DESC:FIELD OF THE INVENTION:
The present invention relates to an improved packaging system for distribution of cooked bread with improved shelf life when stored at ambient temperature. More specifically, the present invention relates to packaging system with food grade film with combination of inert gas composition for partially cooked or semi cooked flat breads like paratha, chapatti, and tortilla made up of grains, millets, cereals and pulses for storage and distribution at room temperature.

BACKGROUND AND PRIOR ART OF INVENTION

Shelf-stable, ready to eat food products are of ever-increasing popularity. Consumers appreciate the convenience of purchasing precooked food products and later enjoying the products, with or without reheating. Today, paratha, Naans and chapattis are exotic choices more suitable for a main meal. This flat bread made out of wheat and other millet has become an important source of carbohydrates in the Asian diet and is preferred all over world because of globalization. Aside from its nutritional value, its popularity has risen, in large part, because of its mild taste and convenience to consume. Unfortunately, it has proved difficult to package commercially acceptable, shelf stable products. Conventional packaging generally shows a limited shelf life, and can dry out quickly due to their formulation.
Certain modification are seen by adding certain additives in the basic formulation as described in US20110311678A1 discloses an antistaling process for flat bread wherein process for retarding the staling of flat bread is disclosed, the shelf life (storage stability) of flat bread can be extended by enzymatic treatment methods to dough used to prepare the flat bread. The enzymatic treatment methods of the present invention retard (slow) the staling of flat bread products. The enzymatic treatment methods of the invention substantially improve the storage properties of the flat bread products. Wherein such additives alter the taste and preference is given to food product without preservation and additives. Various amylases have been suggested for retarding the staling by the addition to dough.
To overcome such addition in the dough and flour of bread oxygen barrier films are used with or without combination with inert gas, EP 1279600 discloses a method for packaging a partially baked bread product into a gas-barrier package under a preservative gas or gas mixture to get a long shelf-life product characterized in that the partially baked bread product coming from the baking oven is packaged in-line while it has not yet cooled down to a temperature of 80 °C or less. It specifically uses thermoplastic polymer sheet to pack the baked food along with modified atmospheric packaging technique. Also the packaging material have Oxygen Transmission Rate (OTR) lower than 10, preferably lower than 5 cm3/m2.d.atm, when measured at 23 °C and 0 % of relative humidity. But it need to pack the partially baked food while it has not yet cooled down below a minimum temperature of 85°C. This designed system is for fermented bread and like product wherein yeast and other fermenting agent are added. The process for preparing and making such bread are also different from the non-fermented flat breads like paratha and chapatti’s. When partially cooked Paratha are packed in PE bags and stored at 8°C or in freezer it stays good for 5 days to 7 days. At room temperature, these paratha have a shelf life of 2 days. On the third day, visible mold, odour and off-flavor are observed.
Accordingly, there has existed a definite need for a simple and effective system and method for packaging shelf-stable, completely cooked or partially cooked bread. There has existed a still further need for such a packaging process that preserves the texture, appearance, and flavor of freshly prepared flat bread preserving its originality, while protecting against microbial contamination. The present invention satisfies these and other needs and provides further related advantages. Such packaging system provides long term stability against changes in their character, and of course stability against microbial contamination.
The present invention offers an improved packaging system for flat bread with extended shelf life. It is an economic and easy packaging system for cooked or semi cooked non fermented flat bread like paratha and chapatti.
The discussion of documents, acts, materials, devices, articles and the like is included in this specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters formed part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application.
SUMMARY OF THE INVENTION

In present invention improved packaging system for cooked flat bread with enhanced shelf life (storage stability) layered polymeric membrane/film along with inert gas composition has been disclosed. The polymeric membrane exhibits an oxygen barrier property and along with the inert gases it inhibits the growth of mould and other degrading factors. The developed system of said packaging provides a long or extended shelf life for the packaged product without any need to freeze the product, sterilize it, and by merely storing it at ambient temperature.
Accordingly one of the embodiments, the present invention provides a packaging system for distribution of cooked or semi cooked flat bread at room temperature comprising of: at least one flat bread item; at least one layered polymeric membrane; inert gas composition; at least one layered gas-barrier laminate having flexible structure materials, wherein the said polymeric membrane and gas-barrier laminate is molded into pouch to dispense the food item and their layers prevent the gas permission and microbial contamination on sealed food item upto 15 days.
Wherein gas- barrier layers has thickness preferably up to 50 to 300 µm.
Accordingly one more embodiments, the present invention provides a method for packaging of cooked or semi cooked flat bread with packaging system as claimed in any proceeding claim, comprising steps of;
a) Polymeric membrane and gas-barrier laminate is molded into pouch,
b) Place food item into pouch,
c) Flush the internal atmosphere with modified gas combinations,
d) Seal the pouch at room temperature.
STATEMENT OF THE INVENTION
The present invention relates to a packaging system for storage of cooked or semi cooked flat bread at room temperature comprising of at least one flat bread item; at least one layered polymeric membrane; inert gas composition; at least one layered gas-barrier laminate having flexible structure materials; wherein, the said polymeric membrane and gas-barrier laminate is molded into pouch to dispense the food item, the said pouch layers prevent the gas permission and microbial contamination on sealed food item with increased shelf life.
The thickness of said molded gas-barrier pouch layer is multi-layer sheet with an Oxygen Transmission Rate (OTR) between 10 to 15 ml / Sq. mt / 24 hr and Moisture Vapor Transfer rate of about 2.5 gm / Sq. mt/ 24 hr at 38° C at 90 % RH.
The gas-barrier laminate is selected from a monolayer structure of a gas-barrier resin or co-excluded with barriers or mixture of both.
The polymers that are suitably be employed for the gas-barrier lamintate are selected from 2µ PVDC film coated with 12µ PET, Resin , Ethylene vinyl alcohol, 50µ Natural Poly 50% LLDPE/Butene copolymer, Linear Zeigler Natta with antiblock and slip / 25% LDPE / 25% LLDPE – Hexene copolymer, Linear single site.
The gas-barrier laminate is a multi- layer sheet with at least one layer of gas-barrier resin having gas- barrier properties. The gas- barrier laminate has thickness preferably up to 50 to 300 µm.
The layered polymeric membrane is layered with at least one gas-barrier laminate, wherein the layered polymeric membrane is selected from ethylene vinyl alcohol, nylon based.
In accordance to present invention, the inert gas composition is mixtures of inert gases selected from carbon dioxide, nitrogen, food grade inert gas, wherein said inert gas composition is between 20% to 40% of total internal volume of package.
The flat bread item is selected from Malabar paratha, paratha, bhakri, thalipeeth, naan, phulka, chapatti, stuffed paratha, theplas and puranpoli, tortilla, pita, Arabic bread, Indian flat bread, lavash, barbari, Sangak, tanoor, taftoon, shami, halabi, mafrood, burr, bairuti, pocket bread, kaboos, Balepkorkun.
The packaging system provides flat bread items prolonged and extended shelf-life when a product is stored at temperature range from 180C to 400C.

DETAILED DESCRIPTION OF THE INVENTION

The making and using of various embodiments of the present invention are discussed in detail below as; it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention.
To facilitate the understanding of this invention, a number of terms are defined below. Terms defined herein have meanings as commonly understood by a person of ordinary skill in the areas relevant to the present invention. Terms such as "a", "an" and "the" are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration. The terminology herein is used to describe specific embodiments of the invention, but their usage does not delimit the invention, except as outlined in the claims.
The present invention relates to a system and method for packaging cooked or semi-cooked flat bread to get a long or extended shelf life when packed at ambient temperature. In the present invention a packaging system for flat bread is developed to provide the shelf stability of up to more than 14 days even stored at ambient temperatures. The said improved packaging system helps to prevents decay as well as maintain quality and taste as well of the packed bread.
One of the embodiments of the present invention is to provide a packaging system developed for bread which can be partially cooked, semi cooked or completely cooked. The partially cooked and semi cooked bread need to be cooked properly before serving, whereas the completely cooked ready to serve bread can be reheated or warmed before serving.
The said packaging system for distribution of cooked or semi cooked flat bread at room temperature comprising of:
a) at least one flat bread item;
b) at least one layered polymeric membrane;
c) inert gas composition;
d) at least one layered gas-barrier laminate having flexible structure materials;
wherein the said polymeric membrane and gas-barrier laminate is molded into pouch to dispense the food item and their layers prevent the gas permission and microbial contamination on sealed food item upto15 days.
The said layered polymeric membrane film is layered with at least one gas-barrier laminate, wherein layered polymeric membrane is selected from ethylene vinyl alcohol, nylon based.
The gas-barrier laminate is selected from a monolayer structure of a gas-barrier resin or co-excluded with barriers or mixture of both. More preferably, the gas-barrier of laminate is a multi- layer sheet wherein at least one layer of gas-barrier resin having gas- barrier properties.
The said gas- barrier laminate has thickness preferably up to 50 to 300 µm.
Flat breads are the healthiest choice and are more preferred in Asia as compared to other continents. They can be fermented and non-fermented. Fermented bread can be prepared by adding fermenting agent like curd, yeast, baking powder etc.
‘Non Fermented Flat Bread’ as used herein means bread prepared from flattened dough and which has a thickness of one millimeter to a few centimeters. A flat bread may be made from a simple mixture of flour, Water and then thoroughly rolled into flattened dough.
In one more embodiment, the flat bread is unleavened, i.e., made without yeast, curd or other fermenting agent. The Flat bread may include further optional ingredients, such as fats like oil, hydrogenated oil and ghee. Flavoring agent like vegetables, spices, pepper, salt, sugar, milk and alike. Flat breads also have a very quick baking time (often 1 minute or lesser).
Examples of flat breads include tortilla, pita, Arabic bread, Indian flat bread (IFB). Further non-limiting example include lavash, barbari, Sangak, tanoor, taftoon, shami, halabi, mafrood, burr, bairuti, pocket bread, kaboos, Balepkorkun, bhakri, thepla,thalipeeth, naan, phulka, chapatti, puranpoli and paratha.
The flat bread includes, for example Wheat flour tortilla and chapatti. In a particular embodiment the flat bread product is a tortilla, paratha. In a particular embodiment the flat bread product is a chapatti.
As used herein “flat bread” may be made from any suitable flour source, e.g., flour sourced from grains, such as, Wheat flour, corn flour, rye flour, barley flour, oat flour, rice flour, or sorghum flour, potato flour, soy flour, millets flour and flour from pulses and combinations thereof (e.g., Wheat flour combined With one of the other flour sources (multigrain); rice flour combined with one of the other flour sources).
Any flat bread process may be used to prepare the flat bread. Methods for preparing flat bread are well known in the art and are disclosed. The process of preparing flat bread generally involves the sequential steps of dough making sheeting or dividing, shaping or rolling the dough this all steps are well known in the art. Baking can be done in one single step or in two separate steps. In the first step of the two-step baking process, the flat bread is baked on hotplate or oven or flame till it firms its shape the bread is partially done. The partially baked bread thus obtained is then submitted in the second step to a complementary baking. While completely baked bread is known to get stale rapidly and is best to be consumed daily, part-baked bread lasts for some time, typically up to few days, depending on temperature and humidity, and the complementary baking gives a product that has the appearance, consistency and flavor of a fresh, just baked, bread and required taste. This two steps baking process is therefore widely used mainly in the supermarkets or retail stores, where partially baked bread products are acquired from an outside plant kitchen, and subjected to the final baking/cooking phase when needed. To increase the shelf life of this partially baked bread, once the partial baking step is over and the product is cooled down and the product is packaged in a thermoplastic material and it is frozen; The disadvantages of the freezing technique are evident as handling frozen products requires specially refrigerated rooms for storage and specially refrigerated wagons for transport and delivery thus increasing costs; the disadvantages of a separate sterilization step, either before or after packaging of the partially baked.
The oven for the first baking step can be electric, oil fired or gas fired hot air baking oven. This first step of partial baking generally requires at least few seconds, typically from 0.30 to 2 minutes, depending on the type of bread (e.g. the type of flour and the amount of water), the weight and volume of the single dough pieces, the baking method and the temperature of the oven.
In this first baking step, the bread is completely structured and acquires definite shape. This will be achieved typically when the temperature at the core of the bread product is of at least 40 °C. The product is cooled at temperature lower than 30°C and lower. Single packs or multi-packs can be made, depending on the market requirement.

Accordingly, the present invention provides a method for packaging a partially/ Semi cooked non fermented flatbread product into an oxygen-barrier polymeric packaging material under regulated atmosphere and getting a prolonged shelf-life package when the product is stored at ambient temperature or at room temperature.
When the flat bread items are packed as per system provided in present invention, then the food items are getting a prolonged shelf-life even if the product is stored at temperature range from 180C to 400C.
In accordance to one of the embodiments, the present invention provides a packing system with regulated atmosphere comprising of inert gas. The said inert gas composition is mixtures of inert gases selected from carbon dioxide, nitrogen or any other inert gases used in food packaging industry, wherein said inert gas composition is up to 30 to 50 % of total internal volume of package, more preferably 30%.
The inert gas composition further comprises volatile components from fats like oil, hydrogenated oil, ghee and flavouring agents like vegetables, spices, pepper, salt, sugar, milk and alike after being packed and stored. The volatile components from fats like oil, hydrogenated oil, ghee and flavouring agent like vegetables, spices, pepper, salt, sugar, milk and partially form to system or added externally.
The packaging system developed is consisting of multilayer food grade film barrier range comprising of Individual Wrapping Sheet (IWS), having improved oxygen/any gas barrier capacity.
The gas barrier capacity of the film is controlled for avoiding the entry of oxygen inside the package and the modified atmospheric packing is help to reduce the amount of oxygen in headspace to 3% or less.
The thickness of the gas-barrier layer will be set in order to provide the overall multi-layer sheet with an Oxygen Transmission Rate (OTR) is between 10 and 15 ml / Sq. mt / 24 hr, Barrier film having Moisture Vapor Transfer rate of about 2.5 gm / Sq. mt/ 24 hr at 38° C at 90 % RH. Typically when PVDC (Polyvinylidene chloride) or EVOH (Ethylene vinyl alcohol ) are employed as the gas-barrier materials, this is achieved with barrier layers 3-6 µm thick. Thicker layers can be used if desired or if a lower OTR is needed, while thinner layers can be used e.g. if a polymer with higher barrier properties is employed.
According to second embodiments, the present invention provides a method for packaging for distribution of cooked or semi cooked flat bread with packaging system as claimed in any proceeding claim, comprising steps of;
a) polymeric membrane and gas-barrier laminate is molded into pouch,
b) place food item into pouch,
c)Flush the internal atmosphere was modified with gas combinations,
d) Seal the pouch at room temperature.

Substantially a gas-barrier Individual Wrapping Sheet (IWS), can be employed for said packaging. Bags, or pouches of flexible IWS materials, typically up to 60 to 300 µm, preferably up to 65 to 70 µm, and more preferably up to 68µm, can suitably be employed as well as films of the above thickness for wrapping up the products. Actually the gas-barrier IWS material may be a monolayer structure of a gas-barrier resin but preferably it is a multi-layer sheet wherein at least one layer has gas-barrier properties. Non-limitative examples of gas-barrier polymers that can suitably be employed for the gas-barrier layer are ; 2µ PVDC film coated with 12µ PET, Resin , 50µ Natural Poly 50% LLDPE/Butene copolymer, Linear Zeigler Natta with antiblock and slip / 25% LDPE / 25% LLDPE – Hexene copolymer, Linear single site.
The modified gas has preferably carbon dioxide and mixture of any inert gases, however mixtures of inert gases with typically up to 30 to 50 % of carbon dioxide, nitrogen dioxide or any other inert gas, can be employed.
The present invention is further described with the help of the following examples, which are given by way of illustration all the parts, percent’s and ratios are by weight unless otherwise indicated and therefore should not be construed to limit the scope of the invention in any manner.
EXAMPLES:
Example 1: Preparation of Paratha:
Malabar Paratha is generally prepared by wheat flour, where in the detail process and proportion is as mentioned below;
Ingredients (measuring cup used, 1 cup = 250 ml)
• 1 cup whole wheat flour/atta
• 1 cup all-purpose flour/maida
• 2 tbsp oil
• ¼ tsp baking soda
• ¾ to 1 cup hot water
• 1 to 2 tsp sugar
• ¾ tsp salt or as required
Process for making paratha:
The whole wheat flour and all-purpose flour with baking soda is sieved together, sugar, salt and oil and hot water is added to flour mixture. Mix and then knead the dough till soft, smooth and elastic. Cover the dough with a moist cloth and keep aside for 45 minutes to 1 hour. Divide into 7-8 balls and roll each ball as thinly as possible into a large round. Now smear or apply oil on the entire surface of the rolled dough. Hold the rolled disc from the top on both sides and pleat them till bottom and roll them like a spiral and press the last edge onto the center of the roll. Spiralled balls are made and covered with wet cloth and keep aside for 15 minutes.
Roll each ball into a paratha of 4-5 inches and place the paratha on the pre heated tava and fry on both sides with oil drizzled on top and the edges till the parathas are crisp and golden to make partially cooked or semicooked paratha just roast it for few seconds till it becomes firm form both sides.
Half cooked parathas were packed in IWS bags and modified with 30 to 50% carbon dioxide gas combinations. Balance nitrogen was flushed in. These packages were then stored in ambient temperatures and studied for shelf life.
Microbiological, physical and chemical analysis was performed on day 0 (before packaging) and then on day 3, 5, 6, 8 and 10. Total plate count, coliforms and yeast and mould were tested as per IS standards (IS 5401, IS 5402, IS 5403). pH, colour, texture, aroma and flavour was also tested to observe impact of shelf life on paratha integrity.
Changes in physical, microbiological and sensory parameters were not observed till day 6. It was seen to change only beyond this which stayed consistent till day 10. When checked for organoleptic changes, it was seen not to differ from day 0 and the flavour, aroma, and most importantly the layer formation which is vital to parathas, stayed intact.
An increased shelf life of 7 days minimum was achieved at room temperature without compromising physical, chemical and microbiological parameters of the parathas.

Example 2: Packaging system:
I. Modified Atmosphere Packaging of Theplas and Puranpoli
Theplas or Puranpoli were placed in IWS (Cryovac) bags and its atmosphere was modified with gas combinations suitable to the product. They were studied for shelf life for 7 days and it was seen that there was no change in the product over time.
A. For Theplas: Stability Analysis
Day TPC CC YM Remarks
0 2.2 x 102 <10
<10
Flavour and texture all good
3 7.5 x 102 80 90 Same as day 0
5 15.7 x 102 3.2 x 102 2.2 x 102 No change in sensory, quality parameters
7 68.8 x 102 8 x 102 6.5 x 102 No change detected
Table no. 1
B. For Puranpoli: Stability Analysis
Day TPC CC YM Remarks
0 125 <10
<10
Flavour and texture all good
3 2.6 x 102 50 75 Same as day 0
5 7.2 x 102 2.1 x 102 3.4 x 102 No change in sensory, quality parameters
7 34.3 x 102 4 x 102 5.6 x 102 No change detected
Table no. 2

II. Modified Atmosphere Packaging of Half cooked Malabar parathas:
Half cooked parathas were packed in gas-barrier pouch/bag and modified with 30 to 50% carbon dioxide gas combinations. Balance nitrogen was flushed in. These packages were then stored in ambient temperatures and studied for shelf life.
Microbiological, physical and chemical analysis was performed on day 0 (before packaging) and then on day 3, 5, 6, 8 and 10. Total plate count, coliforms and yeast and mould were tested as per IS standards (IS 5401, IS 5402, IS 5403). pH, colour, texture, aroma and flavour was also tested to observe impact of shelf life on paratha integrity.
Changes in physical, microbiological and sensory parameters were not observed till day 6. It was seen to change only beyond this which stayed consistent till day 10. When checked for organoleptic changes, it was seen not to differ from day 0 and the flavour, aroma, and most importantly the layer formation which is vital to Malabar parathas, stayed intact.

• Microbiological reports are illustrated in Following table no 3 and 4.
Sample No. Modified Atmosphere
(CO2:N2) Duration CC
Cfu/g Y&M
Cfu/g TPC
1 95:05 Day 0 <10 <10 50
2 90:10 Day 0 <10 <10 75
3 80:20 Day 0 <10 1.20 x 10 2 100
4 95:05 Day 1 <10 TNTC TNTC
5 90:10 Day 1 <10 5600 TNTC
6 80:20 Day 1 <10 8000 TNTC
7 95:05 Day 2 600 TNTC TNTC
8 90:10 Day 2 < 10 TNTC TNTC
9 80:20 Day 2 < 10 9000 TNTC
10 95:05 Day 3 1100 TNTC TNTC
11 90:10 Day 3 < 10 TNTC TNTC
12 80:20 Day 3 < 10 11150 TNTC
13 95:05 Day 4 <10 TNTC TNTC
14 90:10 Day 4 <10 TNTC TNTC
15 80:20 Day 4 <10 TNTC TNTC
16 95:05 Day 5 100 TNTC TNTC
17 90:10 Day 5 < 10 TNTC TNTC
18 80:20 Day 5 < 10 TNTC TNTC

Table no. 3

Sample No. Modified Atmo-sphere
(CO2:N2) Duration CC
Cfu/g Y&M
Cfu/g TPC
1 - Day 0 50 <10 <10
2 - Day 0 <10 <10 <10
3 - Day 0 2.10x 102 <10 1.20 x 10 2
4 70:30 Day 6 7.4 x 106 4.6 x 104 2.70 x 10 4
5 50:50 Day 6 1.90x 107 3.8 x 104 1 x 10 3
6 70:30 Day 8 7.4 x 106 4.6 x 104 2.70 x 104
7 50:50 Day 8 1.90x 107 3.8 x 104 1 x 103
8 70:30 Day 10 1.5 x 107 1 x 103 1 x 104
9 50:50 Day 10 5.6 x 107 1.65 x 105 4 x 104
10 70:30 Day 6 1.5 x 107 5.5 x 103 3 x 104
11 50:50 Day 6 1.6 X 107 2 X 102 5 X 103
12 70:30 Day 8 4.2 x 106 4.5 x 102 5 X 103
13 50:50 Day 8 1.6 X 107 2 X 102 4 x 104
14 70:30 Day 10 1.4 X 107 2 X 103 2 X 103
15 50:50 Day 10 1.3 X 107 4.5 X 103 1.5 X 104
16 70:30 Day 6 1.1X 107 6.5 X 102 5.5 X 103
17 50:50 Day 6 1.5X 107 9.4 X 103 1.6 X 104
18 70:30 Day 8 1.7X 107 4 X 104 1 X 104
19 50:50 Day 8 4.3X 107 8.2 X 104 3 x 103
20 70:30 Day 10 1.1X 107 1 X 104 1.5 X 104
21 50:50 Day 10 3.5X 106 3.3 X 104 1 X 103

Table no. 4

• Sensory Report are illustrated in Following table no 5.

Sample No. Duration Texture Layer Formation Colour Flavour Taste Overall
1 Day 0 3 3 3 3 3 3
2 Day 3 (50) 3 3 3 3 3 3
3 Day 3 (30) 3 3 3 3 3 3
4 Day 5 (50) 3 3 3 3 3 3
5 Day 5 (30) 3 3 3 3 3 3
6 Day 6 (50) 3 3 3 3 3 3
7 Day 6 (30) 3 3 3 3 3 3
8 Day 8 (50) 2.5 2 3 2.5 3 2.5
9 Day 8 (30) 2.5 2 2.5 2.5 3 2.5
10 Day 10 (50) 2.5 2 2.5 2 2.5 2.25
11 Day 10 (30) 2 2 2.5 2 2.5 2.25

Table no. 5
The above embodiments are to be understood as illustrative examples of the invention. Further embodiments of the invention are envisaged. It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be used without departing from the scope of the invention, which is defined in the accompanying claims.

Dated this 10th day of October 2016.
Poonam Dhake Kolhe
Of In10gible Innovations LLP
Applicant’s Agent
,CLAIMS:CLAIMS

We Claim,

1) A packaging system for storage of cooked or semi cooked flat bread at room temperature comprising of:
a. at least one flat bread item;
b. at least one layered polymeric membrane;
c. inert gas composition;
d. at least one layered gas-barrier laminate having flexible structure materials;
wherein, the said polymeric membrane and gas-barrier laminate is molded into pouch to dispense the food item, the said pouch layers prevent the gas permission and microbial contamination on sealed food item with increased shelf life.
2) The packaging system as claimed in claim 1, wherein the thickness of molded gas-barrier pouch layer is multi-layer sheet with an Oxygen Transmission Rate (OTR) between 10 to 15 ml / Sq. mt / 24 hr and Moisture Vapor Transfer rate of about 2.5 gm / Sq. mt/ 24 hr at 38° C at 90 % RH.
3) The packaging system as claimed in claim 1, wherein gas-barrier laminate is selected from a monolayer structure of a gas-barrier resin or co-excluded with barriers or mixture of both.
4) The packaging system as claimed in claim 3, wherein polymers that are suitably be employed for the gas-barrier lamintate are selected from 2µ PVDC film coated with 12µ PET, Resin , Ethylene vinyl alcohol, 50µ Natural Poly 50% LLDPE/Butene copolymer, Linear Zeigler Natta with antiblock and slip / 25% LDPE / 25% LLDPE – Hexene copolymer, Linear single site.
5) The packaging system as claimed in claim 1, wherein gas-barrier laminate is a multi- layer sheet with at least one layer of gas-barrier resin having gas- barrier properties.
6) The packaging system as claimed in claim 1, wherein gas- barrier laminate has thickness preferably up to 50 to 300 µm.
7) The packaging system as claimed in claim 1, wherein said layered polymeric membrane is layered with at least one gas-barrier laminate.
8) The packaging system as claimed in claim 1, wherein layered polymeric membrane is selected from ethylene vinyl alcohol, nylon based.
9) The packaging system as claimed in claim 1, wherein said inert gas composition is mixtures of inert gases selected from carbon dioxide, nitrogen, food grade inert gas.
10) The packaging system as claimed in claim 1, wherein said inert gas composition is between 20% to 40% of total internal volume of package.
11) The packaging system as claimed in claim 1, wherein said flat bread item is selected from Malabar paratha, paratha, bhakri, thalipeeth, naan, phulka, chapatti, stuffed paratha, theplas and puranpoli, tortilla, pita, arabic bread, Indian flat bread, lavash, barbari, Sangak, tanoor, taftoon,shami, halabi, mafrood, burr, bairuti, pocket bread, kaboos, Balepkorkun.
12) The packaging system as claimed in claim 1, wherein the said flat bread items has prolonged and extended shelf-life when a product is stored at temperature range from 180C to 400C.
13) A method for packaging of cooked or semi cooked flat bread with packaging system as claimed in any proceeding claim, comprising steps of;
a) polymeric membrane and gas-barrier laminate is molded into pouch,
b) place food item into pouch,
c) Flush the internal atmosphere with modified gas combinations,
d) Seal the pouch at room temperature.