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Computational and Theoretical Polymer Science Vol. 8, No. 3/4, pp.

331±338, 1998
# 1998 Elsevier Science Ltd. All rights reserved.
PII: S1089-3156(98)00040-3 0189-3156/98/$Ðsee front matter

Effect of the thickness of food packages


made of recycled and virgin polymer layers
coextruded in sandwich form on the time of
food protection
A. L. Perou, S. Laoubi and J. M. Vergnaud*
Laboratory of Materials and Chemical Engineering, Faculty of Sciences, University of
Saint-Etienne, 23, Dr. P. Michelon, 42023 Saint-Etienne, France
(Received 30 December 1997; accepted 4 March 1998)

Reusing old polymer as new food packages is a vast ecological objective. From the scienti®cal point of
view various problems must be resolved for ensuring the food safety. Thus the new food packages are in
sandwich form where the recycled polymer layer with potential contaminant is located between two virgin
polymer layers. The main problem arising is the prediction of the time of food protection. A contaminant
transfer occurs during the coextrusion process through the package, being responsible for a decrease in
this time of food protection. The e€ect of the thickness of the package is especially considered. It appears
during the coextrusion process because the cooling period of the package strongly increases with the
thickness; it also plays a role in the contaminant transfer through the package and into food. The process
of contaminant transfer is studied not only during the coextrusion stage, but also with the food-package
system. The e€ect of the thickness of the package on the time of food protection is especially studied.
# 1998 Elsevier Science Ltd. All rights reserved.

(Keywords: food safety; polymer package; recycling; tri-layer package; processing; heat and mass transfers)

NOMENCLATURE MC Dimensionless number in heat convection


Mt Amount of contaminant transferred after
A Coecient in equation (6)054 time t
x Increment of space Min Amount of contaminant initially in the
t Increment of time recycled polymer layer
c Heat capacity of the polymer R Dimensionless number in mass transfer
C Concentration of contaminant by di€usion
Cs;t Contaminant concentration on the sur- P Dimensionless number in mass transfer
face of the package at time t by convection
Cfood;t Uniform contaminant concentration in  Density of the polymer
the food at time t t Time
D Di€usivity T Temperature
DT Di€usivity at temperature T Ts;t Temperature at the surface of the poly-
D0 Coecient in equation (6) mer at time t, during coextrusion
ht Coecient of convective heat transfer Tair Temperature of air
hm Coecient of convective mass transfer x Abscissa through the polymer thickness
l Thermal conductivity of the polymer
L Thickness of the package
L0 Thickness of the food INTRODUCTION
i Integer characterising position in the
package As already shown, recycling old polymer as new
j Integer characterising time food packages is a desired purpose from the eco-
MH Dimensionless number in heat conduc- logical and perhaps also from the economical point
tion of view1±4. In spite of various problems which
arise, this objective is induced by the Food and
*To whom correspondence should be addressed Drug Administration in the USA and the European

COMP. AND THEOR. POLYMER SCIENCE Volume 8 Number 3/4 1998 331
Effect of food package thickness on the time of food protection: A. L. Perou et al.

Communities5±7. However, as the recycled polymer temperature developing into the package. Asso-
is potentially contaminated from its previous use, ciated with this heat transfer a contaminant trans-
the new food package must be made of tri-layer fer takes place with a temperature-dependent
polymers, the recycled polymer layer being located di€usivity leading to a pro®le of contaminant
between two virgin polymer layers7±9. The transfer concentration through the package in the ®nal
process of contaminant in the food-package system tri-layer package. A numerical model is thus
is controlled by di€usion through the package10,11 built, taking into account both the heat and mass
and either by convection into the liquid food12 transfer18,19.
or di€usion through the solid food13,14. As it The other purpose of this study is to determine
takes time for the contaminant to di€use through by calculation the time of food protection obtained
the virgin polymer layer located between the recy- with this coextruded tri-layer package. The case of
cled polymer and the food, this virgin polymer a liquid food is considered, and the contaminant
layer plays the role of a functional barrier to food transfer is controlled either by convection into the
contamination. food and di€usion through the package with a
The main problem which arises is the prediction constant di€usivity. The transfer of the food into
of this time of food protection. It can be deter- the package is neglected. The initial pro®le of con-
mined either by highly time-consuming experi- taminant concentration is that obtained at the end
ments or by calculation. The mathematical of the coextrusion process. Moreover, the e€ect of
treatment is feasible for the transfer through the the thickness of the package is examined, when the
package alone when the di€usivity is constant10,11. three polymer layers have the same thickness.
When the package is in contact with the liquid
food, with a ®nite coecient of convective transfer
THEORETICAL
in the liquid next to the package surface, a numer-
ical treatment is necessary12,13, in spite of an The following two processes are considered in suc-
attempt to mix the equations obtained on one hand cession: the ®lms coextrusion with heat transfer
with an in®nite volume of liquid and a ®nite coef- and mass transfer at high temperature; the con-
®cient of convective transfer and on the other hand taminant transfer with the food-package system at
with a ®nite volume of liquid and an in®nite con- room temperature.
vection coecient15.
In fact, the problem is far more complex and two Process of ®lms coextrusion
main assumptions have been made in the previous
studies in calculating the time of food protection: Assumptions
(i) the transfer of the liquid food into the polymer
does not interfer on the contaminant transfer, in 1. The three thin ®lms are coextruded and heat
spite of that fact intervenes in case of plasticized and mass transfers are unidirectional through
PVC16,17; and (ii) the contaminant is only located the thickness of these ®lms.
in the recycled polymer layer with a uniform 2. The recycled polymer layer is located between
concentration. This second assumption means that the two virgin polymer layers.
no contaminant transfer takes place during the 3. The three layers are in perfect contact with no
coextrusion of the tri-layers of the package18. In resistance to heat and mass transfer.
fact, during the preparation of the package each 4. Initially, the contaminant concentration is
polymer layer is heated and melted and the tri- uniform in the recycled polymer layer, while
layer polymers are coextruded. The tri-layer ®lm is the virgin polymer layers are free from con-
then allowed to cool down in air. It has been taminant.
shown by calculation that during this short period 5. The package initially at the uniform tempera-
of time at high temperature, a di€usion of the ture of coextrusion (300 or 330 C) is cooled
contaminant takes place with a temperature- down is motionless air at 20 C. Heat is trans-
dependent di€usivity either with bi-layer18 or a tri- ferred by free convection at the air±package
layer19 package. interface and by conduction through the
The ®rst objective in this paper is to evaluate the package.
contaminant transfer during the coextrusion pro- 6. As soon as the three polymer layers are coex-
cess expressed by a concentration pro®le of con- truded, during the cooling period in air, a
taminant in the package. Of course, during the contaminant transfer takes place through the
coextrusion process heat is transferred by free package controlled by Fickian di€usion. The
convection at the package surface and by conduc- di€usivity varies with temperature by follow-
tion through the package, leading to pro®les of ing an Arrhenius' law.

332 COMP. AND THEOR. POLYMER SCIENCE Volume 8 Number 3/4 1998
Effect of food package thickness on the time of food protection: A. L. Perou et al.

Mathematical treatment (Figure 1) tˆ0 recycled polymer Cin


…7†
Heat transfer virgin polymer Cˆ0
The equation of unidirectional heat transfer by
condition through the package is:
  Numerical analysis
@T @ @T The Crank±Nicolson method is used for calculat-
c ˆ l: …1†
@t @x @x ing the temperature and concentration at each time
and position. The thickness of the package is divi-
The initial condition is ded into N slices of thickness x, and increments
of time t are considered. The two integers i; j
tˆ0 0<x<L Tin …2† appear in calculation18, as well as the following
three dimensionless numbers:
The boundary conditions are
2
heat conduction : MH ji ˆ …x † c
t : lj
t>0 xˆ0 lj @T
@x js ˆ ht …Ts;t ÿ Tair † x:h jt
i

xˆL heat convection : MC ji ˆ l ji


…8†
2
…3† contaminant transfer R ji ˆ …x†
t:D Ji

meaning that the rate of heat transferred by con-


vection is constantly equal to the heat brought to Process of contaminant transfer in the food with the
the surface by internal conduction. package-food system
The midplane of the package is a plane of sym-
metry as the layers are made of the same polymer Assumptions
and the concentration of the contaminant is very
low. 1. The contaminant transfer is controlled by dif-
fusion through the package and convection
t>0 x ˆ L2 @T
ˆ0 …4†
@x into the liquid food with a ®nite coecient of
convective transfer. Only one face of the
package is in contact with the food.
Contaminant transfer 2. The di€usion is unidirectional through the
The equation of unidirectional di€usion through package, and the di€usivity of the con-
the package is: taminant through the package is constant. As
  shown in an earlier study20, the e€ect of the
@C @ @C cristallinity of PET (polyethylene ter-
ˆ Dx;t : …5†
@t @x @x ephthalate) on the di€usivity of a con-
taminant is not very important.
with the temperature-dependent di€usivity: 3. The contaminant does not evaporate on the
  surface in contact with air.
A 4. The di€usion of the contaminant is only con-
DT ˆ D0 : exp ÿ …6†
T sidered, by neglecting the transfer of the food
in the polymer. This assumption is generally
made by researchers in that ®eld. However,
The initial condition is:
the e€ect of the food transfer into the polymer
depends essentially on the nature of the poly-
mer±food couple, and not on the presence of
contaminant.
5. Initially, the pro®le of contaminant con-
centration through the package is that
obtained at the end of the coextrusion pro-
cess.
6. The volume of the liquid food is ®nite.

Mathematical treatment (Figure 2)


Figure 1 Scheme of the process of heat and mass transfer during the
The equation of unidirection di€usion through the
stage of coextrusion. package with constant di€usivity is:

COMP. AND THEOR. POLYMER SCIENCE Volume 8 Number 3/4 1998 333
Effect of food package thickness on the time of food protection: A. L. Perou et al.

with the dimensionless numbers:


2
R ˆ …D:t
x†
P ˆ h:x
D
…14†

The amount of contaminant remaining in the


package at each time is evaluated by integrating
the concentration with respect to space12,13.

Figure 2 Scheme of the process of contaminant transfer into the food


with the food±package system. RESULTS

Two kinds of results are of interest: (i) the one


@C @2 C concerned with the contaminant transfer through
ˆ D: 2 …9†
@t @x the tri-layer ®lm during the stage of coextrusion,
leading to a ®nal pro®le of contaminant con-
The initial condition for the pro®le of contaminant centration; (ii) the other with the transfer of con-
concentration is the same as that obtained at the taminant through the package into the food at
end of the coextrusion process. room temperature.
The boundary condition at the package±food Moreover, the e€ect of the thickness of the ®lm
interface is: and of the coextrusion temperature is especially
considered.
t>0 xˆL Dj @C
@x js;t ˆ hm …Cs;t ÿ Cfood;t †
Polyethylene terephthalate (PET) is used for this
…10† purpose, as some data are available for the heat
transfer properties21 and also for the data of the
di€usivity at room temperature20 (Tables 1 and 2).
where Cs;t is the concentration of contaminant on
the package surface at time t, and Cfood;t is the Contaminant transfer during the stage of
uniform concentration of contaminant in the food coextrusion of the tri-layer ®lm.
at time t.
Equation (10) expresses that the rate at which As shown in the theoretical part, during the stage
the contaminant is transferred into the food by, of coextrusion, the three layers at high temperature
convection is constantly equal to the rate at which are coextruded and the ®lm is allowed to cool
the contaminant is brought to the surface by inter- down in air at room temperature. The process of
nal di€usion. heat transfer is controlled by free convection at the
At the package±air interface, there is no transfer: air-®lm interface and by conduction through the
®lm. Of course, simultaneously a contaminant
@C transfer takes place through the ®lm, controlled by
ˆ0 …11†
@x di€usion with a temperature-dependent di€usivity.

Heat transfer during coextrusion


Numerical treatment Depending on the thickness of the ®lm, the tem-
The problem with a ®nite volume of liquid food perature in the ®lm decreases with a given rate
and ®nite coecient of convective transfer must be when the ®lm is in contact with air. The tempera-
resolved by a numerical method12,13. ture±time histories are drawn in Figure 3, for two
The concentration at position i and time temperatures of coextrusion (300±330 C) and for
…j ‡ 1†t is obtained by using: the three values of the thickness of the ®lm
(90 microns with curve 3; 150 microns in 2;
1 j  300 microns in 1).
C ij‡1 ˆ C iÿ1 ‡ …R ÿ 2†C ji ‡ C ji‡1 …12†
R Two positions are considered: the surface of the
®lm, and the midplane of the ®lm in each case.
and on the surface in contact with the liquid: The curves in Figure 3 can lead to the following
conclusions:
j‡1 1 j 
CN ˆ 2C Nÿ1 ‡ …R ÿ 2P ÿ 2†C jN ‡ 2P:Cfood;t
R 1. Of course, the temperature±time histories
…13† start either at 300 or 330 C at time 0. The

334 COMP. AND THEOR. POLYMER SCIENCE Volume 8 Number 3/4 1998
Effect of food package thickness on the time of food protection: A. L. Perou et al.

Figure 3 Temperature±time histories during the cooling period of


Figure 4 Kinetics of contaminant transfer during the coextrusion for
coextrusion at 330C (10 , 20 ,30 ) and 300 C (1, 2, 3) for the three thick-
the di€erent thicknesses and temperatures (300 C: 1, 2, 3; 330 C: 10 , 20 ,
nesses of the ®lms: 300 microns (1, 10 ), 150 microns (2, 20 ); 90 microns
30 ): 300 microns (1, 10 ); 150 microns (2,20 ); 90 microns (3, 30 ).
(3, 30 ).

temperature decreases quickly at the begin- thickness acts not only upon the rate of con-
ning of the process (curves 1, 2, 3 at 300 C taminant transfer but also on the relative
and 10 , 20 , 30 at 330 C). amount of contaminant transferred Mt =Min ,
2. The e€ect of the coextrusion temperature with this statement: the thinner the ®lm, the
clearly appears. faster the contaminant transfer and the
3. The thickness of the ®lm intervene on the rate greater the relative amount of contaminant
of decrease in temperature with the obvious transferred.
statement: the thinner the ®lm, the faster the 3. The e€ect of the coextrusion temperature is of
rate of decrease in temperature. The tempera- great importance whatever the thickness of
ture decreases to around 200 C after only 2 s the ®lm (1, 2, 3 at 300 C and 10 , 20 , 30 at
for the 90 microns thick ®lm. 330 C). Especially the relative amount
4. The thickness of the ®lm is responsible for a Mt =Min of contaminant transferred largely
di€erence in temperature through the ®lm increases with the coextrusion temperature.
depending on position. Of course, the tem- 4. Of course, the rate of contaminant transfer
perature on the surface and at the middle of essentially varies with the temperature depen-
the ®lm is about the same for the thinner ®lm, dency of the di€usivity. Tedious experiments
while a signi®cant di€erence appears for the and calculation are done at temperature
thicker ®lm. around the softening temperature and not yet
published22. Calculation of the di€usivity
Contaminant transfer during coextrusion needs a numerical model similar to that
Resulting from the high temperature of the coex- described in this paper.
trusion process, a contaminant transfer takes place 5. The pro®les of concentration of contaminant
through the ®lm. This transfer is controlled by dif- developed through the ®lm at the end of the
fusion with a concentration-dependent di€usivity, coextrusion stage, e.g. after a few seconds, are
and thus the rate of transfer decreases during the shown in Figure 5 (90 microns), Figure 7
stage of cooling. (150 microns) and in Figure 9 (300 microns)
The results are expressed in two ways: with the for the coextrusion temperature of 330 C.
kinetics of contaminant transfer in Figure 4, and These pro®les are noticed 0 in these three ®g-
with the pro®les of concentration developed ures, being also the initial pro®les of con-
through the ®lm at the end of the coextrusion centration during the contaminant transfer in
process. the package±food system.
Some conclusions are worth nothing: 6. Comparison between these pro®les at time 0
shown in Figures 5, 7 and 9 shows clearly the
1. The transfer of contaminant through the ®lms e€ect of the thickness of the ®lm on the
is very fast, as shown in Figure 4, and it takes transfer. Thus for the thinner ®lm of
place in a few seconds. 90 microns, the contaminant reaches the ®lm
2. The e€ect of the thickness of the ®lm on the surfaces, while it does not for the larger
contaminant transfer appears in Figure 4. The thicknesses.

COMP. AND THEOR. POLYMER SCIENCE Volume 8 Number 3/4 1998 335
Effect of food package thickness on the time of food protection: A. L. Perou et al.

through the package or by the kinetics of con-


taminant transfer into the food.

Pro®les of contaminant concentration developed


through the package
The pro®les of concentration of contaminant
developed through the package in the food±pack-
age system are drawn in Figure 5 (90 microns
thick), in Figure 7 (150 microns) and in Figure 9
(300 microns).
Dimensionless numbers are used: the concentra-
tion as a fraction of the initial concentration of
contaminant initially in the recycled polymer layer
Figure 5 Pro®les of contaminant concentration developed at various before coextrusion; Dt=L2 instead of time, the
times (Dt=L2 ) through the tri-layer package of 90 microns coextruded
at 330 C. relative abscissa x=L. The following conclusions
are of interest:

7. The midplane of the ®lm is a plane of sym- 1. These pro®les of contaminant developed at
metry for the temperature transfer, as well as various times give a fuller insight into the
for the mass transfer. The relative concentra- nature of the process of transfer through the
tion of contaminant at this midplane is of package.
interest: it is around 0.8 for the thinner ®lm, 2. The pro®les are symmetrical with the mid-
0.9 for the 150 micron ®lm and more than 0.95 plane as plane of symmetry when the con-
for the 300 micron ®lm. taminant is still located in the package.
3. When the contaminant reaches the food sur-
Contaminant transfer with the package-food system face, a transfer in the food takes place, and
the pro®les of concentration are not symme-
The contaminant transfer in the package±food trical. On the whole, the concentration on the
system at room temperature is controlled by di€u- package surface in contact with the surround-
sion through the three layer package and convec- ing is higher than on the surface package in
tion into the liquid food. The di€usivity is contact with food.
considered as constant because the concentration 4. For long times, e.g. 0.1 for Dt=L2 , the con-
of contaminant is very low in the package. The centration on the package surface in contact
values of the parameters: the di€usivity, the coe- with the surrounding is even greater than in
cient of convective transfer and the volume of the recycled polymer layer, as already
liquid are shown in Table 2. The value of the coef- shown12.
®cient of convective transfer into the liquid is that 5. The gradient of concentration is always 0 on
obtained in olive oil23. The thickness of 1.6 cm for the package surface in contact with the sur-
the liquid corresponds with a liquid food of 1 litre rounding, as the contaminant does not eva-
in cubic shape. porate in air.
The results are expressed either through the pro- 6. Because of the dimensionless numbers, these
®les of contaminant concentration developed curves can be considered as master curves
which can be used for evaluating the transfer
Table 1 Characteristics for heat and mass transfer during coextru- of contaminant through the package.
sion the stage of coextrusion thickness of the tri-layer package: 0.005/
0.005/0.005 cm
Kinetics contaminant transfer in the food
ˆ 9:9  10ÿ4 ‡ 6:8  10ÿ7  T …cm2 sÿ1 † T:Celsius The kinetics of contaminant transferred into the
l ˆ 6:1  10ÿ4 ‡ 9:6  10ÿ8  T …cal cmÿ2 sÿ1 degÿ † T:Celsius
food are drawn for the three thicknesses of the
h ˆ 2  10ÿ4  exp j ÿ TL ÿ Tair j025 …cal cmÿ2 sÿ1 degÿ1 † T:Celsius
ÿ 
D ˆ 28 240  exp ÿ 13 T800 …cm2 sÿ1 † T:Celsius
package coextruded at 330 C, in Figure 6
(90 microns), Figure 8 (150 microns) and Figure 10
(300 microns). Dimensionless numbers are used for
Table 2 Characteristics of the contaminant transfer into the food each thickness: the amount transferred after time t
Di€usivity D ˆ 10ÿ10 cm2 sÿ1
as a fraction of the initial amount of contaminant
Convective coecient h ˆ 10ÿ8 cm sÿ1 in the recycled polymer; Dt=L2 instead of time.
Thickness of the liquid (per unit area of package)=1.6 cm These kinetics are drawn under three conditions:
1 litre of food in cubic shape
in the hypothetical case when no contaminant

336 COMP. AND THEOR. POLYMER SCIENCE Volume 8 Number 3/4 1998
Effect of food package thickness on the time of food protection: A. L. Perou et al.

transfer takes place during the coextrusion stage an increase in this temperature is responsible
(curve 1); when coextrusion takes place with a for a signi®cant decrease in time of food pro-
contaminant transfer at 300 C (curve 2) and at tection.
330 C (curve 20 ). 4. It stands to reason that the coextrusion pro-
The following conclusions are obtained: cess cannot be neglected, as a signi®cant

1. The shape of the kinetics of contaminant


transfer into the food is typical as already
shown12,13. The rate increases with time more
and more quickly, starting from a zero value
with the curve 1 in Figures 6, 8 and 10.
2. The e€ect of the thickness on the transfer in
the food appears by comparing the curves in
Figures 6, 8 and 10. For instance, with the
thinner ®lm of 90 microns coextruded at
330 C, the contaminant transfer takes place as
soon as the food is put in the package.
3. The e€ect of the operational conditions of the
coextrusion process also appears for each
thickness of the package by comparing the
Figure 8 Kinetics of contaminant transferred into the food from the
curves 1, 2 and 20 . The coextrusion tempera- tri-layer package of 150 microns: (1) with no transfer during coextru-
ture is a parameter of great importance, and sion, (2) with coextrusion at 300 C, and (20 ) at 330 C.

Figure 6 Kinetics of contaminant transferred into the food from the Figure 9 Pro®les of contaminant concentration developed at various
tri-layer package of 90 microns: (1) with no transfer during coextru- times (Dt=L2 ) through the tri-layer package of 300 microns coextruded
sion, (2) with coextrusion at 300 C, and (20 ) at 330 C. at 330 C.

Figure 7 Pro®les of contaminant concentration developed at various Figure 10 Kinetics of contaminant transferred into the food from the
times (Dt=L2 ) through the tri-layer package of 150 microns coextruded tri-layer package of 300 microns: (1) with no transfer during coextru-
at 330 C. sion, (2) with coextrusion at 300 C, and (20 ) at 330 C.

COMP. AND THEOR. POLYMER SCIENCE Volume 8 Number 3/4 1998 337
Effect of food package thickness on the time of food protection: A. L. Perou et al.

transfer of contaminant takes place through Thus this paper has pointed out the importance of
the package. The e€ect of the di€usivity the problem in food-package system with polymer
through the polymer at the coextrusion tem- recycling. It has also laid the way for further stu-
perature and the temperature-dependency of dies using the same numerical treatment in order to
the di€usivity have to be determined with increase the time of food protection. Various ways
accuracy. Some work is in progress along this can be traced: trying to decrease the cooling period
direction22. after coextrusion; using di€erent relative thick-
nesses for the layers of the package with a larger
thickness for the functional barrier in contact with
the food; and improving the experimental techni-
CONCLUSIONS que for determining the temperature-dependency
of the contaminant. The theoretical approach and
Following this study, it stands to reason that a the numerical model described in this paper can be
contaminant transfer takes place in a signi®cant of help to resolve these problems.
manner through the tri-layer ®lm during the stage
of coextrusion. Thus the contaminant is located
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338 COMP. AND THEOR. POLYMER SCIENCE Volume 8 Number 3/4 1998

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