The drive by PFM Packaging Machinery Ltd and Perfotec to solve the problems associated with shelf life at a UK customer has resulted in the development of new technology by Perfotec that will not only provide longer shelf life, but will also reduce lost revenue from wastage and maintain consistency of product quality.
PFM, who has been supplying the UK fresh produce market with equipment for more than 20 years, believes that it is paramount that food packers recognise the importance of achieving the best possible oxygen levels within the packs to ensure that produce stays fresher for longer, as fruit and vegetables continue respiring when they are packaged.
A number of other variables cause products that are grown in different areas to respire at different rates. The actual respiration of fruit and vegetables depends on the type of product, temperature, growing methods, quantity per pack, types of soil used and fertilisation, as well as storage duration, which all contribute to product shelf-life performance.
Respiratory levels and the absorption of moisture are also affected by the packaging material used. The use of laminated film and labels, the amount of printed area on the packaging, the pack’s breathable surface area and whether the material has had anti-fog treatment are all factors that need to be taken into consideration when packaging fresh produce.
Perfotec has developed a revolutionary system that sets fresh produce packs to their optimum oxygen level by perforating the packaging material on-line. The solution increases product shelf life, helps to avoid product discolouration and odour problems and also eliminates the potential problems of bacteria.
It is also the ideal solution to reduce packaging film costs, as standard film is much cheaper than pre-perforated film. It results in upgraded line efficiency and an increase in the quality and shelf life of the packed produce.
This new on-line laser perforation system is available as a stand-alone solution, and can also be retro-fitted onto most of PFM’s highly adaptable vertical form fill and seal (VFFS) machines and horizontal flow wrappers, to provide an integrated solution.
PFM and Perfotec’s knowledge and expertise has created a system that allows packers to perforate film during the packing processes, which takes into consideration the effects of oxygen on the produce. This has been achieved by measuring the gas levels in pre-packed fresh produce by setting the packs to their optimum oxygen levels and adjusting the microperforations accordingly.
This process is called equilibrium modified atmosphere packaging (EMAP), and is the key to extending the shelf life of fresh produce. The rationale behind this new packaging technique is that fresh produce itself respires and therefore uses oxygen. EMAP establishes the best possible oxygen levels in packs, which means that the respiration intensity decreases, enhancing product shelf life and ensuring that the optimum oxygen level is maintained for a much longer period.
With this innovative system from Perfotec, it is now possible to fine tune the permeability of the packaging film, keeping it in balance with all the different variables associated with all fresh produce items. It also takes into consideration the respiration levels of different types of produce such as mushrooms, lettuce, apples and bananas, while identifying the atmospheric temperature and then matching this with the correct micro-perforation size - this achieves maximum product freshness.
Surpassing existing methods utilising pre-perforated films, the solution from PFM and Perfotec is now helping fresh produce packers reduce production downtime, avoid film wastage due to the unreliability of pre-perforation production techniques, while providing increased flexibility.
Simon O’Connor, Perfotec’s UK agent, explains: “Until now, fresh produce companies have struggled with pre-perforated film due to unreliable perforation dimensions and formats, together with extra costs because of high volumes of product waste.”
The move was, in part, prompted by one of PFM’s existing customers, who turned to PFM and Perfotec to find a solution to improve the shelf life of its packs of spinach and kale.
These two products have particularly high respiration rates, which can cause quick discolouration of fresh produce when oxygen levels become too high. Perfotec’s ability to work with partners such as PFM to provide the best solutions has allowed this customer to control respiration rates and extend product shelf life.
The key to achieving such an impressive result was finding a method that could control the high respiration rate of spinach and kale.
O’Connor adds: “Only the packer knows the exact growing conditions, along with the storage and distribution temperatures of the produce when it arrives to be packed, and as such this is another reason why pre-perforated film is largely ineffective. Each product needs a different number of micro-perforations in the packaging film to achieve the optimum gas levels in different temperature chains, which is why laser pre-perforated films are not suitable to achieve the best possible EMAP.”
Identifying the optimum oxygen level and using film that is perforated on-line, which is precisely controlled at the point of wrapping through a unique system interface with PFM’s PV320 and PV360 VFFS machines, has provided an exceptional retro-fit solution for extending the shelf life of all fresh produce products.
This project clearly outlines the flexibility of PFM’s machinery and its ease in accommodating these types of new developments, highlighted by the synchronisation of the laser perforation technology, from Perfotec and PFM’s wrapping equipment.
Despite the added technology, PFM machinery is still able to achieve high packaging speeds of up to 100 packs per minute, meeting increasing demands from the fresh produce market for higher production levels.
PFM sales and operations director Chris Bolton says: “Because of the integrated system with Perfotec, it is now possible for fresh produce packers to capitalise on the advantages of on-line programmable laser perforating film bags, running in complete harmony with wrapping equipment at impressive speeds to maintain high-volume throughput.”
Made from stainless steel for ease of cleaning, PFM’s VFFS machines are servo controlled and have brushless motors for continuous motion. Their rotary, long dwell, horizontal sealing system provides extended sealing time without reducing the packing speed, which is ideal for products such as salads and leafy vegetables.
These features of the PFM equipment, along with impressive set-up and changeover times, make them ideal for the fresh produce industry, where packaging speeds need to be maintained, if not increased, and downtime due to cleaning and maintenance reduced.
Not only has PFM been able to work to integrate this new solution for extending produce shelf life, but all systems from PFM have been thoroughly tested and proven in producing functional, strong and attractive packages, even with oddly sized products and irregular shapes such as peppers, spring onions and leafy salads.
A further important aspect about the option to retro-fit the system to currently operational packing lines is that PFM provides high levels of service and technical support.
Bolton says: “Produce packers demand 24-hour efficiency, so we have a large number of specialised call-out technicians throughout the UK. Also, our tele-service system for machines with Servo On-Line configurations enables us to be connected directly to the machine to rapidly identify and solve problems.”
He added that PFM will now deliver these proven principles of the horizontal form fill and seal sector to other problem products, which will be another significant advance for the company.
Bolton adds: “With our integrated system with Perfotec, fresh produce packers can capitalise on cost savings, as well as superior pack performance in ensuring product shelf life and quality. The results outperform industry norms by far, and the ability to retro-fit the system is of massive benefit. Packers can further extend the cost-effectiveness of their current capital equipment without facing the expense of re-equipping to meet market demands for longer shelf-life produce.”
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