Exploring Acidic Sauce Permeation on High‐Barrier Packaging Film Properties

ABSTRACT High‐performance packaging for condiments, such as hot sauce in meal, ready‐to‐eat (MRE) rations for military personnel, is critical to ensure food quality and safety. This study addresses possible packaging solutions by examining the performance and degradation of multilayer packaging films when exposed to hot sauce. The research involved creating pouches from four different multilayer films, utilizing polymers such as: linear low‐density polyethylene (LLDPE), low‐density polyethylene (LDPE), polypropylene (PP), polyethylene terephthalate (PET), polyesters and polyamide (PA). These pouches underwent accelerated storage testing with liquid hot sauce for 12 months at 80°F. The study focused on understanding the effect of acidic sauce permeation on the chemical properties, surface morphology and colour changes of individual layers within a pouch. The analysis identifies the layer most susceptible to degradation due to hot sauce permeation. It was also found that the sealant layer plays a key role in protecting the hot sauce quality, preventing pouch failure. These findings are critical for enhancing the durability and efficiency of multilayer packaging materials, with broader implications for the food, pharmaceutical and consumer goods industries.