Double wall packaging extends bakery shelf-life

The double wall wrapping system, designed by Joel Gourlain, seals a layer of modified gas around the bread - enabling it to maintain optimum atmospheric conditions, preserving the product throughout transportation and distribution.

The inventor, who holds both the UK and French patents for the process, told bakeryandsnacks.com​ shelf-life could be extended by two to three weeks depending on the type of bread and temperature at which it is stored.

The bread is individually wrapped with a biogradeable micro-perforated film before being placed in a larger bag which is injected with a mixture of modified gases.

Bakers need a flow-wrapper and gas injecting facility in order to implement the double wrapped packaging system which can be used for French breads, croissants or paninis.

The gas does not come into contact with the bread and therefore does not affect the taste but acts to stabilise humidity and prevent moisture deteriorating the bread quality.

Gases such as ethylene, carbon dioxide and moisture are carried away from the bread product to the outer barrier and, as the moisture is regulated, less additives such as E282 calcium propiorate and E300 ascorbic acid are needed in the recipe as a preservative.

According to Gourlain, the invention will mean cost reductions throughout the baking process as it cuts down on waste by eliminating mould formation and extending shelf-life.

Gourlain added: "A double bag would mean a bigger price but at the end of the day you can save a lot of money by reducing the quantity of material and the time taken to prepare it."​

After European trials, Gourlain hopes to introduce the packaging to market by early next year.

According to Gourlain, of the 25 million tonnes of part baked bread manufactured in Europe in 2002, 10 per cent was baked at the selling off point.

He further estimates that there will be a total 3.7 million tonnes of part baked bread manufactured in 2006.