ABSTRACT: Multilayer packaging materials are extensively used in food packaging, particularly for powdered products. In alignment with sustainable development goals, packaging design should aim to minimize material usage while maintaining the protective properties necessary to preserve food quality and safety, thereby reducing environmental impact. A key strategy is to simplify multilayer structures to enhance recyclability. This study aims to evaluate the potential of sustainable alternative packaging materials with reduced metal and plastic content and improved recyclability for pudding powder packaging, as substitutes for conventional films. Four packaging structures were tested: a conventional three-layer laminate (polyethylene terephthalate (PET)/aluminum foil (Al-foil)/low-density polyethylene (LDPE)), two two-layer structures (AlOx-coated PET/LDPE and Al-coated PET/LDPE), and a monolayer metallized biaxially oriented polypropylene (MetBOPP). Samples were stored under accelerated conditions (38 °C and 90% relative humidity) for 180 days, and changes in moisture content, water activity, caking degree, glass transition temperature, color, and sensory attributes were monitored. The experimental data were examined for their agreement with various sorption models by creating adsorption isotherms. The acceptable storage period was estimated using the constants calculated from these models. Statistically significant differences (p < 0.05) were observed among the packaging types, primarily associated with their water vapor permeability, affecting moisture content, water activity, caking degree, and color stability. In terms of moisture content, water activity, and caking degree, the conventional PET/Al-foil/LDPE (Polyethylene terephthalate/Aluminum foil/Low density polyethylene) structure demonstrated the best performance, followed by PET.AlOx/LDPE (AlOx-coated Polyethylene terephthalate/Low density polyethylene), MPET/LDPE (Metallized polyethylene terephthalate/Low density polyethylene), and MBOPP (Metallized biaxially oriented polypropylene), respectively. The sensory analysis scores followed the same ranking; however, all samples maintained scores above the threshold value of 3 throughout the storage period, indicating that they remained acceptable. Caking degree increased moderately (from 0.61% to 0.89%) and was negatively correlated with appearance scores (R2 = -0.89, p < 0.01). Despite slight darkening (Browning Index increased from 18.16 to 20.37), sensory scores for appearance, odor, and taste remained above the acceptable threshold (score > 3.0). Based on the WVTR values of the packaging materials and the application of the GAB model, the estimated shelf lives were 800.32 days for PET/Al-foil/LDPE, 577.92 days for PET.AlOx/LDPE, 407.58 days for MPET/LDPE, and 229.26 days for MBOPP. In conclusion, the longest shelf life was achieved with PET/Al-foil/LDPE, and it was observed that as the WVTR of the packaging materials increased, the shelf life of the cocoa-based pudding powder decreased; PET.AlOx/LDPE and MPET/LDPE could be considered for medium-term storage (up to about 1-1.5 years), while MBOPP appeared suitable only for shorter durations (6-8 months).
