a closure which “bruises” during any attempt to tamper with the product, thus alerting the consumer before the products are purchased (Ahvenainen, 2003). Furthermore, Anticounterfeiting can be developed using holograms, tear labels and tapes, micro-tags, and diffraction devices in order that products are original. Near field communication (NFC) is another form of data recognition technology, which is generally used for smartphones with close devices, such as in the now-familiar form of quick response codes. This technology actually is an upgrade to RFID technology, allowing the data exchange between close devices at distances less than 10 cm (Vazquez-Briseno et al., 2012). Diageo Company has applied this short-range communication technology in beverage ­packaging,

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for example, whiskey and wine, with electronically tagged bottles providing supply-chain tracking to consumers (Packaging Digest, 2016). Herein, the NFC technology is used in the bottle, integrated with labeling, to let consumers interact with the package using smartphones with NFC-application. Thin and flexible NFC tag is attached to each bottle, making it possible for consumers to tap their smartphone simply to the bottle’s back label to access product and brand information. In this context, the NFC is well-positioned devices particularly for anticounterfeiting, as another strong potential market for printed electronic systems. Since the NFC protocol allows modern consumers to carry out product verification themselves, it is increasingly becoming commonplace on smartphones (Advance Packaging World, 2016). Therefore, the NFC can be seen as an advancement of RFID technology, since both of them use radio frequencies for communication; however, NFC has a very short transmission range, in this way NFC-based transactions are inherently secure, while RFID can operate in a long distance range, thus NFC is more suitable for exchanging sensitive information in short distance compared to RFID.

10.5  Other Sensors and Devices Technology-driven inspection for processing and packaging industries in food and beverage has resulted in various methods for quality assurance, identification, and traceability of products. In this context, to reveal developments in sensors applied to beverage packaging lines, manufacturing companies are making smart cameras and highspeed cameras easier to use. Currently, there is a trend for companies to provide portable as well as in-line instrumentation, for example, gas leak detectors and in code readers, etc. RFID is an emerging technique for improving traceability in the supply chain, and some labeling machines additionally program an embedded chip as described above. Other sensor systems on display, and relevant to quality assurance, included X-ray and metal detection equipment for revealing contaminants in food and beverage and leak detection systems for ensuring the integrity of modified atmosphere packaging (Connolly, 2007). The development of these new sensing systems is being boosted by consumer awareness of food safety concerns, and by the producers’ cost considerations regarding product recalls. The hazard analysis and critical control point (HACCP), international and national food standards agencies that have been implement the programs for food safety, and their recommendations and regulations increasingly affect the food and beverage packaging industries, including their encouragement to the adoption of technology-driven inspection and monitoring in the logistics, supply chain, and retail sectors.

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10.5.1  Leak and Gas Detection Witt Gas Techniques Ltd. produces leak detection systems for food and beverage packaging, called LEAK-MASTER INLINE machine that fits on the packaging line immediately after the packaging process (www.wittgas.com). Packages move along the conveyor belt into the testing chamber, where a ceramic sensor detects any leaking carbon dioxide and triggers an alarm. It is a fully automatic and nondestructive micro-leak detector with a measuring range of 0–5000 ppm and a resolution of 1 ppm and operates at speeds of up to 15 test cycles per minute. This manufacturer also produces mobile hand-held gas analyzers, for example, OXYBABY V (www.wittgas.com). This mobile oxygen or oxygen/carbon dioxide detector is powered by rechargeable batteries, where the gas was sampled rapidly with a fine needle and logs up to 100 readings. Its software provides traceability of the logged measurements for HACCP purposes. The instrument uses an electrochemical cell for oxygen detection and infrared absorption of carbon dioxide. It needs a minimum of 4 mL of gas for oxygen d ­ etection, and 6 mL for combined O2/CO2, and can be used to check small packages, for example, milk powder, juices, etc. The result is displayed within a second on its graphics display, with a range from 0% to 100% in steps of 0.1%. The oxygen sensor has a lifetime within 2 years, while the carbon dioxide detector has an unlimited lifetime. A piercer attachment for the portable detector allows users to detect the gas in the headspace of bottles and cans of soft drinks and alcoholic beverages.

10.5.2  X-ray and Metal Detection The X-ray is an automated food inspection that is necessary to reduce both labor costs and maintain high productivity. Two important methods are widely employed: X-ray-based inspection and multispectral inspection. The X-rays absorption differences are caused by the difference in density or thickness in the food to be packaged is used as a principle work for inspection. It is also possible to detect both small and large product contaminants such as glass, plastic, rubber, bone, stone, and metal in foodstuff and beverage. Food and beverage producers need to ensure that products and packaging contain no external materials. Contaminants, such as metals can be detected by determining magnetic properties of metals or metals electrical conductivity. As X-ray absorption depends on the chemical composition of the material, therefore, X-ray is able to detect contaminants both metallic and nonmetallic (Connolly, 2007). Thus, external objects are detected by the difference between their absorption and that of the surrounding material and need to be tuned to the particular product and contaminant. Nowadays, X-ray machines are used on beverage

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lines to detect stones or wood contamination in natural products such as juice and milk, and metal or glass in liquor and wine. Company, such as Separation and Sorting Technology GmbH, has been worked with customers in different industries to produce and develop systems for contaminant inspection, including a system called Raycon X-ray inspection system for the packaging industry that determine a range of contaminants in packaged goods, checks for the individual weight of the product components, and checks for low fill as well as air inclusions (www.se-so-tec.com). This second-generation system is with advanced capability of image processing, using a lower power X-ray source. Here, the integrated high voltage power supply of X-ray tubes generate a beam of radiation that spans the width of the product, while the conveyor belt motion scans this along with the product’s length. Then, a transducer measures the intensity of the X-radiation emerging and converts it to a digitized X-ray absorption image that amenable to image processing techniques. Thus, product defects can be detected including leaks and contaminants. Ishida Europe Ltd. produces the IX-GA X-ray inspection system with a self-learning genetic algorithm to optimize both reliability and sensitivity, to detect impurities down to 0.3 mm in size. It detects material such as tin and aluminum, hard rubber, stones, plastic, and shells in food and beverage products in top-sealed, thermoformed trays, and flexible bags, as well as in unpacked products. In addition, it is able to distinguish unexpected metal components such as the clips on sausages and juices, from external items. In order to protect the user against exposure to X-radiation, the stainless steel body accompanied lead curtains, warning lights, and automatic stop procedure. S+S Inspection Ltd. produces a range of inspection machines in addition to the Raycon X-ray system that can remove and recycle contaminants (www.splussinspection.com). Using a fast-moving ejector flap, the Rapid 5000 system detects and separates metals from freefalling bulk materials and is used for powders and fine-grained substances, for example, herbs and spices, tea, milk powder, and cereals immediately prior to bagging or carton filling. The Varicon-D is a conveyor-based metal detection system where packed or unpacked products can be examined. There it consists of a wide range of pushers, blow nozzles, and swivel arms to be used in conjunction with the detector to separate the faulty products in many different applications. The company also has produced the Liquiscan system that can be used for removing metal particles from viscous liquids and pastes. The GF 4000 is a metal separator for vacuum or pressure feed systems in the plastics industry. The S + S range of systems measures magnetic properties, density, polymer structure, chemical composition, color intensity, and transparency as well as electrical conductivity.

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10.5.3  Machine Vision and Other Inspection Devices Currently, image processing, become a trend for the nondestructive method for foodstuff and beverage inspection and grading (Park et  al., 2008). Current developments in hardware and software have extended to accommodate multispectral and hyperspectral imaging technique for advanced food and beverage quality and safety inspection, such as detection of defects, contamination, and even disease. The dual-band spectral imaging systems have a two-port camera system where consists of the CCD cameras with the two identical monochromes, an optical system with the two narrow bandpass filters. The optical components of the imaging system have a lens unit, a beam splitter, and two bandpass filters as well as two back lens units. The basic principle of the optical system involves the reflected light of an object that being collected by the front lens and then split by the beam splitter, where 50% is reflected back at a right angle, and then the rest is allowed to pass through straight. Two bandpass filters are enclosed in C-mount filter holders and attached to each exit port of the beam splitter. Fourier transform infrared spectroscopy (FTIR) is applied to detect contaminants, such as sulfite in alcoholic and nonalcoholic beverage (Verma and Deb, 2007). Near-infrared (NIR) chemical imaging is investigated, based on differences observed at unique wavelengths, as a tool for the high-throughput analysis of self-contained microbial identification including quality attributes such as physical and chemical characteristics, which allow determination of protein, fat, moisture or even tissue content in food and beverage (Dalle Zotte et al., 2006). Cognex Corp. produces a various handheld and fixed-mount readers, with a software algorithm called IDMax to recognize and decode the 2D matrices very rapidly (www.cognex.com). The DataMan 7500 series consist rugged handheld devices with a shock-absorbing rubber over-mold that read 1D and 2D codes (Fig.  10.4). These readers are essentially smart cameras with special purpose by integrating lighting, imaging, and software. In order to help the operator aim at the code, the device projects a horizontal green light bar and is activated by a manually operated trigger. The pixel image sensor provides sufficient resolution for the software to decode 13 mil barcodes at up to 62 mm distance, and 5 mil 2D codes at up to 35 mm. The low-angle lighting for dot peen and laser-etched marks provided by “UltraLight” illumination system, and diffuses illumination for marks on reflective curved surfaces, and then the software automatically selects the best illumination for each marking method and material that it encounters. Furthermore, similar to the traditional smart camera, Cognex’s In-Sight fixed mount ID readers are designed to be mounted permanently at various stages in the production line. The series includes the

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Fig. 10.4  The DataMan 7500 manufactured by Cognex Corp. is a handheld 1D and 2D code reader that automatically selects the best lighting for the particular mark (www.cognex.com).

7200 part-per-minute-throughput 5410 model and the high-­resolution 5411 model could be used for verifying the code qualities of rather than just reading them. A smart imaging sensor called Checker 101 with built-in lighting and industrial input/output connector for part detection and inspection (www.cognex.com). It detects parts at up to 3000 pm without an external trigger. In addition, it uses a browser-like interface to guide the user through the steps of teaching the part and selecting the features for inspection that can be used by untrained operators. This company has extended its well-established PatMax geometric pattern matching tool and produced PatFlex, which works on flexible packaging and finds logos as well as text on packages that change shape during production. It can be employed in conjunction with gauging, guidance, and inspection tools. In the production line, it can be installed at multiple points the machine vision systems that read barcodes and text as well as inspect for defects, measure parts, monitor color and sort, and count products, even more, note orientation for handling devices. Olympus also produced i-SPEED 2, a high-speed camera that is portable and no needs for PC to operate (www.olympusindustrial. com). It is produced to be user-friendly, with applications in studying bottlenecks and jams in the processing line and capturing images at

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high speed for slow-motion playback as well as study. The images can then be transferred to a PC for further detailed investigation, via removable flash cards or via the Ethernet or Bluetooth connection. The camera consists a custom-designed CMOS sensor that incorporates a high-speed processor with measurement, storage, and editing capability. It has accessories include rigid or flexible endoscopes to inspect the cleanliness of pipes in foodstuff and beverage processing equipment. Balluff Ltd. produces various sensors for packaging applications, such as the BFS 27K high-speed color sensor, the BOS 6K retro-reflective sensor for transparent materials, the BWL through-beam and the BIS M RFID data tracker (www.balluff.co.uk). For example, the BOS 6K detects packaging materials, such as thin films and transparent bottles. It also can be trained on the material dynamically without stopping the process. While the BWL family of through-beam sensors are rugged self-contained units for part- and gripper-positioning, pallet transfer, and pick and place tasks (www.balluff.co.uk). The color sensor is used for color detection, quality control, positioning, verification, and sorting. Besides, it is also dedicated to fast-running operations.

10.6 Conclusion As a universal trend in beverage packaging, companies have been constantly upgrading the entire automation and supply chain processes, utilizing advanced technology systems, particularly sensors and sensing devices, aiming at ensuring the manufacturing and production processes, assembly lines, including monitoring and control as well as instrumentation and data management in all process from producers to customers. In this context, the development of sensor technology from expensive, bulky, and mechanical sensing devices to small, cost effective, and smart sensors has offered reliable information, rapid, enabling interfacing with a large centralized control system, or local shop computers, or even with customers’ smartphone. Therefore, sensors have been considered as the most promising and game-changing technology for future intelligent/smart packaging systems. Recently, there has been more interest globally in the quality and safety of beverages. In this regard, the producers are on the verge of minimizing the product cycle and offering high-quality beverage at lower costs so as to overcome the challenges of increased price competition after the global recession. In this regard, the beverage packaging market sector requires accurate, fast, and simple taste evaluation methods. Nowadays, some of the major sensors employed in the beverage process industries include pressure sensors, flow sensors, level sensors, and temperature sensors as well as imaging with a smart camera. Chemical sensors and biosensors for liquids and gases, industrial

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cameras, sensors for condition-based monitoring and humidity sensors as well as contaminants are also gaining importance as they can increase plant productivity and achieve high product qualities. Taste or vapor sensors, on the other hand, can detect deteriorated taste qualities in the foodstuffs and beverages industry. Future works on the sensor development for beverage packaging could be focused on the microsensor and nanosensor with nanomaterials and nanostructures, including sensor array on chips as an electronic tongue for a taste and a sweetness sensor, or an electronic nose for an aroma, or vapor of high-quality beverage, such as whiskey and wine.

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Further Reading Packaging Digest, 2017. How Smart Packaging Sensors Safeguard Foods and Drugs|Packaging Digest. http://www.packagingdigest.com/smart-packaging/ how-smart-packaging-sensors-safeguard-foods-and-drugs-2017-04-13. (Accessed September 14, 2017).