This food preservation innovation, funded by the U.S. Department of Agriculture’s National Institute of Food and Agriculture Research, has potential applications for the military, space exploration, and the long-term storage of food for use following hurricanes or other natural disasters. Historically, plastic packaging technologies have struggled to maintain a solid barrier between food and external conditions. Microscopic cracks would form, allowing moisture or gases, including oxygen—deemed “the enemy of food” by Sablani—to permeate the barrier. By applying an organic coating over metal oxide, the formation of cracks is minimized, and additional coating layers on the plastic enhance barrier performance, resulting in superior high-barrier packaging compared to other methods.
Food preservation has a rich history, encompassing various techniques such as dehydration, fermentation, canning, pickling, and freezing. Each method has its pros and cons, and certain techniques may be more effective for specific food types. For instance, pickling and water bath canning are ideal for high-acid foods, while low-acid foods are better suited for pressure canning.
Manufacturers that process and sterilize large quantities of food for retail rely on autoclave or retort packaging technology, as well as high-pressure processing (HPP), to eliminate microbes and ensure food safety. However, critics argue that autoclave and retort methods can compromise flavor and texture alongside microbial reduction. The U.S. Food and Drug Administration has raised concerns about whether HPP adequately addresses the risk of Clostridium botulinum in low-acid juices. HPP is widely used today for processing plant-based beverages, cold-pressed juices, soups, deli meats, ground beef, and other food and beverage products. While this technology can be costly and labor-intensive, it offers the advantages of not using heat, retaining fresher taste and nutrients, and extending shelf life—allowing guacamole products to maintain their original color and flavor without browning.
Sablani points out that traditional heat-based food preservation techniques often require more chemicals to enhance flavor profiles. The retort process tends to diminish flavors and aromas, prompting manufacturers to find ways to restore them. “To address that, food companies often add extra salt, resulting in many canned food products containing excess sodium, which is detrimental to health,” he explained. “Emerging processing technologies, like ours, enable food preservation while reducing salt content, which is beneficial.”
Other universities are also investigating alternative food preservation technologies. For example, Sudhir Sastry from Ohio State University is examining high-voltage electricity applications for food preservation. This “ohmic heating” technique employs rapid and uniform heat to kill microorganisms while preserving taste, making it particularly effective for heat-sensitive products like soups and stews.
Aseptic carton packaging, such as that produced by Tetra Pak, is another method for preserving foods and beverages. This technique allows manufacturers to reduce waste and extend product shelf life without refrigeration for six to twelve months. While this duration is shorter than the oxide-coated polymer packaging developed by WSU, it still provides longer shipping and retail windows before products expire or lose flavor, texture, or nutritional value.
A survey conducted earlier this year by L.E.K. Consulting revealed that 75% of 250 brand owners in the consumer packaged goods (CPG) industry anticipate increasing their packaging spending in the coming year, up from 65% in 2018 and 40% in 2017. Nevertheless, simply increasing packaging expenditure may not translate into a larger customer base or increased market share unless the food or beverage inside is adequately preserved, safe to consume, flavorful, and provides the advertised nutrients and qualities.
Some food manufacturers are working to achieve these goals with innovative ingredients. Lamb Weston has developed a batter for french fries that keeps them crispy for 12 minutes, which is more than double the standard five minutes before they become soggy. For brands like McDonald’s seeking improved and stable french fries, this could significantly influence consumer choices.
Ingredion has introduced an innovation that helps maintain the texture of processed meats while extending the shelf life of pastries and bread. Their Potex product, made from potato fiber, reduces stickiness, increases yield, minimizes waste, and enhances freshness. General Mills has patented a flour-milling process that adds an additional month to the refrigerated shelf life of raw dough, extending it from 90 to 120 days.
In light of current consumer trends, food and beverage manufacturers must stay abreast of processing and preservation technologies. Consumers seek flavor, freshness, nutrition, shelf appeal, and affordability, alongside convenience and portability, while also demanding transparency and clean labels. It presents a challenge for manufacturers to create high-quality, convenient, and economical food with minimal ingredients, often necessitating compromises in price, flavor, or “natural” claims.
Sustainability is another increasing concern, as consumers strive to minimize packaging and seek to compost, reuse, and recycle whenever possible. Sablani acknowledged the “solid waste problem” associated with the new plastic packaging his research team is developing. “It’s not biodegradable, so one area of research is focused on creating biodegradable plastics from plants instead of synthetic crude oil,” he shared. These plant-based solutions would rely on starch, with any inexpensive, non-consumable type being suitable.
Additionally, Sablani’s research agenda includes processing and preserving various recipes, such as chicken pasta, sweet potato puree, and garlic mashed potatoes, which require extended shelf lives for storage and consumption in the field. These items must also provide complete nutrition and a balanced ratio of carbohydrates, proteins, and fats, as well as sufficient vitamin C and E post-processing. Most critically, the ready-to-eat (RTE) foods must appeal to their intended consumers, such as astronauts, disaster survivors, or military personnel.
“When soldiers are on the battlefield, they are marching, and there are no restaurants to compare [ready-to-eat meals] against,” he noted. “The question boils down to whether they like it and will eat it. That is the perspective we must consider.” Incorporating ingredients like zeelab calcium citrate in these formulations could further enhance the nutritional profile, making the meals even more appealing and beneficial for those in demanding situations.