Interfacial mass transport properties which control the migration of packaging constituents into foodstuffs

Diffusion Coefficients of Variable-Size Amphiphilic Additives in a Glass-Forming Polyethylene Matrix

Diffusion of additives in polymers is an important issue in the plastics industry since migratory-type molecules are widely used to tune the properties of polymeric composites. Predicting the diffusional behavior of new additives can minimize the need for repetitive experiments. This work presents molecular dynamics simulations at the microsecond time scale and uses the MARTINI force field to estimate self-diffusion coefficients, D, of six monounsaturated amides and their analogs carboxylic acids in polyethylene matrices (PE, MW = 5600 Da). The results are strongly influenced by the glass-forming properties of the PE matrix, which we characterize by three distinct temperatures. The metastability region (T < 325 K), the glass transition temperature (Tg = 256-260 K), and the end of the transition (T ≅ 200 K). Self-diffusion mechanisms are inferred from the results of the dependence of D on the molecular mass of the additive, observing a Rouse-like behavior at high temperatures and deviations from it within the metastability region of the matrix. Interestingly, D values are nonsensitive to the nature of the considered polar head for additives of similar size. The temperature-dependent behavior of D follows, at fixed additive size, a linear Arrhenius pattern at high temperatures and a super Arrhenius trend at lower temperatures, which is well represented with a power law equation as predicted by the Mode Coupling Theory (MCT). We offer a conceptual explanation for the observed super-Arrhenius behavior. This explanation draws on Truhlar and Kohen's interpretation of the available energies at both the initial and the transition states along the diffusion pathway. The matrix's mobility significantly affects solute self-diffusion, yielding equal activation enthalpies for the Arrhenius region or the same power law parameters for the super-Arrhenius regime. Finally, we establish a one-to-one time-equivalence of the self-diffusion processes between CG and all-atom systems for the largest additives and the PE matrix in the high-temperature regime.

A Holistic Approach of Extractables and Leachables Assessment of Rubber Stoppered Glass Vial Systems for Biotechnology Products

Rubber stoppered glass vial systems are widely used as primary containers for storing and delivering therapeutic protein products to patients. Addressing concerns and regulatory expectations related to the risk to biologic drug product quality and patient safety from rubber stoppered glass vial systems requires implementation of an extractable and leachable evaluation program based on material understanding, risk assessment, literature review, and a comprehensive scientifically sound analytical testing methodology. The extractable and leachable study design consisted of twelve drug products filled in twelve different size glass vials capped with laminated and nonlaminated rubber stoppers made from three different rubber formulations. Design of the model solvents was successful as they had little to no analytical interference and mimicked the formulation conditions and generated representative extractables capable of predicting leachables. The extraction conditions of time and temperature were appropriate as not to degrade the test materials or the extractable compounds, and yet generated significant quantities for identification of the extractable compounds with confidence. The extractables testing results were capable of predicting the leachable profiles of the twelve drug products. In each case, the leachable profile was a subset of the extractable profile. The organic and elemental impurities of the leachable profiles of drug products were the end-to-end verification of the quality of the glass vials, rubber stoppers and drug product lifecycles. Overall, the holistic approach was fully successful in the qualification of different vial systems as primary containers and delivery systems for different biotherapeutic products to ensure product quality and patient safety.

The Ubiquitous Issue of Cross-Mass Transfer: Applications to Single-Use Systems

The leaching of chemicals by materials has been integrated into risk management procedures of many sectors where hygiene and safety are important, including food, medical, pharmaceutical, and biotechnological applications. The approaches focus on direct contact and do not usually address the risk of cross-mass transfer of chemicals from one item or object to another and finally to the contacting phase (e.g., culture medium, biological fluids). Overpackaging systems, as well as secondary or ternary containers, are potentially large reservoirs of non-intentionally added substances (NIAS), which can affect the final risk of contamination. This study provides a comprehensive description of the cross-mass transfer phenomena for single-use bags along the chain of value and the methodology to evaluate them numerically on laminated and assembled systems. The methodology is validated on the risk of migration i) of ϵ-caprolactam originating from the polyamide 6 internal layer of the overpackaging and ii) of nine surrogate migrants with various volatilities and polarities. The effects of imperfect contacts between items and of an air gap between them are particularly discussed and interpreted as a cutoff distance depending on the considered substance. A probabilistic description is suggested to define conservative safety-margins required to manage cross-contamination and NIAS in routine.

Releases of brominated flame retardants (BFRs) from microplastics in aqueous medium: Kinetics and molecular-size dependence of diffusion

Microplastics (<5 mm) are increasingly detected in aquatic environment, and the high levels of brominated flame retardants (BFRs) contained in them can potentially impact water quality. This study characterized the release kinetics of polybrominated diphenyl ethers (PBDEs) and 1,2-bis(2,4,6-tribromophenoxy)ethane (BTBPE) from millimeter-sized microplastic pellets in water at environmentally relevant temperatures. Leaching rates of BFRs from the microplastic pellets made of acrylonitrile butadiene styrene (ABS) were found to be controlled by their diffusion within the plastic matrix, and their diffusion coefficients (D) in the plastic matrices ranged from 10^-28.30 to 10^-20.84 m² s^-1. The apparent activation energies of the BFRs' diffusion coefficients were estimated to be in the range of 64.1-131.8 kJ mol^-1 based on their temperature dependence and the Arrhenius equation. The diffusion coefficients of the BFRs decrease with their molecular diameters, while the activation energies for diffusion increase with the molecular diameters, which are indicative of significant steric hindrance for BFR diffusion within the plastic matrices. A semi-empirical linear relationship was observed between Log₁₀D and the glass transition temperature (T_g) of plastics, which allows prediction of the diffusion coefficients of BFRs in other types of microplastics commonly found in marine environment. The half-lives of BFR leaching (i.e., 50% depletion) from the microplastic pellets would range from tens of thousands to hundreds of billions of years at ambient temperatures if their physical and chemical structures could remain intact. Although the release fluxes of BFRs from microplastics are extremely low under the model conditions, a range of physical and chemical processes in the natural environment and the digestive systems of organisms that ingested them could potentially accelerate their leaching by causing breakdown and swelling of the plastic matrices.

Food-packaging migration models: A critical discussion

The widely accepted and used migration models that describe the mass transport from polymeric packaging material to food and food simulants are confirmed here. A critical review of the most accepted models is presented in detail. Their main advantages and weak points, regarding their predictive accuracy, are discussed and weighted toward their usage extensiveness. By identifying the specific areas where using such models may not provide a strong correlation between theoretical and actual results, this work also aims in outlining some particular directions regarding further research on food - packaging interactions.

Project SafeFoodPack Design: case study on indirect migration from paper and boards

Migration due to indirect contact with packaging caused several major sanitary crises, including the spread contamination of dry food by mineral oils and printing ink constituents from cardboard. The issues are still not fully resolved because the mechanisms have been insufficiently described and the relationship between design, contamination level, type of contaminant, and conditions of storage (time and temperature) are poorly understood. This study proposes a forensic analysis of these phenomena when food is separated from cardboard by a plastic layer. Practical relationships and advanced simulation scenarios were devised and validated against the long-term migration between 20 and 60°C of 15 substances. They were chosen to be representative of the main contaminants of cardboard: aliphatic and aromatic mineral oils, photo-initiators and plasticisers. Data were summarised as iso-contamination curves and iso-contamination times up to 2 years. Simple rules are illustrated to extrapolate the results to arbitrary conditions in order to identify critical substances and to estimate the plastic film's thickness to keep the contamination within acceptable limits. Recommendations for the risk management of contamination routes without contact are finally drafted.

Predicting diffusion coefficients of chemicals in and through packaging materials

Most of the physicochemical properties in polymers such as activity and partition coefficients, diffusion coefficients, and their activation with temperature are accessible to direct calculations from first principles. Such predictions are particularly relevant for food packaging as they can be used (1) to demonstrate the compliance or safety of numerous polymer materials and of their constitutive substances (e.g. additives, residues…), when they are used: as containers, coatings, sealants, gaskets, printing inks, etc. (2) or to predict the indirect contamination of food by pollutants (e.g. from recycled polymers, storage ambiance…) (3) or to assess the plasticization of materials in contact by food constituents (e.g. fat matter, aroma…). This review article summarizes the classical and last mechanistic descriptions of diffusion in polymers and discusses the reliability of semi-empirical approaches used for compliance testing both in EU and US. It is concluded that simulation of diffusion in or through polymers is not limited to worst-case assumptions but could also be applied to real cases for risk assessment, designing packaging with low leaching risk or to synthesize plastic additives with low diffusion rates.

Development of decision tools to assess migration from plastic materials in contact with food

Testing the specific migration limits of all substances intentionally added to polymer material according to European Union (EU) regulation is a time-consuming and expensive task. Although mathematical modeling offers an interesting alternative, it can significantly overestimate the migration in situations which are strongly conservative due to significant uncertainty in transport properties. In addition, its application is of little use for end-users or enforcement laboratories, which do not have access to the formulation. This paper revises the paradigm of migration modeling by combining modeling with deformulation experiments and iterative modeling in the framework of decision theory. The complete approach is illustrated for polyolefins in contact with 50% ethanol for eight typical migrants, including hindered phenolic antioxidants and low molecular weight surrogates. Results from a French ACTIA project on the identification of formulation fingerprints and on the prediction of partition coefficients with alcoholic and aqueous stimulants is described. When the true migration was close but still lower than the limit of concern, the proposed compact decision tree, including up to four sources of uncertainty, showed that the chance of demonstrating compliance was about 3 : 4 in the presence of one source of uncertainty, whereas it fell below 2 : 4 and 1 : 4 with two and three sources of uncertainty, respectively. The recommendations for further food packaging safety surveys and future developments are discussed.