Episode 4: Amaretti

In today's episode, we take a close look at the iconic Italian biscuit, Amaretti, focusing not only on its delightful taste but also the critical importance of packaging.

Starting with Eric Schaller, who leads us through a series of in-depth tests to examine how well this traditional sweet is protected from external factors such as air, moisture, and environmental conditions.

Packaging and Gas Analysis: Ensuring Freshness

One of the key tests we explore in this episode is gas analysis. Packaging plays a huge role in maintaining the freshness of Amaretti biscuits, particularly with their soft and delicate structure. Eric takes us through the process of puncturing the pack and running a gas analysis to measure the internal atmosphere. Though the packaging may not be under modified atmosphere conditions, we see how the reactive gas inside influences the product’s freshness over time.

We discuss how the lack of CO2 in the packaging can impact the biscuit’s moisture retention, which is critical given the high sugar content and low moisture in Amaretti. Proper gas analysis ensures that packaging is capable of protecting against environmental factors that could degrade the biscuit's quality, leading to early spoilage or loss of texture.

Leak and Burst Tests: Gauging Packaging Strength

Another important aspect of packaging that Eric investigates is the strength and reliability of the seals. The podcast goes deep into leak tests and burst tests, critical in assessing the pack's ability to withstand pressure and prevent air or moisture from entering. The tests show some fascinating results—particularly in terms of how small folds and wrinkles in the packaging material can lead to weak spots that compromise the integrity of the seal.

We learn about the testing of both large and small packs, with emphasis on how differences in seal quality, thickness of the material, and even the size of the packaging affect the overall leak rate. Smaller packs often have better resistance to burst tests, but they are also more prone to defects due to minimal surface area, folds, and handling during production. In one test, a pack with an end seal that was too weak bursts at lower pressure than expected, showing the importance of consistent packaging standards.

The Role of Material in Shelf Life and Oxidation Prevention

In addition to gas and leak testing, we explore the role of packaging material in extending shelf life, particularly against risks like oxidation. Amaretti biscuits, made from sugar, apricot kernels, and almonds, have a high fat content due to the nuts, which makes them more susceptible to oxidation. The current packaging material, while offering some protection, allows significant light penetration. Light exposure accelerates the oxidation of the nuts, potentially degrading the flavor and texture of the biscuit over time.

A key takeaway from this episode is the recommendation to use metallized or coated films that provide enhanced protection against light. This simple change could significantly extend the shelf life of Amaretti by preventing oxidation, ensuring the biscuits retain their quality from production to consumption.

Conclusion: Striking the Balance Between Taste and Packaging

The tests and analysis conducted in this episode show that packaging plays a pivotal role in the longevity and quality of Amaretti biscuits. From gas analysis to leak tests, we gain insights into the subtle details that can make or break a product's shelf life. While the biscuit itself is a simple confection made with sugar and almonds, ensuring it stays fresh for consumers requires careful consideration of packaging material, sealing quality, and protection against environmental factors like moisture and light.

In conclusion, this episode highlights that while taste may be what attracts consumers, it is the packaging that determines whether a product remains at its best. For brands looking to improve their packaging processes, focusing on leak-proof seals, effective gas retention, and better light protection could be the keys to delivering a consistently fresh and delicious product.

Stay tuned for future episodes with Eric, Jos Vast and Jacob van Kogelenberg, where we’ll continue to explore the technical side of biscuit production and packaging, always with the goal of ensuring your favorite biscuits stay fresh for as long as possible.