MAXIMISING SHELF-LIFE:

Understanding, setting and

extending the shelf-life
of your food and
beverage products

eBook
 3.3.2. Historical data 23
CONTENTS
3.3.3. Microbiological quality shelf-life testing 24
1. Introduction 3
3.3.4. Challenge testing 24
1.1. Best before and use-by dates 4
4. Quality 25
1.2. Setting a shelf-life 5
4.1. Physical and chemical parameters 25
1.3. Drivers for reviewing shelf-life 7 Case Study: Testing a new colour
27
1.4. Drivers for extending shelf-life 8 ingredient over life

2. Shelf-life testing 9 4.2. Nutritional considerations 28

2.1. Worked examples of testing considerations 11 4.3. Sensory attributes 28
2.2. Conducting testing over life 12 5. Packaging 30
2.3. Accelerated shelf-life testing 13 5.1. Controlling the product’s environment 30
3. Microbiology 15 5.2. Shelf-life of the packaging itself 32
3.1. Factors influencing shelf-life 16 5.3. Interaction and migration 34
Case Study: Ingredient shelf-life impact on 6. Extending shelf-life 35
17
product shelf-life
6.1. Methods for extending shelf-life 36
3.2. Processing and storage 19
Case Study: Superchilling seafood 37
3.2.1. Overview of preservation processes and
19 Case Study: HPP processing of vegetable juices 39
packing technologies
3.3. Measuring microbiological shelf-life 21 6.2. Building a business case 40
3.3.1. Predictive modelling 22 6.3. Implementing a shelf-life extension project 44
Why choose Campden BRI? 45
 1 INTRODUCTION

Campden BRI provide tailored, expert support Maximising and extending product shelf-life can offer many
in all areas of shelf-life evaluation, maximisation benefits to manufacturers, retailers and consumers, and
and extension, and have specific expertise in is a key product optimisation strategy for reducing costs
and increasing profits. But, when setting the shelf-life of a
microbiology, chemistry, sensory, regulatory
new product or considering any shelf-life extension for
and product innovation services. As thought an existing product, safety and quality must be carefully
leaders in the food and beverage industry, considered throughout product life to ensure that they are
Campden BRI have produced this Shelf-life not compromised.
eBook to share their knowledge and provide
support for their members, clients and the There are references to EU and UK industry guidance and
legislation within this eBook – whilst overarching shelf-life
wider industry.
principles may be transferable to many different markets,
The shelf-life of a food or beverage product is the time legislation and guidance should be checked to ensure
that it remains both safe to consume and of acceptable compliance in the countries of production and sale.
quality (when stored and handled under the recommended
conditions). This means that it still fulfils its sensory, chemical,
physical, nutritional and microbiological requirements.
Understanding the shelf-life of your products is essential
in assuring their safety and quality, and maintaining
consumer confidence.

3
1.1. Best before and use-by dates Don’t forget, you may also need to provide storage
instructions for when the pack has been opened, such as
Date marking types will vary country by country depending ‘once opened, keep refrigerated and use within 2 days’. Just
on local legislation, which should always be checked before as for the shelf-life itself, in many cases the shelf-life once
embarking on shelf-life related work. In the EU, foods opened would need to be validated / verified to ensure it
required to carry a date mark have to be labelled with has been objectively set.
either a ‘Best Before’ or a ‘Use By’ date.
Food and beverage businesses must be clear on why they
‘Best before’ dates relate to the quality of a food or are using either a ‘use by’ or ‘best before’ indication. This
beverage product. They indicate that, after the specified date, decision requires understanding of what factors are limiting
the product may no longer be of the quality that you would the shelf-life in order to determine what risks may develop
expect but that it will still be safe to consume. over time. If a business decides to use a ‘best before’ date,
they must be certain there is no risk to consumers if the
‘Use by’ dates relate to food safety and are applied to product is consumed after the specified date (there is
food and beverage products that, from a microbiological no time limit on this ‘after’ period!), and it must also be
perspective, are highly perishable (Regulation (EU) No understood that a retailer can legally sell a product after the
1169/2011, which has been retained in UK legislation). If ‘best before’ has passed. If a ‘use by’ date is displayed, food
the product is consumed after the ‘use by’ date, there is a and beverage businesses must have a valid reason for using
risk that the food will be unsafe and cause illness – usually that date, and have data to show that the use of this type of
due to unacceptable levels of pathogenic / illness-causing date marking is correct and safe for their product.
microorganisms (‘pathogens’) or their toxins. Foods can be
consumed up until midnight on the ‘use by’ date, but not The shelf-life for many products carrying ‘use by’ dates is
afterwards, and the storage instructions provided must be driven by microbiological limits that are set out in legislation
carefully followed to ensure safety. It is also mandatory (for example, Commission Regulation (EC) No 2073/2005
to include on pack any special storage conditions and/or which has been retained in UK legislation) or industry
conditions of use that your product’s shelf-life relies upon guidance. It is of the greatest importance that the legislation
(such as ‘keep refrigerated’).

4
and guidance in place in the countries of manufacture and 1.2. Setting a shelf-life
sale of any product are understood, before setting its
shelf-life.

Microbiological limits may be lower if your product is aimed

specifically at a particular consumer group, for example
‘vulnerable individuals’ such as infants or the elderly, as
opposed to the general population. Shelf-life should be determined using sound
scientific principles that take into account all
Additionally, deterioration of sensory, nutritional or other relevant formulation, manufacturing, distribution
quality parameters may limit the shelf-life to one that is and storage factors that may affect how the
shorter than would be applicable for microbiological food product’s characteristics change over time. If the
safety alone. shelf-life assigned is too long, the product may not
meet the requirements of food safety legislation
In some markets, there may be defined products that are
not required to be labelled with a date marking. In the EU or the manufacturer’s vision of optimum quality
(Annex X of Regulation (EU) No 1169/2011), for example, (due to food spoilage or unacceptable levels of
this applies to a list of products including fresh fruit and particular microorganisms). However, if it is too
vegetables, beverages containing 10 % or more by volume short (much shorter than is necessary to protect
of alcohol, vinegar and solid sugar, among others. Such food safety and quality) then this can negatively
exceptions will usually be highlighted in local legislation. affect costs, waste and profit margins.”

Linda Everis | Microbiology Section

Lead for Safety & Spoilage at
Campden BRI

5
Figure 1: Shelf-life setting steps that may be used for a new product, changed product or shelf-life extension project

1 Establish product parameters (for example, formulation, processing/packing method, packaging, storage conditions).

2 Check the shelf-life related legislation and guidance in place in the countries of
manufacture and sale.

3 Check which microorganisms may grow and limit the shelf-life of the product (spoilage microorganisms
and pathogens)

4 Determine whether the microorganism(s) identified in Step 3 may be of concern regarding

growth in the product (such as pathogens in excess of the regulatory limit or other microorganisms at levels that affect quality). To do
this may require the use of one or more of the following: expert knowledge, predictive microbiology, historic data, HACCP and/or microbiological
risk assessment, challenge testing, shelf-life testing.

5 Conduct quality shelf-life testing - sensory, physical, chemical, nutrition.

6 Set the final shelf-life based on results of steps 4 and 5 and relevant legislation.
Always consider any abuse of the product by the consumer when setting final shelf-life. Consider if there is a need to set an opened shelf-life, and if
so obtain objective evidence to determine what this is.

7 Ongoing review of relevant legislation and guidance, HACCP, production area environmental testing, final product testing (at time of
production and at end of life) and consumer complaints. [OUTCOMES MAY TRIGGER RETURN TO STEP 1/2/3]

8 Any product development activities. [RETURN TO STEP 1]

6
Step 1 is the ideal opportunity to design your product with Considerable expertise and experience is needed to
a particular shelf-life in mind, as the formulation, processing guarantee that all of the necessary considerations are
/ packing method and storage conditions all impact the included in the setting or extension of a product’s shelf-
feasible shelf-life range for your product. Understanding the life, in order to ensure product safety, quality and legal
detail of what can influence shelf-life may enable you to compliance. All food and beverage products need to be
leverage these factors to maximise your product’s shelf-life. considered on an individual basis. Where a manufacturer
does not have this expertise or experience in-house, they
Shelf-life is best considered and influenced within product should seek the support of an external partner.
design / early in product development, however there are
still strategies that you may adopt to extend your product’s
shelf-life through reformulation / innovation / renovation of 1.3. Drivers for reviewing shelf-life
its recipe, processing, packing, packaging
and storage. Assigning the correct shelf-life is paramount for the
commercial success of a new product. Any subsequent
changes to formulation, packaging, manufacturing, distribution
and storage should trigger a review of both the HACCP
(Hazard Analysis and Critical Control Points) plan and the
shelf-life of the product, both of which may be influenced by
one or more of these factors. As an example, a formulation /
ingredient modification that causes a change to parameters
such as salt or sugar level, pH / acidity or preservatives can
impact on microbial survival and growth, and therefore affect
a product’s shelf-life.

All changes, however small or unimportant they may seem,

could have unexpected consequences for your product’s
shelf-life if not properly evaluated. This can be especially

7
true for multiple small changes that combine to have a big,
unintended impact1.

It is important to conduct a periodic review (at least

annually) to verify that the shelf-life being used is still correct
and determine whether it needs to be reassessed. Such
reviews should consider changes in guidance or legislation,
changes to the product itself, commercial considerations,
consumer complaint information, and whether there is
evidence that the indicated storage conditions are not
being routinely achieved in practice (for example, in retail or
domestic settings).
can be challenging to know which strategies to apply. The
1.4. Drivers for extending shelf-life validation of a shelf-life extension process (shelf-life testing
of an improved product over the new, longer shelf-life)
Increasing the length of a product’s shelf-life may offer and application of the extension strategy (for example, the
improved profit margin, reduced waste, less frequent / purchase of a more hygienic filling machine or new freezer,
larger production runs, increased MLOR (minimum life on or the reformulation of a product) will require time and
receipt) and better quality food (which maintains its quality investment from your business.
for longer). As well as being more cost-effective and efficient
for manufacturers, it may also enable possibilities for To get the necessary buy-in, a thorough business case is vital
geographical expansion of product distribution. (see Chapter 6). As well as return on investment needing
to be demonstrated, you must ensure that your shelf-
Any shelf-life extension project must be carefully considered life extension strategy maintains your product’s integrity,
to ensure that food safety and quality are not compromised. quality and safety, while remaining feasible and efficient to
With so many different interconnecting considerations it manufacture.

8
 2 SHELF-LIFE TESTING

A key step for any shelf-life determination

or shelf-life extension project is assessing
which testing considerations are relevant to
your product.
This Shelf-life Testing chapter indicates which sections of
this eBook may be most relevant to particular product
categories (Figure 2), and provides some worked examples
of testing to consider when determining shelf-life. In Figure
2 and the worked examples, the considerations listed are in
relation to shelf-life evaluation only, and are not for setting
routine testing criteria – food business operators must set
other criteria for their routine testing (for example, HACCP
verification testing).

Some considerations and limitations for conducting

accelerated shelf-life testing are also covered
(see Section 2.3).

9
Figure 2: Testing to consider over life for setting / proving a shelf-life

Ambient Chilled Frozen

Wet Dry Preservation process Unprocessed /

/ kill step applied no kill step
Ready meals
Cottage cheese
Preservation process / Chilled soups
kill step applied Cooked meats

Pasteurised Sterilised Unprocessed / Water Water Short ≤ 10 Longer / Protein Packaged / Frozen Variable
(pH < 4.6) (pH ≥ 4.6) no kill step activity activity days life extended > Raw meat prepared raw throughout conditions
Canned Canned foods (cold fill) ≥ 0.6 to < 0.6 (eg Pasteurised 10 days life / fish produce life Defrost /
beverage Protein / milk Ketchup approx 0.80 Powders 70°C for 2 mins (eg Pasteurised Raw meat- Salad Cook or eat freeze-thaw
Hot-filled drinks Bread Grains / Pasta or equivalent) 90°C for
10 mins or
alternatives Prepared fruit from frozen products
sauces Pastries Crisps equivalent*)
products

Testing to consider over life:

Quality Quality Microbiology Microbiology Quality Microbiology Microbiology Microbiology Microbiology Quality Microbiology
Packaging Packaging Quality Quality Packaging Quality Quality Quality Quality Packaging Quality
Sensory Sensory Packaging Packaging Sensory Packaging Packaging Packaging Packaging Sensory Packaging
Nutrition Nutrition Sensory Sensory Nutrition Sensory Sensory Sensory Sensory Sensory
Microbiology Nutrition Nutrition Nutrition Nutrition Nutrition Nutrition
Very low
Lack of kill Microbiological water activity This treatment These conditions
step may be testing would prevents the is designed to are designed Due to being unprocessed, a Freezing inhibits the growth of
If pH is less than 4.6 the
made feasible typically be growth of control Listeria to control number of pathogens and spoilage microorganisms and the deterioration
growth of pathogens and spoilage
by intrinsic for spoilage microorganisms. monocytogenes, non-proteolytic microorganisms may need to be of nutritional parameters during
microorganisms is reduced /
elements of microorganisms which can Clostridium considered for determining the frozen storage.
eliminated by a pasteurisation
the product able to grow grow at chilled botulinum. Other shelf-life. For freeze-thaw products when
kill step.
that prevent at lower water temperatures. pathogens defrosted, the safe shelf-life and
A higher pH (≥ 4.6) means that
pathogen activity. Other vegetative or spoilage decline of nutritional parameters
a harsher kill step is required
survival or limit pathogens microorganisms needs to be established.
to eliminate pathogens, such as
Clostridium botulinum. growth to non- would also be may affect the
Where the appropriate kill step is harmful levels. controlled by this shelf-life.
applied, microbiology is not typically Microbiological process. Other
a consideration for testing over life. testing would microorganisms
typically be for may limit the
any pathogenic shelf-life of these
or spoilage product groups.
microorganism
that could limit
shelf-life.

* or other controls in place2 for non-proteolytic C. botulinum

10
The above testing considerations and the following worked
examples are not exhaustive and are a guide only – they AMBIENT-STABLE PRODUCT:
should not be followed without gaining expert advice. Pasteurised, high acid (pH < 4.6)
Products need to be considered on an individual basis, as beverage in an aluminium can
in some cases other tests may be required to ensure safety
Shelf-life testing considerations:
and legal compliance and quality, which must be assured
throughout shelf-life. • Quality – appearance, colour, separation /
sedimentation, texture / viscosity (Chapter 4)
• Sensory (Section 4.3)
• Nutrition – vitamin content (if applicable)
2.1. Worked examples (Section 4.2)

of testing considerations • Packaging (Chapter 5) – pack integrity (Section 5.2),

aluminium pick-up (Section 5.3)
• Assessing for taint (Chapter 4 and Section 5.3)

CHILLED PRODUCT: Cooked, ready-to-

eat sandwich meat, in gas-flushed (modified
atmosphere) packaging

Shelf-life testing considerations: DRY PRODUCT: Crisps and similar snacks

• Microbiology – safety and spoilage (Chapter 3) Shelf-life testing considerations:
• Quality – appearance, colour, texture, rancidity
(Chapter 4)
• Quality – moisture, texture, structural integrity,
rancidity (Chapter 4)
• Sensory (Section 4.3)
• Sensory (Section 4.3)
• Packaging – gas analysis, pack integrity (Chapter 5,
see Section 5.1 for modified atmosphere packaging)

11
2.2. Conducting testing over life If the product is to be subjected to multiple storage
conditions (for example, a freeze-thaw product), the
To ensure safe product for the consumers (right through varying timings of the different storage conditions need to
to the end of a product’s shelf-life), considerable expertise be considered, the worst case factored into the shelf-life
and experience is needed to consider all necessary factors applied to the product, and timing guidance provided to the
for designing a validation / testing plan. The same is true for consumer on pack. Similarly, for multi-use products, the life
analysing shelf-life data, among other considerations, and of the product once opened needs to be determined and
setting an appropriate shelf-life for a new product or shelf- validated, and the required conditions and timescale must be
life extension. communicated on pack.

When a shelf-life is measured and defined, this is based on Careful consideration must be given to how many
the intended storage conditions, which must be displayed different batches or production runs / trials your shelf-life
on pack. Factors such as temperature (ambient, chilled, samples will come from, at what frequency you will test
frozen), lighting and moisture / humidity can all affect and them, and how many samples you will test each time.
limit shelf-life. The manufacture, onward distribution chain, This may depend on the expected / intended shelf-life
retail storage conditions and consumer handling all need of the product and the number of test parameters
to be considered when setting shelf-life. If shelf-life studies being monitored.
apply conditions that offer less chance of microbial growth
than actually occurs in reality (such as a study using a storage It is recommended, as an absolute minimum, to test at least
temperature of 4 °C when 8 °C occurs in reality) then the the start / end of the intended shelf-life and three evenly
life will be over-estimated and the product may spoil, or / logically distributed intervals in between, as well as to
worse cause illness, when applied to commercial product. test beyond the intended shelf-life. But it may be prudent
Samples for shelf-life testing therefore need to be produced to test more frequently than this. At each interval, it is
using the real manufacturing process, and their storage recommended to conduct testing at least in triplicate, as this
conditions must be true to those that the product is likely to is more reliable than a single result.
be subjected to throughout its shelf-life.

12
 For some types of ambient stable foods there are models
available to help predict shelf-life. CIMSCEE3 and the
Campden BRI acidified foods models can help predict the
potential for microbial spoilage over time. Where models
are not available / applicable, the most common acceleration
technique is to increase the storage temperature of shelf-life
testing samples. However, this may not be representative;
not all relevant microbial growth and chemical reactions will
speed up at the same rate and the differing temperature
conditions may even cause the type / species of
microorganisms present / growing in the product to
be different.

The Arrhenius model may be applied to study the

relationship between storage time and temperature,
2.3. Accelerated shelf-life testing in relation to accelerating the physical and chemical
deterioration of a food product throughout storage by
For many products there is often a desire to accelerate their storing it at a higher temperature (typically around 37°C
shelf-life testing to get results more quickly – especially for for ambient products). Campden BRI use this model within
products with a longer shelf-life. applicable client shelf-life projects, as it can be used to
predict the new / accelerated version of the shelf-life based
Accelerated shelf-life testing should not be relied upon for on input data (such as the expected or known shelf-life
determining microbiological shelf-life, but can be useful for of the product at the standard storage temperature).
assessing changes in product quality in conjunction with the Although storage at around 37 °C can accelerate the
steps outlined in Figure 1, alongside completing the same natural deterioration of the product, this method too has
testing in real time. its limitations and may not always mimic actual real-time
storage results.

13
As well as increasing temperature, exposing the product
to high intensity light may be used to replicate ‘worst case’
conditions or for accelerated shelf-life testing (in relation
to, for example, colour change or vitamin degradation).
Additionally, increasing the oxygen levels or humidity of the
storage conditions, or a combination of these approaches,
may be applied in some cases.

For any accelerated testing you will need to be able to

prove that the acceleration methods used are valid. This can
be done by modelling the comparisons of accelerated and
real-time data. As well as speeding up chemical reactions,
processes and deterioration that may have occurred in the
standard storage conditions, accelerated shelf-life conditions
may also cause different or additional outcomes that would
need to be understood. As such, unless there is sufficient
existing data from equivalent products to prove that your
accelerated timeframe and conditions are applicable for
modelling the full shelf-life of your product, its shelf-life will
have to be measured in real time.

14
 3 MICROBIOLOGY

For products within which microorganisms Some definitions:

can survive and grow, their impact may be
• Pathogens – microorganisms that cause food poisoning
the limiting factor for shelf-life. It is critically
and other foodborne illness.
important that it is established whether a
product can support the growth of pathogens • Spoilage microorganisms – any microorganism that
or the formation of microbial toxins. can grow within a product and cause a change in quality
that the manufacturer or consumer would
find unacceptable.

• Water activity (aW) – a measure of how much water

in a product is available for microorganisms to use to
survive and grow. An aW of 1.00 is pure water, lower
values show a decrease in the amount of available water.

• pH – a measure of acidity. Low pH values are more acidic

than high ones. A pH of 7 is considered neutral (neither
acidic or alkaline).

15
3.1. Factors influencing shelf-life
Shelf-life is influenced by many aspects of manufacturing
practice (such as production hygiene) and product
formulation. Food quality, stability and safety can be achieved
by the correct use of Hurdle Technology; using a combination
of factors that each prevent or slow microbial growth, and
therefore work together to achieve the desired shelf-life1. It
is important to verify the effectiveness of the combination of
hurdles used against the microorganisms that may be present
in the product. If in doubt, expert help should be sought.

Factors affecting a product’s

microbiology and shelf-life
• Raw material quality Ingredients will vary in the type and level of microorganisms
• Heat process / ‘kill step’, where applicable present and in how well they support the growth of
these microorganisms, and this may vary between origins
• Product formulation - pH (acidity),
water activity, preservatives / suppliers of the same ingredient. Higher microbial levels
present in the ingredients may mean higher levels could be
• Packaging, including gas atmosphere
reached more quickly in the final product, but this depends
• Temperature and storage conditions (commercial on the processing methods used and intrinsic properties
production, distribution, warehousing, retail
storage / sale, consumer handling) of the food (such as pH, aW and so on). It is clear that the
microbiological quality of any ingredient, and its own shelf-
• Environmental hygiene of production area life, may influence the microbiological load and therefore the
shelf-life of the final product.

16
 at Campden BRI designed a study to investigate the
impact of the age of these ingredients on the achievable
shelf-life of coleslaw. The shelf-life end point was based
on microbial levels reached within the product, the
unacceptable limit of which was defined using levels
stated in guidelines published in November 2009 by the
then Health Protection Agency regarding assessing the
microbiological safety of ready-to-eat foods.

Coleslaw made with two-day-old ingredients reached

an unacceptable level of microorganisms (and therefore
the end of its shelf-life) in just 9 days. Whereas coleslaw
CASE STUDY: made using one-day-old ingredients reached the same
level after 10 days, and that made with fresh ingredients
Campden BRI research with lasted 12 days. Though a UK source was used to define
Coleslaw – ingredient age can the microbial limit here, the overarching principal and its
significantly affect the achievable relationship to shelf-life is universal; whatever limit is set,
it may be reached more quickly if the ingredients used
shelf-life of a final product contain a higher number of certain microorganisms.

Coleslaw contains three raw ingredients - onion, carrot This work provided invaluable insight that could be used
and cabbage - with potentially high microbial levels that when carefully balancing the management of ingredient
could increase over time during storage. Microbiologists waste and finished product safety and quality.

17
Figure 3: Minimum pH levels for the growth
of different microorganisms
Once your ingredients (with their varying microbiological
pH <1.5
Apergillus
load) are combined, there are then aspects of the combined
formulation to consider.
1.8 Candida
Dekkera 2.0
2.8 Alicyclobacillus • The pH (acidity) and aW of your product both affect
Lactic acid
bacteria the ability of microorganisms to survive and grow.

3.6 - 4.0 • They may also impact the effectiveness of any

3.6 preservatives used.
E.coli (Shiga
toxin producing
3.8
strains)
Salmonella
Both pH and aW may change throughout the life of some
products. This means that for products where microbial
4.3 - 4.5 growth is controlled by pH and / or aW, the shelf-life may be
4.3
Bacillus cereus limited by the changes in these parameters1, and you must
(spores/heat 4.39 4.4
resistant) Listeria E.coli 4.5 ensure that these controlling parameters do not change to
monocytogenes (Non Shiga toxin
producing strains)
Aeromonas
Clostridium
an extent that compromises shelf-life.
Bacillus spp perfringens
The packaging materials used for your food or beverage
4.6 - 4.9 product may influence the product shelf-life by the extent to
4.6 which they allow migration of gases and moisture into / out
Clostridium
botulinum proteolytic 4.9 of the pack. The atmosphere within the packaging can also
Yersinia
enterocolitica
Campylobacter
Vibrio
impact the type of microorganisms that can survive and how
parahaemolyticus well their growth is supported (see Section 5.1).

5.0

5.0 5.0
Clostridium
Brochothrix botulinum
Pseudomonas non-proteolytic 18
3.2. Processing and storage 3.2.1. Overview of preservation
A product’s processing conditions and manufacturing processes and packing technologies
environment can have a substantial impact on its shelf-life.
Shelf-life can be limited or extended based on the selection
The process used to inactivate microorganisms, the storage
of preservation process and filling / packing technology used
conditions of ingredients, process intermediates and final
to produce it.
product, and the hygienic status of the manufacturing
environment may all affect the survival and growth of Thermal processing uses heat to destroy microorganisms in
microorganisms and the risk of product contamination. All a food or beverage product. Additionally, heat may inactivate
could have an effect on the shelf-life of the final product. enzymes (naturally present in the product or produced
by microorganisms) that may otherwise have an adverse
effect on product quality and shelf-life. Thermal processing
may therefore influence a shelf-life that could otherwise be
limited by microbial growth or chemical spoilage. Heating
techniques include cooking, retorting and pasteurisation,
and the temperature that the product is heated to, and for
how long, influence how much the microbial population in
the product / packaging is reduced. For example, a sterilised
product typically has a longer shelf-life than a pasteurised
one (lower temperature thermal process than sterilisation),
because sterilisation processes achieve a greater reduction in
microorganism levels.

Non-thermal preservation processes may also be applied

with the aim of reducing the level of microorganisms (but
without applying heat). Non-thermal processes may include

19
subjecting the product to high pressure or applying plasma For many products, the final manufacturing procedure
or ultraviolet light. Shelf-life will be influenced by which will be placing it into its packaging. Even at this stage it is
microorganisms and key enzymes are inactivated1 – and important to consider whether the packaging will affect
more importantly, which are not. the shelf-life of the product – contaminated packaging
material will result in product contamination that could
Many elements of manufacturing process design affect affect product quality, safety and shelf-life. In some cases
the shelf-life potential for your end product. For example, manufacturers consider the need for decontamination of
depending on the process used, the preservation process packaging materials before they are used, particularly if an
could be applied either before or after the product is already processed food is placed into them.
inside its packaging. If applied afterwards, then both the
product and packaging have been decontaminated and the
opportunity for recontamination is limited (see packaging
integrity in Chapter 5). However, if the product is processed
before being filled, there is a risk of recontamination and the
hygiene of the manufacturing environment becomes critical
(see Section 6.1).

20
3.3.Measuring identifying and controlling hazards within the production of
a food or beverage product – see Campden BRI Guideline
microbiological shelf-life 42) or microbiological risk assessment (a structured
Understanding the factors that support and limit shelf-life process for determining and evaluating the risk posed by
length is one thing – but how do you assign a shelf-life that microorganisms in a particular food or beverage product –
you know, from a microbiological perspective, will prevent see Campden BRI Guidelines 28 and 46).
product spoilage and keep consumers safe?
Whichever method is used it is recommended that the
There are four commonly used methods to determine product is assessed throughout (and beyond) its intended
the shelf-life of a product with respect to its microbiology shelf-life to determine and validate what shelf-life should be
and these may be used singly or in combination by allocated to the product and displayed on pack.
manufacturers to give an accurate view.
For microbiological quality shelf-life testing and challenge
These methods are: testing, the storage conditions used must be true to what
the product would realistically be subjected to in real life. If
1. Predictive microbiology (predictive modelling) there is any uncertainty in conditions to use, then a ‘worst
case’ scenario should always be adopted.
2. Use of historical data

3. Microbiological quality shelf-life testing

4. Challenge testing

The methods selected depend on the risk level for growth

of pathogens and spoilage microorganisms in the product.
This can be determined through a HACCP study (Hazard
Analysis and Critical Control Points; a systematic way of

21
Figure 4: 3.3.1. Predictive modelling
Example of a model used to predict microbial growth rate
Predictive modelling is the computer simulation of the
growth of microorganisms in food and beverage products.
Microbial growth curves are generated for a range of
microorganisms from laboratory data. Mathematical
equations are applied to the data to construct models that
allow a prediction of how the microorganisms are likely to
grow in the conditions expected to be present within a
particular product.

The models often take into account factors such

as temperature, pH (acidity), aW, oxygen levels and
preservatives (such as salt, sugar and / or chemical
preservatives), and can be used to predict the rate of
microbial growth and therefore estimate the shelf-life that
a product will have. Campden BRI has developed a suite of
predictive models that predict spoilage for different product
groups and for a wide range of spoilage microorganisms.
There are online predictive systems, such as ComBase, that
can be used to predict growth of pathogens.

Predictive modelling is by far the quickest method to

assess levels of microbial growth, allowing cost effective
exploration of different ‘what if ’ scenarios when developing
new products, reformulating or extending shelf-life. However,

22
predictive modelling is – after all – just a prediction. It does 3.3.2. Historical data
not factor in changes in aW and pH over time, differences in
structure across a food sample, the presence of competing Many companies hold a large amount of historical
microorganisms or the presence of any naturally occurring microbiological testing data on the products that they
antimicrobials that may be applicable for some products. produce. This can be useful when attempting to estimate
shelf-life of a new or modified product. If a new product has
Despite the limitations of predictive modelling, the indication very similar constituents, processing conditions, packaging
of the likelihood of microbial growth is useful in hazard and storage conditions to an existing product, then it may
analysis / risk assessments. It can be used to indicate be that the shelf-life will be similar. Likewise, if a new product
whether pathogens may grow and therefore form part of has reduced levels of a preservative (for example, lower
determining whether further work, such as challenge testing salt), or is processed at lower temperatures or shorter times,
or a detailed assessment of historical data, is required – then the shelf-life may well be shorter.
allowing a more targeted approach.
Historical data can be very efficient and useful in estimating
shelf-life, as the data already exists. However, great care is
required in its interpretation and it may be that additional
predictive modelling or microbiological testing work is
needed to confirm the shelf-life estimated from the use of
historical data.

23
3.3.3. Microbiological Challenge testing often uses the microorganisms that
pose the highest risk in limiting the product’s shelf-life and
quality shelf-life testing these will be determined through the HACCP plan or risk
Quality shelf-life testing is concerned with the survival and assessment.
growth of naturally occurring microorganisms, as well as
Depending on the microorganisms in your product, the
changes to other quality parameters that are discussed
challenge microorganisms may be those that could cause
in Chapter 4. Quality shelf-life testing generally relates
spoilage (for example, yeasts that cause spoilage in low pH
to products where pathogens are not expected to be
products) or those that could pose a risk to health (for
present or to be able to survive / grow. The samples used
example, the pathogen Listeria monocytogenes that may grow
for this type of testing should be produced using the same
in some foods stored at low temperatures).
ingredients, processes, equipment and packaging as would
be used for commercial production of product intended When it comes to interpreting the data, for some
for the consumer. After production, levels of relevant microorganisms any sign of growth is unacceptable. For
microorganisms should be monitored over the others, however, some level of growth may be acceptable.
intended shelf-life. Limits are defined for certain microorganisms and product
categories and this interpretation of challenge testing data
should be made by a relevant expert1.
3.3.4. Challenge testing
Challenge testing is the laboratory simulation of what can
happen to a food or beverage product, during distribution
and subsequent handling, if it were to be contaminated
with a microorganism. Challenge testing is the deliberate
inoculation (contaminating the product with a known level
of a particular microorganism) of your product with relevant
microorganism(s) and then monitoring their levels over the
intended shelf-life.

24
 4 QUALITY

Microbial growth is not the only factor Data from assessing sensory attributes, as well as other
that can limit a product’s shelf-life. Where quality parameters and indicators, should be used to make
microbiological shelf-life has been determined, an informed commercial decision regarding product shelf-life.
it is also necessary to ensure that the quality
parameters of the product will remain 4.1. Physical and chemical parameters
satisfactory within the safe shelf-life.
Many product parameters can change when a food
Aside from microbial spoilage, factors limiting quality or beverage product is stored. Some changes will be
shelf-life can include moisture loss or gain, staling, rancidity, considered a quality defect (such as colour change) and
changes to appearance, texture, odour and flavour, the others (for example, a change in pH) may be an indicator or
uptake / development of a flavour taint and changes in risk / cause for quality defects.
nutritional levels.
For any physical and chemical parameters measured in
The remainder of this chapter is written with respect to quality shelf-life testing, such as pH, texture / viscosity and
conducting quality shelf-life testing. Where there is a risk density, it is important to understand what effects these
of pathogen growth over life, this must take priority in measured parameters have on shelf-life (and therefore
determining shelf-life. Sensory assessments should only take why that test is being done), and to have set objective
place for product that has been deemed microbiologically acceptability limits for each of them before undertaking
safe to consume. testing. Much of this should have already been determined
earlier in the product development process, as part of
writing the product specification, but it is important to

25
understand how this relates to interpreting the results of
quality shelf-life testing and troubleshooting the cause of any
unsatisfactory results.

Chemical food spoilage is an unwanted quality change,

which can manifest as staling, discoloration, thinning (of
sauces, for example, due to starch degradation) or rancidity;
the development of off-flavours and odours (for example,
from the breakdown of proteins in meat, lipid oxidation or
uptake of a taint from an external source). Many texture,
flavour and colour issues can be the result of reactions that
are aided by the presence of specific enzymes (which may
be microbial in origin).

Quality shelf-life testing can be conducted internally within

many food and beverage businesses, or the services of
an external testing partner can be sought. In the case of
ingredient suppliers, for example, the use of an independent
third party to assess new ingredients over a product’s shelf-
life may be valuable.

26
 BRI to investigate the performance of their naturally
sourced lycopene-based and beta carotene-based
individual colours and blends for the colouring of surimi
seafood sticks.

Lycored wanted to compare the stability of several

of their individual colours and blends against other
colouring options. Campden BRI developed a method
to compare ten different individual colours / blends on
each of the seafood sticks, in order to provide a clear
and direct comparison. The seafood sticks were then
stored in chilled conditions and exposed to light levels
CASE STUDY: significantly higher than typical food display conditions –
Proof of colour performance over simulating a ‘worst case scenario’.
life – comparing ten different colour The research provided by Campden BRI used an
solutions on the same seafood stick objective colour measurement system (VeriVide’s
‘DigiEye’), and showed that Lycored’s naturally sourced
Maintaining colour stability and integrity during shelf-life individual colours and blends remained stable with little
is a key challenge for surimi seafood stick manufacturers. to no migration or fading in surimi seafood sticks for up
Lycored, producers of carotenoid and lycopene-based to three months – much longer than other colouring
ingredients for the food industry, approached Campden options tested.

27
If you do not have the capability or equipment in-house to at all stages of its saleable life. An understanding of the
perform shelf-life studies, an external testing partner can stability of your ingredients and product formulation, and the
deliver the necessary access. What’s more, working with a nutrients / components within, are important for designing
partner to provide shelf-life testing can free up personnel, a testing plan and for ensuring compliance with relevant
allowing them to focus on other priorities. labelling / nutritional legislation and guidance for the markets
within which your product is sold.

4.2. Nutritional considerations Where changes have been made to your product’s
formulation, it follows that you will reassess the nutritional
Within European Commission guidance4, there are declaration – however, it is also possible that changes to
tolerances for how much the true nutritional values of a manufacturing processes or packaging may also impact on a
product (for each nutritional parameter, such as sugars, product’s nutritional properties over its life.
protein and fat) can differ from that stated on the nutrition
labelling of that product. These tolerances apply for the
whole of the product’s saleable life. 4.3. Sensory attributes
Nutritional claims (such as ‘high protein’, ‘low fat’ or ‘high Aside from the expectation that food and beverage
fibre’) must be compliant to relevant legislation on nutrition products should be safe to consume, almost certainly the
and health claims (Regulation (EC) No 1924/2006 which has most important elements for the majority of consumers
been retained in UK legislation) throughout the whole of the are those relating to the sensory attributes of the product.
product’s shelf-life. In some cases, this may be a factor that Over the course of time, all products will eventually fail to
limits the life that can be applied to a product.Your products conform to the sensory related elements of their product
must comply with legislation and guidance relevant to the specification.
markets in which you will be producing and selling them.
Sensory attributes typically assessed during quality shelf-life
Nutritional analysis needs to be conducted to ensure that testing are appearance (including colour), odour, flavour,
the product is compliant to relevant legislation and guidance texture and mouthfeel. As with all quality parameters, it is

28
 test conditions, by a minimum of three trained sensory
assessors. The sensory assessors should be screened (for
ability / sensory acuity), highly trained, and independent from
the project management team (to minimise the potential for
bias and expectation error). The samples should be assessed
in a way that reflects the intended consumer end use. For
example, if a product is designed to be sold and consumed
chilled then the sensory assessments should be conducted
with chilled samples.

Where applicable, and if possible, many sensory assessments

best practice for a degree of ‘buffer’ to be included when
employ the use of a reference sample at each assessment
using this data to set a shelf-life, to reduce the incidence of
timepoint. This should be a representative sample (control)
complaints and to account for imperfect storage conditions.
that is considered to be both typical and of acceptable
The aim of conducting sensory assessments over shelf-life quality. In this way, comparative testing can be conducted in
is to monitor and record the changes that occur in the relation to the reference sample.
sensory attributes outlined above. This can be done by a
In order to set the shelf-life for your product, both the safe
sensory panel (a group of sensory assessors) objectively
shelf-life and quality shelf-life need to be considered – the
describing the product’s sensory attributes and their
‘working shelf-life’ (the life applied to the product) will be
intensities, at each assessment interval (timepoint) of the
shelf-life, and using this to identify when changes occur1 and driven by whichever is the shortest.
the magnitude of that change.

Samples should be evaluated blind, under controlled sensory

29
 5 PACKAGING

As well as being a means of communicating 5.1. Controlling the

information about your product, of product’s environment
transporting it, and of physically protecting it
Much like many other factors influencing shelf-life, the
from damage and contamination, the packaging
atmosphere inside a product’s packaging impacts the type of
used for your food or beverage product can microorganisms that can survive in the product and how fast
influence the shelf-life by the extent to which their levels can grow.
the packaging materials allow migration
of gases, moisture, light and microbial Gas composition within a pack will influence the microbial
contaminants into the pack. growth and enzymic and chemical reactions that can occur
in the product1. As such, modified gas atmospheres and
vacuum packaging can be used to limit these activities by
removing the air from the pack (vacuum packing, or ‘VP’) or
by adjusting the mixture and levels of gases that the product
is exposed to (modified atmosphere packing, or ‘MAP’).

For low oxygen MAP and VP, the objective is the removal
of oxygen from the pack. The presence of oxygen facilitates
the growth of many pathogens and spoilage microorganisms,
as well as oxygen-dependent (aerobic) reactions that could
lead to off taints. As such, carbon dioxide is often added to
the product’s environment (inside the primary packaging) to

30
extend the shelf-life of specific products. Moisture being able to migrate across packaging to the
inside of a pack will affect the environment that a product
Reducing the oxygen levels in a pack and replacing with is exposed to, and this ingress could come hand-in-hand
carbon dioxide and nitrogen gases has a dual effect. with that of microbiological contamination. Relative humidity
Eliminating oxygen prevents the growth of strictly aerobic relates to the concentration of moisture in the atmosphere
bacteria, some of which are potent spoilage microorganisms, surrounding a food, which will transition into the food itself if
whilst carbon dioxide is itself antimicrobial, helping slow the the food is ‘less moist’5.
growth of many microorganisms. However, by removing
oxygen, the growth of anaerobic microorganisms may be Where you are producing dry products, such as breakfast
favoured – lactic acid bacteria may become a prominent cereal or spice mixes, the drivers for wanting to keep the
spoilage microorganism, and pathogens such as Clostridium product and its environment dry are obvious. There are
botulinum may, if present, be able to grow. For a number of many more products, however, where relative humidity
years the UK Food Standards Agency (FSA)2, for example, needs to be controlled. This is because it may affect
have issued specific guidance on shelf-life requirements for the food’s water activity (as the moisture around the
VP and low oxygen MAP products. This guidance specifies a food transfers into it), which may affect the ability of
limited shelf-life, unless particular parameters of pH, aW, salt microorganisms to grow (which of course can affect shelf-
or thermal process are used, or a challenge test has been life). What’s more, product quality can also be impacted by
done to show that C. botulinum is not a risk. moisture-related changes to its texture / structure.

Reducing oxygen is not the only strategy – the discoloration Light may also affect shelf-life. Allowing your food or
of fresh red meat, from a red colour to brown, is slowed beverage product to be exposed to light may leave it
down by high oxygen levels. This can be leveraged to vulnerable to light-induced breakdown of components
maintain the meat’s red colour by using high oxygen MAP; within. Whilst different packaging materials can protect
increasing oxygen levels during packing and using a packaging from this to varying extents, such considerations are usually
film that acts as an oxygen barrier to maintain these high balanced with allowing the consumer to be able to see for
oxygen levels in the pack1. themselves what the product inside the packaging looks like
(before purchasing and opening it).

31
In milk, for example, light-induced reactions of riboflavin (a For many packaging formats, the performance over the
natural component of milk) can cause off flavours / odours1 shelf-life of typical products will be well established – but
and other vitamins can be degraded by exposure to light. what if there is little data for your particular product or your
What’s more, the colour of many products can be affected packaging / product combination, or you are using a new
by exposure to light – so, there may be opportunity to slow type of packaging?
down these colour changes (by selecting the right packaging
materials) to extend the product’s quality shelf-life. Many of the tests used to determine whether packaging is
fit for purpose should also be tested over shelf-life. With
new materials coming onto the market with little historical
5.2. Shelf-life of the packaging itself data, it is important to test the material in conjunction with
the product to ensure they are both compatible over the
Packaging needs to be physically robust enough to protect product’s shelf-life. If working with or investigating a new
the product within, not become damaged itself and retain material then a shelf-life study needs to be carried out on
the integrity required to be able to perform the barrier the packaging material itself as well as the product.
function described above. If packaging fails, a food product
may become unsafe or spoil before the end of its shelf-life.

32
Below are just some of the things to consider: There are also moves to the use of reusable packaging
– unless the correct hygiene measures are employed
• Material strength during cleaning and decontamination, this could equate to
a higher microbiological load that may affect the applied
• Integrity of the seal packaging decontamination procedure and result in a higher
microbiological load in the final product.
• Ability to act as a suitable barrier
(regarding both its barrier properties and its
suitability for food contact)

• Performance in the resistance of grease

and moisture penetration

• Resistance to heating, chilling and freezing

With environmental issues high on the agenda there is

pressure for food and beverage manufacturers to reduce
the amount of packaging they use and focus on sustainability.
However, such changes could affect product quality, safety
and shelf-life. For example, a lighter-weight plastic container
may allow more gas migration across it than its heavier
weight counterpart of the same material (a concern for
both ingress of gas and for loss of carbonation, for example).
And moving away from coloured plastics, for reasons of
recyclability, may leave a question mark for the packaging’s
protection against light penetration.

33
5.3. Interaction and migration would make the product unsafe to consume, cause an
“unacceptable change in the composition of the food” or
Some packaging materials may interact in various ways with cause unacceptable sensory changes / deterioration.
the food and beverage components that they come into
contact with, and migrate into food over time. Clearly this To test packaging, ‘overall migration’ analysis can be used
has to be considered when setting or extending a shelf-life. to test any tendency of the packaging material to transfer
components into the product (either from the packaging
Migration of chemicals from or through packaging can material itself or from the external environment). There are
detrimentally affect product quality (through tainting, for also a number of specific chemicals for which the migration
example), and even its safety and legal compliance. Packaging into the product can be tested if they are contained within
migration and taints can occur at any point in the food chain the packaging. In both cases, the testing is specific to the
and their analysis and root cause determination can be type of product and storage conditions that the packaging
complex and challenging. will be used for (either by using the real product, a similar /
equivalent product, or a recognised ‘simulant’ that is known
Your packaging must comply with legislation and guidance to have equivalent properties to the product with respect
relevant to the markets where you will be producing to how it interacts with packaging).
and selling your products. In many cases this will include
considerations over shelf-life and may include packaging Packaging optimisation is an important part of product
material requirements and / or considerations for how development and will have an effect on shelf-life, potentially
the packaging materials may interact with your product. extending it if used correctly. However, the packaging needs
For example, there are EU and retained UK regulations to be proven to be effective and safe, protect the product,
regarding materials intended to come into contact with and preserve the product’s characteristics throughout shelf-
food (such as Regulation (EC) No 1935/2004, which has life without allowing any contamination to enter the product.
been retained in UK legislation). To comply, packaging
must not transfer constituents to food in quantities which

34
 6 EXTENDING SHELF-LIFE

Any shelf-life extension project must be

carefully considered to ensure that food safety
and quality are not compromised. With so
many different interconnecting considerations
All in all, there’s a lot for food and beverage business
it can be challenging to know which strategies operators to consider when it comes to setting
to apply. shelf-life and selecting the right date marks.We
work extensively helping manufacturers in defining
The extension validation process and application of the
the best date mark type to use, maximising shelf-life
extension strategy will require time and investment for
so that products are economic to produce and less
your business. To get the necessary buy-in, and to ensure
that the project can meet its aims, a thorough business case likely to become waste, and ensuring the safety of
will be key. As well as demonstrating the project’s return these products for consumers. For both the full shelf-
on investment (ROI), you must ensure that your product life and the ‘open’ shelf-life once the packaging has
will remain feasible and efficient to manufacture and that been opened, we can help back up shelf-lives with
the shelf-life extension strategy will maintain your product’s required data to ensure food and beverage products
integrity, quality and safety.Your business case will need to have a long life whilst remaining safe to consume.”
include the detail of the timeline and testing plan for proving
the new shelf-life with respect to quality and safety. Dr Roy Betts,
a research Fellow at Campden BRI
and Microbiology expert

35
6.1. Methods for extending shelf-life Lowering aW can also reduce the ability of microorganisms
to grow within food and beverage products. Dried foods
One of the first things to consider when extending a can have a long shelf-life whilst the formulation of higher
product’s shelf-life is how to reduce the risk of microbial moisture products can be adjusted (for example, by
growth. This can be done by reducing microbial levels, increasing salt or sugar content) to reduce aW.
or slowing their growth rates in the product. There are a
number of ways in which this can be achieved, the majority Preservatives have long been used to inhibit microbial
of which are already well established. growth. Chemicals such as sorbate, benzoate and sulphur
dioxide have been successfully applied in many foods and
As covered in Chapter 1, shelf-life is best considered beverages and tend to have an enhanced effect at lower
and influenced within product design / early in product pH levels. Some ingredients are known to contain natural
development. However, reviewing the way your product antimicrobials (such as plant essential oils) that exert
is made, processed, packaged and stored can also identify antimicrobial effects.
opportunities to influence and extend the shelf-life of an
existing product. Changing product storage conditions can change the rate
of growth for microorganisms that are present. Lowering
Changing the pH of a product is likely to affect the growth temperature can reduce or even prevent the growth of
of microorganisms within that product; lowering pH reduces some microorganisms, but this strategy can only be used
their ability to grow, whilst raising pH increases it. The nature when it is known that the reduced temperature can be
of some highly acidic, low pH foods does not support the maintained. Extension of shelf-life for some chilled products
growth of pathogens and many spoilage microorganisms will can be achieved through a process known as superchilling;
be inhibited. Some foods are deliberately acidified as a shelf- a method based on the temperature at which a product
life extension strategy, whilst fermented foods rely on either starts to freeze (around -2 °C), in place of conventional
naturally present or added (harmless) microorganisms to chilled storage (3 - 8 °C).
grow, produce acid and reduce the product’s pH, which can
considerably extend shelf-life.

36
 Superchilling is the point at which a product starts to
freeze, and facilitates a long shelf-life without affecting the
product’s sensory attributes. The reduced temperature
drastically slows the rate at which microbial and chemical
spoilage defects develop.

Campden BRI have over 10 years of experience in

superchilling. Swift temperature reduction is essential to
avoid textural and structural damage to the product, and
the Campden BRI team supported Lyons Seafoods with
CASE STUDY: sensory and quality analysis as well as microbiological
Superchilling prawns drastically testing.

improves product shelf-life By adopting the superchilling technique, Lyons were able
to extend the shelf-life of their cooked prawn products.
Lyons Seafoods, the UK’s leading supplier of seafood,
wanted to improve their efficiency and offer their What’s more, the project brought a 20 % decrease in
customers an increased minimum life on receipt water and electricity use and meant that Lyons were
(MLOR). After seeing Campden BRI’s work in this area, able to cook bigger batches less often (which reduced
Lyons considered superchilling their cooked prawn their product waste and hygiene costs).
products as a possible solution.

37
As mentioned previously, the way a food or beverage
product is processed and packed will also affect its shelf-life.
As an example, if a product is packed into its final container
and then heat processed, it is likely to have a longer life than
the same product that is processed and then filled into its
final container. The exception to this is where aseptic packing
technology is applied – with aseptically packed food and
beverages, both product and container are treated with an
antimicrobial process (‘kill step’) separately, then are brought
together for filling within a controlled, aseptic environment.

Increasing thermal processing temperature (or time) will

also exert a greater effect on microorganisms, but may
reduce quality. However, if processes are lowered to
improve quality, it is possible that shelf-life may be reduced
unless other actions are taken (such as decreasing pH,
introducing preservatives or decreasing aW).

Limiting the level of microorganisms present in your product however UV cannot penetrate products and can only
in the first place may also be a good way to potentially be used on surfaces or in clear solutions. Alternative /
extend your product’s shelf-life. Additional processes, such non-thermal processing methods such as high pressure
as treatment with UV light, can be used in conjunction with processing (HPP) may also be employed.
a thermal process to achieve an even greater reduction
of microorganisms from your product and / or packaging,

38
 types of microorganisms that can limit the shelf-life of
this type of product, and if any microorganisms surviving
after processing would be able to grow within the
intended storage conditions and shelf-life.

The team at Campden BRI were able to advise as to

the target microorganisms to assess and on appropriate
packaging, treatment conditions and potential effects
on the product, as well as assist in new product
development.
CASE STUDY:
High Pressure Processing For the analysis, Campden BRI made use of their pilot
HPP plant that is situated in a class 2 microbiology
of vegetable juices laboratory (where challenge tests can be performed
with certain pathogens).
Innocent Drinks partnered with Campden BRI for
support in investigating how high pressure processing As a result of their expertise and facilities, Campden
(HPP) could be applied to their vegetable juices to BRI were able to provide Innocent Drinks with the
improve quality whilst maintaining safety. They wanted knowledge that the HPP processing was effective and
to determine if HPP would be sufficient to destroy the that the products were microbiologically stable.

39
Adjusting packaging technology, packaging materials and 6.2. Building a business case
modifying the atmosphere inside packaging can all be used
to influence shelf-life. Incorporation of certain additives into When looking to implement a shelf-life extension strategy,
packaging can be used as a strategy for extending product you will likely need approval from a number of internal
shelf-life. Packaging that contains an ‘oxygen scavenger’ stakeholders, including senior management. Whilst there are
additive can be used to keep oxygen levels low inside the obvious benefits to a product having a longer shelf-life, most
pack – to inhibit microbial growth and oxygen dependent extension projects will require a business case to rationalise
reactions associated with chemical spoilage. Other the required investment.
examples include additives that release antioxidants or
other preservative chemicals (such as sorbates) or additives A business case provides justification for the change
that allow the packaging to provide improved temperature you want to make to the way your product is produced
insulation or an improved barrier against light. (whether that be a change to the formulation, the
processing or packing method, or the packaging). It should
There are a number of ways that shelf-life can be increased include an in-depth assessment of the investment required,
/ extended, but care must be taken to ensure that all other the benefits of implementing the new approach and an
elements of the product support this increase. For shelf-life evaluation of any risks associated with the strategy. Building a
extension projects, the steps outlined in Figure 1 may be business case helps communicate the high-level information
used to determine and prove the new shelf-life as part of that stakeholders need to be able to approve the process
the overall project plan. and makes sure everyone’s expectations are aligned.

The most important messages for a business case to convey

are why your solution will be beneficial to the company and
how it will be implemented in practice. Communicating this
involves four steps, as shown in Figure 5.

40
Figure 5: Summary of how to develop a business case

HOW TO BUILD A COMPELLING BUSINESS CASE

INTRODUCE IDENTIFY
1 THE PROBLEM 2 THE SOLUTIONS

• What are the limitations of the current shelf- • What potential shelf-life extension strategies
life for your product? could be used for your product?
• What benefits would be gained from a • Which would deliver enough of an increase?
realistically feasible extension?

RECOMMEND DESCRIBE ITS

3 A SOLUTION 4 IMPLEMENTATION

• Which of the strategies provides the • How will you action your solution, and what
best increase compared to the resources are required?
investment required?
• What data do you have to back up
this strategy?

41
 INTRODUCE IDENTIFY
1 THE PROBLEM 2 THE SOLUTIONS

Although you know what the issue is, a business case should Once the background has been established, outline the
begin by explaining this to ensure that all key stakeholders solutions available. What potential shelf-life extension
are also aware. What are the limitations of the current shelf- strategies could be used for your product? Which would
life for your product? What benefits would be gained from a deliver enough of an increase?
realistically feasible extension?
To truly convey that an approach is best, compare it to the
Clearly define what the existing problem in your other options; three or four should provide a compelling
organisation is, and how this relates to shelf-life. Highlight any case. If it is helpful, begin with a longlist of options and
associated time frames to solve the concern. narrow them down based on suitability.

To further strengthen the need for your proposed solution, When weighing up the different solutions, ensure that
outline how addressing this challenge will support any wider you take an evidence-based approach. For each proposed
strategic plans of the organisation. And, if possible, include option, consider and note both the benefits and the risks. In
background information on the competitive landscape that addition, evaluate the cost of the solution and its feasibility.
will help explain why the project is necessary now.

42
 RECOMMEND DESCRIBE ITS
3 A SOLUTION 4 IMPLEMENTATION

Which of the strategies provides the most favourable Describing the implementation of your shelf-life extension
balance of shelf-life increase compared to the investment strategy will help you clearly demonstrate to stakeholders
required to achieve it? How does this balance with the risks? that the approach is feasible and practical to implement.
What data do you have to back up this strategy?
It should include how the objectives will be achieved, the
Answering these questions may require, for example, the approximate total project cost and ROI, other resources
microbiological risk (or HACCP) assessment, data from required, the project timeline, and your plans for how to
kitchen samples where applicable, provisional determination mitigate any potential risks.
of the maximum safe shelf-life and / or indications from
predictive modelling (see Section 3.3).

The rationale for your chosen solution may also include the
balance between the cost of implementing the strategy and
the ROI that the shelf-life extension is expected to deliver.
With all the different options written down, it is easier for
you to justify a given solution. Weigh up the pros and cons
of each approach; creating a ranking system can be
beneficial here. With all the rationale detailed, propose a
solution that clearly meets the needs of the business.

43
6.3. Implementing a Investing time in writing a solid business case is essential to
maximise chances of project approval and overall success.
shelf-life extension project Describing the implementation of your shelf-life extension
As well as getting the solution in place (such as carrying out strategy (step 4 of ‘Building a business case’) will essentially
reformulation work or installing new processing equipment), be your project plan that you can then follow should the
a key part of a shelf-life extension project timeline and its project be approved.
milestones will be the shelf-life testing. For this,
Figure 1 provides an overview of the steps you may
need to consider.

Where shelf-life length is not limited / defined by regulations

or guidance affecting the countries of manufacture or
sale, it will be up to individual food and beverage business
operators to define the cut-off point of acceptable shelf-life
for their product. The safety of the product is non-negotiable
and must always be assured. Cut-off definitions for quality,
however, may depend on the degree of risk (for example,
regarding consumer complaints) the business is willing to
take. The amount of freedom here may depend on the
type of products – namely the freedom applies more so to
quality shelf-life testing (whereas safe shelf-life testing has
a more clearly defined end point). In all cases this would
include factoring in a degree of ‘buffer’ to provide a margin
of safety and to account for imperfect storage conditions.

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WHY CHOOSE CAMPDEN BRI?

Considerable expertise and experience is What’s more, working with a partner can free up personnel,
needed to ensure product safety, quality and allowing them to focus on other priorities. And a partner like
legal compliance when setting or extending Campden BRI brings broad knowledge and expertise across
a range of areas, which can help find the most effective
a product’s shelf-life. Products need to be strategy for your product. Campden BRI can provide
assessed on an individual basis to ensure tailored, expert support in all areas of shelf-life evaluation,
that all of the necessary considerations are maximisation and extension, and have specific expertise
taken into account in the data collection, in microbiology, chemistry, sensory, regulatory and product
interpretation and decision-making. Where innovation services.
a manufacturer does not have this expertise
or experience in-house, they should seek the
support of an external partner. Get in touch today to discuss how our
experts can identify opportunities to maximise
While your own internal teams may be able to develop and and extend shelf-life, and support their
implement a shelf-life extension strategy and perform the implementation for your new and existing food
shelf-life testing needed to determine and validate the final and beverage products.
shelf-life, working with a partner can bring many benefits.
They can provide their experience and facilities, such as pilot
testing plants, dedicated storage and sensory panels, meaning Linda Everis
you don’t have to repurpose valuable space or invest in any
additional facilities.

45
GET IN TOUCH TODAY REFERENCES
1. Campden BRI (2019) Evaluation of microbiological shelf-life of foods
(2nd edition). Guideline 46.
So we can help you benefit from 2. Food Standards Agency (2020) The safety and shelf-life of vacuum and
modified atmosphere packed chilled foods with respect to
maximising the shelf-life of your food non-proteolytic Clostridium botulinum. Food Standards Agency.
and beverage products. 3. Comité des Industries des Mayonnaises et Sauces Condimentaires de
la Communauté Économique Européenne. (1992). CIMSCEE code
for the production of microbiologically safe and stable emulsified and
non-emulsified sauces containing acetic acid. Comité des Industries
des Mayonnaises et Sauces Condimentaires de la Communauté
www.campdenbri.co.uk Économique Européenne, Brussels, Belgium.
4. European Commission Guidance Document for Competent
Authorities with regard to the setting of tolerances for nutrient values
support@campdenbri.co.uk or https://food.ec.europa.eu/system/files/2016-10/labelling_nutrition-
vitamins_minerals-guidance_tolerances_1212_en.pdf
shelflife@campdenbri.co.uk 5. Food Safety Authority of Ireland (2019) Guidance Note No. 18 –
Validation of Product Shelf-life (Revision 4)

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