INCORPORATING COLD CHAIN
FEATURE the package . Produce managers especially like high quality graphics that they can use in supermarket floor displays .
Pre-printed cartons are , however , usually reserved for the introduction of new products or new brands . Market research has shown that exporters may benefit from sophisticated graphics . The increased cost usually does not justify use for mature products in a stable market , but this may change as the cost of these containers becomes more competitive .
• Paper and mesh bags Consumer packs of potatoes and onions are about the only fresh produce items you will still see packed in paper bags . The more sturdy mesh bag has much wider use . In addition to potatoes and onions , cabbage , turnips , citrus , and some specialty items are packed in mesh bags . Sweet corn may still be packaged in mesh bags in some markets . In addition to its low cost , mesh has the advantage of un-inhibited air flow . Good ventilation is particularly beneficial to products like onions . Supermarket produce managers like small mesh bags because they make attractive displays that stimulate purchases .
However , bags of any type have several serious disadvantages . Large bags do not palletise well , and small bags do not efficiently fill the space inside corrugated containers . Bags do not offer protection from rough handling . Mesh bags provide little protection from light or contaminants . In addition , produce packed in bags is correctly perceived by the consumer to be less than the best grade . Few consumers are willing to pay premium price for bagged produce .
Paper bags are now also increasing being used by retailers for purchasers but where you will also see the use of paper packaging is in freshly made confectionary items and even the use of ready to eat foods such as pies and baked goods .
• Plastic bags Plastic bags are the predominant material for fruit and vegetable consumer packaging . Besides the very low material costs , automated bagging machines further reduce the packing costs . Film bags are clear , allowing for easy inspection of the contents , and readily accept high quality graphics . Plastic films are available in a wide range of thicknesses and grades and may be engineered to control the environmental gases inside the bag . The film material " breathes " at a rate necessary to maintain the correct mix of gasses and water vapor inside the bag .
Since each produce item has its own unique requirement for environmental gases , modified atmosphere packaging material must be specially engineered for each item . Research has shown that the shelf life of fresh produce is extended considerably by this packaging . The explosive growth of pre-cut produce seen on any supermarket shelf these days is due in part to the availability of modified atmosphere packaging that slows or eliminates the natural process of oxidisation .
In addition to engineered plastic films , various patches and valves have been developed that affix to low-cost ordinary plastic film bags . These devices respond to temperature and control the mix of environmental gases . They also enable the consumer to manage multiple uses of the product .
• Plastic bins Plastic bins are used extensively in fruit and vegetable packhouses at the starting point of the cold chain . They are available in vented and solid configurations with smooth interior surfaces that can reduce waste and downgrade . Various ventilation designs also reduce cooling time and therefore saves energy . Their clean , non-porous surfaces eliminate many HACCP risks associated with wood bins . They can weigh up to 45 % less than wooden bins for quicker , safer handling and stacking and can also be stacked up to eight units high . They have optimal compatibility with most handling equipment and certain manufacturing practices such as on-piece products reduce maintenance and cleaning . Capacities can be as little as a few litres up to thousands of litres capacity .
• Shrink / cling wrap One of the newest trends in produce packaging is the shrink wrapping of individual produce items . Shrink wrapping has been used successfully to package a variety of fresh fruit and vegetables as well as ready to eat foods . Shrink wrapping with an engineered plastic wrap can reduce shrinkage , protect the produce from disease , reduce mechanical damage and provide a good surface for stick-on labels . Shrink wrapping material also comes in different types such as on rolls and in sleeves .
Cling film is another very popular packaging material for a variety of goods and as a versatile solution has applications across the cold supply chain from pallet wrapping to the wrapping of certain produce individually .
• Rigid plastic packages Packaging with a tops and bottoms that are heat-formed from one or two pieces of plastic are known as clamshells . Clamshells have gained in popularity because they are inexpensive , versatile , provide excellent protection to the produce , and present a very pleasing consumer package . It would be plausible to accept that this is the most common type of produce packaging used in South Africa for fresh fruits and vegetables . Clamshells are most often used with consumer packs of high value produce items like small fruit , berries , mushrooms , etc ., or items that are easily damaged by crushing . Clamshells are used extensively with pre-cut produce and prepared salads , as well as baked goods .
• Foil trays Aluminium foil trays are yet another major packaging solution for produce and along with treated cardboard lids are used in a lot of frozen foods , ready to eat meals , takeaways and packaged pre-cut fresh foods .
The list goes on to include polystyrene , boxes for frozen goods , sandwiches , wooden food containers , plastic and paper cups , glass , and so on .
As environmental pressures continue to grow , the disposal and recyclability of packaging material of all kinds will become an increasingly important aspect . Common polyethylene , for example , may take from 200 to 400 years to breakdown . The addition of as little as six percent starch will reduce that time to 20 years or less . Packaging material companies are developing several starch-based substitutes that will break down in a landfill as fast as ordinary paper and will be seen more and more as developments progress .
The move to biodegradable or recyclable plastic packaging materials may be driven
Cling film wrapped punnets of mushrooms . In the background - box cartons and plastic mesh bags of produce .
by cost in the long term , but by legislation in the near term . Some authorities have already proposed a total ban on plastics and some retailers locally have also already transitioned to more environmentally friendly packaging and delivery of produce in containers that can be re-used at the consumer level – thus also reducing what gets thrown away .
Standardisation Produce package standardisation is interpreted differently by different groups . The wide variety of package sizes and material combinations is a result of the market responding to demands from many different segments of the produce industry . For example , many of the large-volume buyers of fresh produce are those most concerned with the environment . They demand less packaging and the use of more recyclable and biodegradable materials , yet would also like to have many different sizes of packages for convenience .
Packers aim to limit the variety of packaging they must carry in stock , yet they have driven the trend toward pre-printed , individualised containers . Shippers and trucking companies want to standardise sizes so the packages may be better palletised and handled .
Produce buyers are not a homogeneous group . Buyers for chain stores have different needs than buyers for food services . For grocery items normally sold in bulk , processors want largest size packages that they can handle efficiently - to minimise unpacking time and reduce the cost of handling or disposing of the used containers . Produce managers , on the other hand , want individualised , high-quality graphics to entice retail buyers with in-store displays .
Selecting the right container for one ’ s produce is actually not as simple as dumping it in a box anymore . For each commodity , the market has shown that it demands certain standards and technology , market acceptability , and disposal regulations are constantly on the change .
When choosing a package for produce , role players must actually be actively consulting the market , and in fact all role players in the chain such as facility managers , refrigeration engineers , logistics companies etc , to understand how each process influences or is influenced by the selection .
Article Sources :
• Food and Agricultural Organisation
• General industry engagement
• Global Cold Chain Alliance
• Mpact Plastic Containers
• NC State University cooperation paper
• NNZ Packaging
• StePac
• Tecra Automation
• The Institute of Packaging ( SA )
• United Exports
• Vantage Market Research
• World Health Organisation CLA
Various fresh produce on display for consumers at a wholesale outlet . Several packaging solutions in application .
COLD LINK AFRICA • September 2022 www . coldlinkafrica . co . za 29