SmartBioplastic food packaging to extend shelf-life and reduce pollution

SmartBioplastics based on available bioplastics or edible materials, in combination with bioparticles functionalised with anti-bacterial enzymes, will extend shelf-life and enhance food safety of fresh food products while reducing pollution associated with food packaging.

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Food packaging plays a critical role in protecting fresh food from damage and contamination over its shelf life but the petroleum-based plastics most commonly used have significant detrimental environmental impacts. Commercially-available biodegradable plastics are considerably more expensive, but do not provide additional functionality, and many do not readily decompose, requiring dedicated end-of-life facilities.

SmartBioplastics are a revolutionary food-packaging material created from compostable and edible bioplastics functionalised with tailored antibacterial bioparticles.

‍SmartBioplastics will add value to the New Zealand primary sector by extending the shelf-life of fresh food products enabling the fresh food sector to derive greater value from their products, capture new markets and create new licensing streams for New Zealand while simultaneously reducing pollution by replacing conventional plastic packaging with functional SmartBioplastics that generate less greenhouse gas emissions during their life-cycle.

Main Aims of the Programme

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- Enhancing New Zealand’s exports by increasing shelf-life and product safety

- Creating a new class of globally-relevant food packaging materials

- Reducing the complexity of traditional multi-layered food packaging

- Replacing petroleum-plastic packaging, reducing plastic pollution and greenhouse gas emissions

- Protecting against food-borne illnesses and food spoilage

[1]

Principle of SmartBioplastics production

A synthetic gene fusion combining the bioparticle synthase gene and a gene capable of lysing bacterial cells is expressed during high-density fermentation, resulting in tailored bioparticles displaying the lytic enzyme on their surface. Methods of embedding such tailored bioparticles on different types of bioplastics are explored for applications of SmartBioplastics that will extend product shelf-life and consumer safety through antimicrobial properties.

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Food Spoilage Model System 1

Campylobacteriosis is the most frequently notified disease in New Zealand, most often caused by ingestion of contaminated poultry meat. Current incidence remains high at ~8,000 reported cases per annum.

Campylobacter is a global food-safety threat across a wide range of foods, with campylobacteriosis deemed an infectious diseases likely to challenge global export markets.

SmartBioplastics will deliver immediate impact as food packaging materials active against Campylobacter, creating a value-add opportunity for the New Zealand food sector by increasing product shelf-life and food safety.

Deploying SmartBioplastics across branded and home-brand consumer retail products (around 80% of NZ domestic consumption) is projected to deliver an 80% reduction in Campylobacter contamination.

[2]

Campylobacteriosis notification by DHB in 2004 Source

Food Spoilage Model System 2

Vacuum packed fresh meat stored under refrigeration can be contaminated by psychrophilic Clostridium. Their production of CO₂ leads to blown-pack-spoilage, both contributing to shelf-life limitations, economic losses, and risks to consumer safety.

Psychrophilic microbial food-spoilage is a recognised food safety risk and acceptable microbial loads can be exceeded after only two days when stored at 12˚C.

[3] Clostridium perfringens

[4] Blown pack spoilage of vacuum packed meat by Clostridium estertheticum

Environmental Impact

SmartBioplastics will reduce plastic pollution and reduce the greehhouse gas emissions associated with plastic packaging and with the breakdown of food discarded due to spoilage.

Rising consumer awareness globally is driving increased demand for biodegradable bioplastics. Packaged food is a key driver of this growth, and consumers demand on-package information such as recycling and carbon footprint. However, only ~18% of packaging is recycled by consumers in New Zealand. Given correct disposal, New Zealand uptake of SmartBioplastics could result in 11,200T less plastic waste going to landfill by 2034, equivalent to 21,200T fewer CO₂ emissions.

[5]

Soil contamination by petroleum-based plastics is a huge problem. Fast Breakdown of compostable bioplastics is increasing soil quality after composting.

Life Cycle Assessment

The environmental footprint of SmartBioplastic manufacture, use, and end-of-life will be assessed through a Life Cycle Assessment. The aim is to ensure that SmartBioplastics create a smaller environmental impact than petroleum-based plastics while remaining commercially viable.