H2020 NanoPack Project: Pilot production line for functional polymeric nanocomposites from natural halloysite nanotubes: demonstration of controlled release of active antimicrobials in food packaging applications.
- Type Project
- Status Filled
- Execution 2017 -2019
- Assigned Budget 7.665.218,00 €
- Scope Europeo
- Main source of financing H2020
- Project website Proyecto NanoPack
NanoPack will demonstrate a solution for extending food shelf life through the use of novel smart antimicrobial surfaces applied to active food packaging products. Pilot lines will be implemented in operational industrial environments to manufacture commercially viable, consumer-accepted antimicrobial polymer films. This will minimize the amount of preservatives needed to maintain freshness, add value, and ensure safety throughout the supply chain.
The project will employ natural halloysite nanotubes (HNTs) as reliable and safe carriers of bioactive compounds that cannot migrate from the packaging to the food. Maximizing safety, they slowly release small amounts of potent, volatile, and broad-spectrum natural agents into the headspace of the packaging. The use of nanotechnology allows for:
- Introduce sensitive molecules into polymer films.
- Maintain antimicrobial functionality without affecting film properties.
- To fabricate potent antimicrobial surfaces with tunable properties, while creating a pH-activated "gatekeeper" effect to slow the release of the encapsulated cargo. The resulting film will exhibit antimicrobial properties unattainable with current state-of-the-art technology.
The processes throughout the supply chain will be validated through five pilot tests on existing production lines:
- Antimicrobial loading.
- Production of antimicrobial HNT polymer.
- Production of antimicrobial packaging film
- Use of the new packaging in food products. Commercial viability will be assessed, including consumer acceptance and legal, regulatory, safety, and environmental aspects.
The success of NanoPack will result in a validated, consumer-accepted nanotechnology-based antimicrobial food packaging that will improve food safety, prevent foodborne illness outbreaks, and reduce food waste caused by premature spoilage. Higher-performing, safer, and smarter products will position Europe as a leader in food nanotechnology and smart antimicrobial packaging, while boosting the sector's competitiveness and growth.
Activities included preparatory work, four pilots, and activities to increase project impact. Preparatory work included functionalizing the internal and external surfaces of HNTs to maximize loading and controlled release of antimicrobial payloads. In addition, the antimicrobial activity of 12 EOs and their combinations against relevant food microorganisms was tested. Specifically, a combination of carvacrol, thymol, and cinnamaldehyde showed very promising and synergistic antimicrobial activity against E. coli, Listeria innocua, and Penicillium commune (representing Gram-positive bacteria, Gram-negative bacteria, and mold, respectively). Different concentrations were tested in the pilots to achieve the highest antimicrobial efficacy at low concentrations. Successful scale-up of the loading process was performed on three types of HNTs: pristine (unprocessed) and two types of functionalized HNTs: etched and silanized. The loading process imparts improved thermal stability of at least 30°C to the EOs, enabling their melt compounding with polymers at high manufacturing temperatures. Melt compounding of three types of filled HNTs from Pilot I with different polymers was successfully performed. Masterbatches from Pilot II were characterized to evaluate processability and antimicrobial activity. Processing of various compounds as part of Pilot III was performed using existing facilities in industrial pilot plants. In addition, films were produced at large and small industrial facilities, CFlex and Tommen, respectively, demonstrating the transferability of the technology to large and small production plants.
Various configurations of NanoPack active films (different number of layers and essential oil contents) were tested in different food systems, including dairy products, bakery products, meat, fish, and fresh produce (cherries). The safety of HNT use was assessed for both manufacturing personnel and consumers consuming NanoPack-packaged foods. Safety and toxicity studies in mice revealed that HNTs do not cause cytotoxicity; however, etched HNTs (e-HNTS) were associated with lung inflammation. Working with HNTs during large-scale application of pristine and etched HNTs is feasible if recommended precautions are taken. Ecotoxicological studies investigated the effects of pristine and e-HNTs in the aquatic environment. Tests with D. magna showed no inhibition of reproduction in the case of pristine HNTs, but e-HNTs prolonged the period to first fry and reduced the number of live offspring. The results prompted the decision to proceed solely with pristine HNTs. Migration studies measured the movement of HNTs and essential oils from the films to the food. It was concluded that HNTs do not migrate out of the film. Dossiers for the HNTs and the three potent essential oils (EOs) were prepared for submission to EFSA. This was done after determining how an active package should obtain food contact approval in the EU. Life cycle assessment (LCA) studies were conducted continuously, including environmental life cycle assessment (ELA), life cycle costing (LCA), and social life cycle assessment (SLC).
The results showed that HNTs do not contribute significantly to potential overall environmental impacts. The LCA showed that the final cost per m² of the plastic film is in line with the average cost of a multilayer film on the market (between €3 and €5/kg). The s-LCA showed that the greatest risks were identified in the resource extraction phase, where more developing countries are involved. Innovation management continued throughout the project, and commercial feasibility studies were completed. Global consumer and retailer acceptance studies were conducted in Europe and China, which showed promising results in terms of consumer and retailer acceptance of the NanoPack technology. Opportunities for exploitation beyond the project were explored among industrial partners, and some research partners expressed interest in collaborating. The results were communicated to a wide range of key stakeholders through various targeted tools and channels, including a website, brochures, roll-ups, articles in specialized media, newsletters, media engagement, webinars, scientific articles, videos, social media, and event presence.
Seven scientific publications were produced, and two more are in preparation based on NanoPack's work. Training workshops on the use of HNTs as carriers for antimicrobial essential oils in food packaging were held, and the final event was held in association with the AIPIA international packaging event, where the project was widely presented. Consortium members participated as speakers, led sessions, and had a booth.
NanoPack developed and demonstrated pilot-scale and scale-up production of nanotechnology-based antimicrobial materials to extend food shelf-life using novel active packaging. NanoPack's objective was to develop, scale-up, and execute four pilot trials in operational industrial settings to manufacture commercially viable antimicrobial polymer nanocomposite films accepted by both retailers and consumers. Using natural halloysite nanotubes (HNTs) as reliable and safe carriers of bioactive natural essential oils (EOs), the project demonstrated that NanoPack food packaging has the potential to extend the shelf-life of perishable foods.
The pilots included scale-up production for loading HNTs with antimicrobial EOs (Pilot I), combining loaded HNTs with polymers for use as masterbatches in film production (Pilot II), producing films using masterbatches produced in Pilot II (Pilot III), and packaging different types of food with NanoPack films.
Commercial viability, safety and regulatory issues, societal benefits, and life cycle assessments were evaluated. Commercialization was planned, intellectual property rights protection was secured, and a dossier was prepared for submission to EFSA for approval to use HNTs as carriers loaded with specific essential oils as antimicrobial agents in food packaging.
Building on lessons learned from previous attempts to industrialize and commercialize nanomaterials in food packaging, NanoPack demonstrated, validated, and piloted antimicrobial films in flexible food packaging applications. By taking the novel nanotechnology out of the laboratory and scaling up different processes in the chain, the project advanced the technology to full-scale production in real-world industrial settings. It addressed scientific, technological, economic, safety, and regulatory challenges, as well as barriers to furthering the industrialization and commercialization of novel polymer-HNT nanocomposites capable of delivering bioactive payloads.
Environmental toxicology studies conducted an in vivo assessment of the use of HNTs in food packaging production for the first time and created guidelines for their safe use. Personnel safety was studied at the pilot sites, and the NanoPack project is the first to report these results. Migration studies demonstrated that HNTs do not migrate out of films, whereas EOs do, inducing antimicrobial activity alongside organoleptic effects. Regulatory issues were addressed, and a set of four dossiers was prepared for submission to EFSA, requesting approval to exploit HNTs and three essential oils (carvacrol, thymol, and cinnamaldehyde) for food packaging with antimicrobial activity. Within the framework of innovation activities, steps to bring the technology to TRL 9 were outlined, and significant dissemination and communication activities generated interest in the adoption of NanoPack.
- TECHNION - ISRAEL INSTITUTE OF TECHNOLOGY
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