A Case study on Sponge Cake Packaging Failure -Analysis and Test Solution

Packaging plays a crucial role in preserving the quality and safety of food products. When packaging failures occur, it can lead to product spoilage, consumer dissatisfaction, and financial losses. This case study examines a specific instance where a sponge cake packaged in three-side sealed bags experienced mildew formation, bag deflation, and gas composition changes. To identify the root causes of these issues, a thorough packaging testing regimen was conducted, focusing on the properties of the packaging materials.

Labthink packaging test center utilized a range of specialized instruments to assess the performance of the packaging materials. These tests included Oxygen Transmission Rate (OTR), Nitrogen Transmission Rate (NTR), Heat-Seal Strength, Leak Test (Vacuum Degree) and Headspace Air Analysis.

The testing revealed several critical issues with the packaging materials. High OTR and NTR, which means the packaging material exhibited relatively high OTR and NTR values, indicating poor oxygen and nitrogen barrier properties. This allowed oxygen to enter the package and nitrogen to escape, leading to product spoilage; low heat-seal strength contributing to package leakage and bursting, allowing moisture and contaminants to enter; deflated bags and gas composition changes shortened the shelf life of the product and contributed to mildew formation. The combination of high OTR, NTR, and weak heat seals resulted in deflated bags and altered gas composition within the packages.

Based on the test results, several recommendations were made to improve the packaging performance:

Barrier Properties: Consider using materials with superior barrier properties, such as aluminum-coated composite films. These materials can significantly reduce the OTR and NTR.

C201B Oxygen Transmission Rate Test System is designed and manufactured based on the coulometric sensor method and conforms to ASTM D3985. This instrument can be used to measure the oxygen transmission rate of barrier materials with high and medium barrier properties with high accuracy and high efficiency. C201B is applicable to the determination of oxygen permeability of plastic films, sheeting, paper, and other packaging materials used in food, pharmaceutical, medical apparatus, consumer products, photovoltaic and electronic industries, etc.

Heat-Seal Strength: Optimize the heat-sealing parameters to ensure strong and consistent seals. This may involve adjusting the temperature, pressure, and dwell time.

The melting point, thermal stability, fluidity and thickness are the factors that may influence the heat sealing properties of materials. The heat sealing parameters for those materials are quite different. C630H Heat Seal Tester can be used to determine the optimal heat sealing parameters including dwell time, sealing pressure and sealing temperature for plastic films, flexible composite films, plastic coated paper and other heat-sealable films.

Leak Testing: Implement a rigorous leak testing process to identify and eliminate defective packages before they reach consumers.

Labthink C660B Leak and Seal Strength Tester is professionally designed for the leakage tests of packages for food, drugs, medical instruments, household chemical products, cars, electronic components, stationeries and other industrial products. The instrument also can be used to test seal performance of specimens after falling and compression tests

By addressing these issues, the packaging of the sponge cake can be improved to enhance product quality, extend shelf life, and reduce waste.