What Makes the Good Packaging for Frozen Pizza?
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Among all sorts of frozen and heat-to-eat meals, there is one that always has been dominating consumer preference – Pizza.
In the United States, one in every eight Americans eats pizza on any given day (USDA, 2014). People are nowadays too preoccupied with their jobs and tight living pace that they don’t have time to cook, yet with the frozen pizza bought from the grocery placed into the oven, it is just 3 minutes away from a tasty bite.
According to the report by Grand View Research, the global frozen pizza market size was valued at USD 17.3 billion in 2020 and is expected to grow at a compound annual growth rate (CAGR) of 5.1% from 2021 to 2028. And in such a prospective consumer market, another trend apart from the growing market volume is the shift from traditional packaging to more sustainable ones to achieve environmental goals.
In this session, we talk about:
- what different packaging can pizza have,
- the most used packaging for frozen pizza,
- and take an insight into the pros and cons of each other,
- as well as which is the most popular packaging.
Some Figures about Frozen Pizza
- The global frozen pizza market was valued at approximately $12.8 billion in 2020 and is projected to reach a value of $20.8 billion by 2027.
- People in the United States spend on frozen pizza $ 4.4 billion each year, with 66.7% of the households having regular consumption of frozen pizza.
- In the United States, frozen pizza sales increased by over 30% in 2020 due to the COVID-19 pandemic and resulting lockdowns.
- According to a survey conducted by Statista, 36% of Americans eat frozen pizza at least once a month.
- Pepperoni is the most popular topping for frozen pizza in the United States, followed by sausage and mushrooms
Primary Concerns with Frozen Pizza Packaging
Frozen food packaging fits the complex environment all through the supply chain from its processing and production to the transportation, warehousing and then display on the shelves. In general, there are six facts to concern:
- The packaging must comply with local or regional applicable regulations
- The packaging must be capable of providing adequate protection so that the frozen food can stay stable with its nature and quality
- Features and characteristics of the packaging materials: for example, just like the CarrierKote of Westrock which is able to withstand low temperature and humidity.
- Able to offer physical protection to keep frozen food safe from damage through transportation and distribution.
- Attractive packaging design that can serve as an ideal marketing and branding medium.
- Test and verification of the packaging’s food safety
An ideal packaging for frozen pizza must be with the following five characteristics:
- It must have high barrier properties to prevent contact between the product and oxygen and to prevent moisture evaporation. This helps to preserve the freshness of the pizza and prevent spoilage. The packaging must also be hygienic and free from any harmful substances that could leach into the food.
- It must be impact-resistant and puncture-resistant.
- It must be resistant to low temperatures so that the packaging material does not deform or crack even at -45℃.
- It must be oil-resistant.
- It must be hygienic, preventing toxic and harmful substances from migrating and permeating into the food.
Following this chapter, we will extend the topic to discuss from primary packaging to secondary packaging about concerns regarding food safety for frozen pizza packaging.
Shrink Wrapping is the Common Primary Packaging for Frozen Pizza
In most cases, the frozen pizza is tight-wrapped by the plastic film which is shrunk by heat. The so-called shrink wrapping is how pizza is packaged before cardboard boxes.
Shrink wrapping is a packaging process that involves placing the product inside a plastic film and then using heat to shrink the film around the product. This creates a tight seal that helps to prevent air and moisture from entering the package, which can cause spoilage and contamination. Shrink-wrapping also helps to protect the food from physical damage during transportation and storage.
The plastic flexible packaging used for frozen pizza can be divided into two main categories:
Composite Packaging
Composite plastic film packaging is a type of packaging that involves bonding two or more layers of plastic films together with adhesive to create a single, multi-layered material. The composite structure of the film provides a combination of properties from each layer, such as high barrier properties, strength, flexibility, and printability
A problem here is that the adhesive often contains harmful substances such as esters and benzene, which can easily penetrate the food and cause contamination.
High Barrier Multilayer Packaging by the Coextrusion Method
The multi-layer co-extruded high-barrier packaging is produced using environmentally friendly packaging materials and has five, seven, or nine layers. It does not use adhesive but instead uses extruders to melt different types of resin materials such as PA, PE, PP, PET, EVOH, LDPE, HDPE, etc. together.
It has the characteristics of being pollution-free, high barrier, strong, and structurally flexible. It enables the food packaging and packaging material production process to achieve pollution-free standards and with the packaging’s stretching and tearing strength significantly improved. It can withstand temperatures as low as -45°C and as high as 120°C, achieving a vacuum degree of up to 100%. All the above features make the multi-layer co-extruded high-barrier packaging an ideal option for frozen pizza primary packaging.
Antifungal Plastic Packaging
Allyl isothiocyanate (AITC) is a natural compound found in some plants such as mustard, horseradish, and wasabi. It has antimicrobial properties and is effective against fungi and bacteria.
In the context of food packaging, AITC can be incorporated into plastic films or coatings to create active packaging that can help to inhibit microbial growth and prolong the shelf life of food products. The AITC in the packaging material slowly releases over time, creating an environment that is inhospitable to microorganisms that cause spoilage.
Credit: Lucas F. Lopes
Journal of Food Processing and Preservation
The use of AITC in plastic packaging for frozen pizza has been shown to be effective in inhibiting the growth of fungi and bacteria in the pizza samples. This can extend the shelf life of frozen pizza and reduce food waste caused by spoilage, thus improving food safety.
Referring research by Lucas F. Lopes, the use of AITC in the packaging material was found to be effective in inhibiting the growth of Penicillium nordicum in chilled pizza samples for up to 10 days. The study suggests that the use of AITC in food packaging could improve food safety and reduce food waste caused by spoilage.
What Makes a Good Box Packaging for Pizza?
Packaging that comes into contact with food ingredients should be in compliance with safe-food-serving standards no matter whether it is primary or secondary packaging.
While with secondary packaging we focus on the aesthetics of packaging design with the expectation that the products can be more attractive. It is also suggested to prioritize the safety of food packaging. In the case of frozen pizza, the carton and box that contains the shrink-wrapped pizza should be of food-grade paper packaging. To achieve this goal, attention should be paid to printing and paper materials.
Corrugated Box for Frozen Pizza
A corrugated box is a type of packaging made from a combination of three layers of paper: an inside liner, an outside liner, and uting that runs in between them. The uting provides cushioning and support to protect the contents of the box during transportation.
Kraft paper Box for Frozen Pizza
Kraft paper is a type of paper that is made from wood pulp and has high strength and durability.
The wood fiber of coniferous trees is the main raw material for making kraft paper. As the fibers of this type of tree are relatively long, in order to preserve their toughness as much as possible, they are typically treated with chemical agents such as caustic soda and sulfide. The fibers are closely intertwined with each other, which helps to maintain the inherent toughness and strength of the wood fiber. Therefore, the strength of the resulting kraft paper is much higher than that of ordinary paper, making it more durable.
Credit: My Kraft Supplies
A Kraft paper box is a packaging container made from this material. It is often used for packaging frozen pizzas because it can withstand low temperatures and protect the pizza from freezer burn.
What is a Fluorescent Agent with the Box Packaging?
Fluorescent agents are a type of fluorescent dye, which is a complex organic compound.
A fluorescent agent is a type of chemical additive that can make the packaging material appear brighter or more vibrant under UV light.It can excite incident light to produce fluorescence, making the substance seen by the naked eye appear whiter, brighter, and more vivid. The papermaking industry commonly uses liquid brighteners, because they can improve the overall appearance of paper products in sunlight.
In food packaging, the use of fluorescent agents is not desirable because they can migrate from the packaging material to the food and be ingested by consumers. The presence of fluorescent agents in paper used for food packaging does not meet food safety requirements. Moreover, food packaging paper containing fluorescent agents may migrate into the food during use, which can be absorbed by the human body, difficult to decompose, and accumulate in the body over time, posing a risk to human health.
To detect whether food packaging paper contains obvious fluorescent substances, a handheld dual-wavelength ultraviolet lamp can be used. Simply shine the lamp onto the packaging paper, and if the paper exhibits an obvious fluorescence reaction, it indicates the presence of fluorescent substances.
What is the Best Raw Material for the Box Packaging for Pizza?
Box packaging paper made entirely of virgin wood pulp poses no risk of contamination and can safely come into contact with food without transferring harmful substances onto it.
Virgin wood pulp fibers have good toughness, high density, and strong strength. They also have better processing performance and do not require the addition of special ingredients to improve the appearance, color, and performance of the paper during production. This not only improves the efficiency of resource utilization, but also results in paper with a good touch, natural color (uniform color, no mold spots, no black spots, etc.), good printing effect, and no odor.
Regenerated or Recycled Box Packaging?
In some countries, the use of recovered or recycled boxes is forbidden for the box packaging of pizza. Recovered or recycled paper and box may contain printing inks, adhesives and other toxic substances which are not intended for food contact. For example, in Italy, the local law requires the use of only regenerated material as box packaging for pizza rather than the recycled paper board.
Summary
Good packaging for frozen pizza is not only about appearance but is more complex than what we would suppose.
Basically, a good frozen pizza packaging should have the following characteristics:
- Protection: The packaging should be able to protect the pizza from damage during transportation and storage.
- Preservation: The packaging should be able to preserve the freshness and flavor of the pizza for as long as possible.
- Convenience: The packaging should be easy to open, close, and store.
- Information: The packaging should provide clear and accurate information about the ingredients, nutritional value, cooking instructions, and expiration date of the pizza.
- Innovation in packaging materials: The use of advanced. composite and innovative packaging materials are recommended to extend the pizza’s shelf life.
- Food safety and compliance: The packaging of frozen pizza must comply with applicable regulations and laws.
To achieve these characteristics, packaging manufacturers can consider using active and intelligent packaging technologies, such as AITC, that can help extend the shelf life of frozen pizzas and prevent the growth of harmful microorganisms. Companies can also explore innovative packaging designs that can improve the user experience, such as easy-to-tear perforations, microwave-safe materials, and resealable closures.
