Packaging Sensor Predicts Shelf Life of Perishable Foods
BlakBear's paper-based electrical gas sensor measures the remaining shelf life of meats, poultry, and fish, more accurately than misleading expiration dates.
The BlakBear sensor determines the shelf life of perishable foods like packaged fresh meats by detecting and measuring the gas emitted from the products as they spoil.
Photo courtesy of BlakBear.
A new smart packaging solution will soon hit the market in a bid to combat food waste. BlakBear, a London-based food supply chain company, has developed a paper-based electrical gas sensor that indicates the remaining shelf life for packaged meats, poultry, and fish in real time that the company says is more accurate than traditional expiration dates and provides accountability in the supply chain.
Chief Technology Officer Giandrin Barandun, along with CEO Max Grell and COO Michael Kasimatis, created the BlakBear smart labels when they were bioengineering students pursuing their Ph.D.s in the Guder Research Group at Imperial College London. Placed inside the packaging or embedded within a multilayered packaging material, the label measures the remaining shelf life of packaged meats, chicken, and fish by detecting gas emitted from the perishable foods as they spoil in order to accurately quantify their shelf life.
Precise shelf life measurements
The paper-based label features two electrodes printed on it as well as an embedded RFID chip. When food spoils, microbes release ammonia gas. The paper’s cellulose fibers absorb this water-soluble gas and then dissociate it into ions. The electrodes sense and measure the ionic conductivity present in the layer of water that is already naturally present in the paper’s fibers to determine the shelf life of the product. “We correlate the voltage or the electrical signal that we measure from the dissolved gas with the actual microbe and organoleptic data,” Grell says.
“The sensor can measure ammonia gas down to 200 parts per billion, which is more than 100 times better than the best human noses,” he adds. “So it’s much more sensitive than what you could do yourself. And it responds in seconds as well.”
Consumers can access shelf-life data in real time when they scan the RFID tags embedded in the BlakBear label with their smartphones.Photo courtesy of BlakBear.
Sensing the benefits
Grell says the BlakBear sensor can mitigate food waste caused by fixed expiration dates. About 1.3 billion tons of food is wasted globally each year, according to the Food and Agriculture Organization of the United Nations. Part of the problem is that consumers misinterpret those conventional date labels. Sell-by dates designate when a product is at peak quality and flavor and are not indicators of food safety, according to the U.S. Department of Agriculture. But many consumers mistakenly throw away edible food based on those conservative expiration dates.
According to Grell, the BlakBear sensor offers shelf-life data that is much more accurate than food expiration dates. Consumers can access the shelf-life data in real time when they scan the RFID tags with their smartphones. In addition, the BlakBear web app can send consumers reminders to their smartphones notifying them of how much shelf life remains in their packaged foods—indicating whether it is still safe to eat the products or to discard them after purchase.
Food manufacturers can use the shelf-life data from the BlakBear label to improve quality control and add shelf-life days to the products in their supply chains. For example, they can choose the best shipping routes to optimize freshness. In addition, if a product is spoiling faster than it should or the packaging has been tampered with, the manufacturer can immediately locate and fix the problem.
Another benefit of the BlakBear label is its affordability, according to the company. Each label could cost less than 5 cents each to make at high volumes. “It basically comes down to the cost of the RFID microchip because paper is the cheapest substrate material on earth,” Grell says.
BlakBear says it is currently trialing its paper-based electrical sensors with large U.K. and North American protein processors and retailers, but declined to mention the specific brands it is working with. While the BlakBear sensor has proven effective with fresh meats, chicken, and fish, the company is testing the sensor to see if it can be applied to other packaged food products. BlakBear is also working with TPG Rewards, a marketing technology company, to develop consumer marketing programs that leverage the RFID technology embedded in the packaging.
Developing containers as well
In the meantime, BlakBear is also developing reusable food storage containers with the sensors now that more people are cooking at home due to the COVID-19 pandemic. “It’s in response to the new world that we’re in,” Grell says. “People can’t go out to eat, so they have to store a lot of food at home. We’re testing the waters there.”
In a time of considerable uncertainty, a constant you can count on is PACK EXPOInternational and Healthcare Packaging EXPO.PACK EXPOthis November is taking place, either as a live and virtual event combination, or an all-virtual event. Learn more athttps://www.packexpointernational.com.
Discover cutting-edge packaging and processing solutions in the inaugural Packaging World/ProFood World Innovations Report. From high-speed filling machines to mono-material lids, see how the latest advancements from PACK EXPO International 2024 are driving safety, sustainability, and extended shelf life—shaping the future of dairy food and beverage packaging.
Looking for CPG-focused digital transformation solutions? Download our editor-curated list from PACK EXPO featuring top companies offering warehouse management, ERP, digital twin, and MES software with supply chain visibility and analytics capabilities—all tailored specifically for CPG operations.
Consumers can access shelf-life data in real time when they scan the RFID tags embedded in the BlakBear label with their smartphones.Photo courtesy of BlakBear.
