Metal cans, while boasting excellent barrier properties, raise concerns about leaching and environmental impacts. This study explored plastic trays, a potential alternative for canned food packaging. First we delved into the plastic tray’s characteristics, including its composition and permeability to oxygen and water vapor. Secondly, we conducted a comparison between the newly introduced plastic packaging and traditional metal cans, focusing on their interactions with food during the sterilization process and their effects on the quality of Tunisian pea sauce. The composition analysis revealed that the plastic tray was composed of polypropylene (PP) (with a single endothermic peak at 168 °C), while the film was found to have a mixture of PP internally and polyethylene terephthalate (PET) externally (with two endothermic peaks at 161.96 °C and 243.81 °C). Plastic trays showed good results in water vapor permeability (0.832 g/m².d) but exhibited higher oxygen permeability (190 g/m².d), raising oxidation concerns. Migration testing confirmed plastic packaging safety (<10 mg/dm²), while some simulants exceeded limits in metal cans. pH levels remained consistent between both packaging types, but varied significantly over a 28-day storage. Total Volatile Basic Nitrogen (TVBN) levels differed significantly between plastic and metal packaging, with notable variations observed over time with maximums of 0.3 mg/100 g for plastic trays and 0.17 mg/100 g for metal cans. Sensory evaluation revealed that tasters were adept at differentiating between canned pea sauce in plastic trays and metal cans (83%, 10/12), with taste and color exhibiting significant differences (p < 0.05). This underlines the impact of packaging material on canned food quality and consumer preference, with minimal influence on other sensory aspects. This data empowers manufacturers to make informed packaging decisions for a diverse range of canned foods.

As lifestyles continue to evolve, the demand for canned foods, particularly in collective catering, has seen a notable surge. Traditional recipes, including the beloved Tunisian dish of pea sauce, are increasingly sought in canned formats. This study aimed to develop a canned pea sauce recipe and optimize its sterilization parameters. The formulation of the pea sauce involved considerations of factors influencing sensory quality, such as the pre-cooking time of the meat, the amount of tomato paste, and the spice mixture. To assess the sterilization process, two scales were tested: scale 1 (115°C for 60 min) and scale 2 (115°C for 45 min). Stability tests were carried out, and sterilization values were determined using the Biglow method. Various parameters, including pH, peroxide index, total volatile basic nitrogen (TVBN), and titrable acid values, were determined in conjunction with sensory evaluation comparing the final product under both thermal scales.The optimal recipe parameters were identified as a pre-cooking time of 6 minutes, 14 grams of tomato paste, and 7.60 grams of the spice mixture. Both the two scales were validated, yielding sterilizing values of 9.9 min and 8.3 min for scale 1 and scale 2, respectively. Stability tests of the optimized canned pea sauce showed satisfactory results for the two thermal scales. However, scale 2 exhibited slight improvements in pH, peroxide index, TVBN, titratable acidity, and various organoleptic parameters compared to scale 1.These findings contribute to the formulation of an optimized canned pea sauce recipe with enhanced stability and sensory attributes, addressing the increasing need for convenient food options in contemporary lifestyles, particularly in shared catering environments.