Investigating Residual Solvents and Barrier Efficiency in Food Packaging: Implications for Regulatory Compliance

Food packaging is necessary for ensuring the quality and safety of food. However, production materials can migrate from packages to packaged foods if they contain residual solvents due to ink printing by-products that may have deteriorated into components with risks to human health after a certain period in time during storage. The objectives of this work were to (1) quantify prohibited and restricted residual solvents (methanol, ethylene glycol, and toluene) in flexible potato chip packaging by using validated gas chromatography; (2) determine water vapor permeability qualities with permeation analyzers;(3) evaluate safer solvent substitutes through Hansen Solubility Parameters; (4) compare environmental impacts utilizing life cycle assessment. Five individual samples of locally-available local leaders and imports were examined. Local brands had significantly higher levels of residue solvents (methanol: 0.042–0.268 mg/m2; ethylene glycol: 0.263–1.247 mg/m2 toluene: 0.012–0.792) than imported and leading brands. The properties of each barrier varied significantly, with Sample D additionally showing the lowest WVTR at (0.14 g/m²/day) and sample B had a low O₂ transmission rate at (3.58 cm3/m2/day) respectively but it is much bigger than one can be bearable if not controlled timely by near field imaging [ref]. Four less hazardous substitutes were pinpointed through Hansen solubility parameters: ethanol for methanol, propylene glycol monomethyl ether acetate (also known as 1-methoxypropyl acetate or PGMEA) to replace ethylene glycol and a n-propyl alcohol/n-propyl acetate mixture stood in lieu of toluene. Most items had lower environmental impacts for leading brands and imports, LCA found. These results highlight the importance of strict Good Manufacturing Practices, implementation of high barrier films, solvent displacement and unified national laws in Pakistan. It presents a global architecture that links local practice to international standards on safety and sustainability.

Mahnoor Mujeeb, Saad Nadeem and Shan Ali Virk