Introduction
Packaging fresh fruits and vegetables is one of the more leading steps in the long and complex journey from grower to consumer. Bags, crates, hampers, baskets, cartons, bulk bins, and palletized packaging are suitable packaging for handling, transporting, and marketing fresh produce. More than 1,500 separate types of packages are used for produce in the U.S. And the number continues to increase as the business introduces new packaging materials and concepts. Although the business ordinarily agrees that box standardization is one way to reduce cost, the trend in new years has moved toward a wider range of box sizes to accommodate the diverse needs of wholesalers, consumers, food service buyers, and processing operations.
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Packing and packaging materials lead a considerable cost to the produce industry; therefore it is leading that packers, shippers, buyers, and consumers have a clear comprehension of the wide range of packaging options available. This fact sheet describes some of the many types of packaging, including their functions, uses, and limitations. Also included is a listing, by commodity, of the common produce packaging suitable to the industry.
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The Function of packaging or Why box Produce?
A considerable ration of produce buyer and buyer complaints may be traced to box failure because of poor design or inappropriate option and use. A properly designed produce box should contain, protect, and recognize the produce, satisfying everybody from grower to consumer.
Packaging Points
Recyclability/Biodegradability.
A growing number of U.S. Markets and many export markets have waste disposal restrictions for packaging materials. In the near future, approximately all produce packaging will be recyclable or biodegradable, or both. Many of the largest buyers of fresh produce are also those most concerned about environmental issues.
Variety.
The trend is toward greater use of bulk packages for processors and wholesale buyers and smaller packages for consumers. There are now more than 1,500 separate sizes and styles of produce packages.
Sales Appeal.High capability graphics are increasingly being used to boost sales appeal. Multi-color printing, distinctive lettering, and logos are now common.
Shelf Life.
Modern produce packaging can be institution engineered for each commodity to increase shelf life and reduce waste.
Containment
The box must enclose the produce in suitable units for handling and distribution. The produce should fit well inside the container, with tiny wasted space. Small produce items that are rotund or oblong (such as potatoes, onions, and apples) may be packaged efficiently utilizing a range of separate box shapes and sizes. However, many produce items such as asparagus, berries, or soft fruit may want packaging specially designed for that item. Packages of produce ordinarily handled by hand are normally tiny to 50 pounds. Bulk packages moved by fork lifts may weigh as much as 1,200 pounds.
Protection
The box must protect the produce from mechanical damage and poor environmental conditions during handling and distribution. To produce buyers, torn, dented, or collapsed produce packages normally indicate lack of care in handling the contents. produce packaging must be sturdy enough to resist damage during packaging, storage, and communication to market.
Because approximately all produce packages are palletized, produce packaging should have enough stacking force to resist crushing in a low temperature, high humidity environment. Although the cost of packaging materials has escalated sharply in new years, poor quality, lightweight packaging that are categorically damaged by handling or moisture are no longer tolerated by packers or buyers.
Produce destined for export markets requires that packaging to be extra sturdy. Air-freighted produce may want special packing, box sizes, and insulation. Marketers who export fresh produce should consult with freight associates about any special packaging requirements. Additionally, the Usda and various state export agencies may be able to furnish specific packaging information.
Damage resulting from poor environmental operate during handling and transit is one of the leading causes of rejected produce and low buyer and buyer satisfaction. Each fresh fruit and vegetable commodity has its own requirements for temperature, humidity, and environmental gas composition.
Produce packaging should be produce kindly - helping to claim an optimum environment for the longest shelf life. This may contain special materials to slow the loss of water from the produce, insulation materials to keep out the heat, or engineered plastic liners that claim a suitable mix of oxygen and carbon dioxide.
Identification
The box must recognize and furnish beneficial information about the produce. It is former (and may be required in some cases) to furnish information such as the produce name, brand, size, grade, variety, net weight, count, grower, shipper, and country of origin. It is also becoming more common to find included on the package, nutritional information, recipes, and other beneficial information directed specifically at the consumer. In buyer marketing, pack- age appearance has also come to be an leading part of point of sale displays.
Universal product Codes (Upc or bar codes) may be included as part of the labeling. The Upcs used in the food business consist of a ten-digit motor readable code. The first five digits are a number assigned to the specific producer (packer or shipper) and the second five digits rehearse specific product information such as type of produce and size of package. Although no price information is included, Upcs are used more and more by packers, shippers, buyers, and Example of a Upc retailers as a fast and suitable formula of catalogue operate and cost accounting. Sufficient use of Upcs requires coordination with everybody who handles the package.
Types of packaging Materials
Wood
Pallets categorically form the base on which most fresh produce is delivered to the consumer. Pallets were first used during World War Ii as an Sufficient way to move goods. The produce business uses approximately 190 of the 700 million pallets produced per year in the U.S.. About 40 percent of these are single-use pallets. Because many are of a non-standard size, the pallets are built as inexpensively as possible and discarded after a particular use. Although standardization efforts have been gently under way for many years, the efforts have been accelerated by pressure from environmental groups, in addition to the rising cost of pallets and landfill tipping fees.
Over the years, the 40-inch wide, by 48-inch long pallet has evolved as the unofficial suitable size. Standardization encourages re-use, which has many benefits. Besides reducing cost because they may be used many times, most pallet racks and self-operating pallet handling equipment are designed for standard-size pallets. suitable size pallets make Sufficient use of truck and van space and can accommodate heavier loads and more stress than lighter single-use pallets. Additionally, the use of a particular pallet size could substantially reduce pallet catalogue and warehousing costs along with pallet repair and disposal costs. The adoption of a pallet suitable throughout the produce business would also aid efforts toward standardization of produce containers.
In the early 1950s, an alternative to the pallet was introduced. It is a pallet-size sheet (slipsheet) of corrugated fiberboard or plastic (or a aggregate of these materials) with a narrow lip along one or more sides. Packages of produce are stacked directly on this sheet as if it were a pallet. Once the packages are in place, they are moved by a specially qualified fork lift qualified with a thin metal sheet instead of forks.
Slipsheets are considerably less high-priced than pallets to buy, store, and maintain; they may be re-used many times; and they reduce the tare weight of the load. However, they want the use of a special fork-lift attachment at each handling point from packer to retailer.
Depending on the size of produce package, a particular pallet may carry from 20 to over 100 private packages. Because these packages are often loosely stacked to allow for air circulation, or are bulging and difficult to stack evenly, they must be secured (unitized) to preclude shifting during handling and transit. Although widely used, plastic straps and tapes may not have completely satisfactory results. Plastic or paper projection tabs should all the time be used to preclude the straps from crushing the corners of packages.
Plastic stretch film is also widely used to fetch produce packages. A good film must stretch, hold its elasticity, and cling to the packages. Plastic film may conform categorically to various size loads. It helps protect the packages from loss of moisture, makes the pallet more fetch against pilferage, and can be applied using partial automation. However, plastic film severely restricts allowable ventilation. A common alternative to stretch film is plastic netting, which is much great for stabilizing some pallet loads, such as those that want forced-air cooling. Used stretch film and plastic netting may be difficult to properly deal with and recycle.
A very low-cost and approximately fully self-operating formula of pallet stabilization is the application of a small number of special glue to the top of each package. As the packages are stacked, the glue secures all cartons together. This glue has a low tensile force so cartons may be categorically separated or repositioned, but a high shear force so they will not slide. The glue does not gift disposal or recycling problems.
Pallet Bins. Huge wooden pallet bins of milled lumber or.plywood are primarily used to move produce from the field or orchard to the packing house. Depending on the application, capacities may range from 12 to more than 50 bushels. Although the height may vary, the distance and width is ordinarily the same as a suitable pallet (48 inches by 40 inches). More Sufficient double-wide pallet bins (48 inches by 80 inches) are becoming more common in some produce operations.
Most pallet bins are locally made; therefore it is very leading that they be consistent from lot to lot in materials, construction, and especially size. For example, small differences in allinclusive dimensions Pallet bin can add up to big problems when several hundred are stacked together for cooling, ventilation, or storage. It is also leading that stress points be adequately reinforced. The average life of a hardwood pallet bin that is stored face is approximately five years. When properly protected from the weather, pallets bins may have a beneficial life of 10 years or more.
Uniform voluntary standards for wood pallets and other wood packaging are administered by the National Wooden Pallet and box Association, Washington, Dc. Additionally, the American community of Agricultural Engineers, St. Joseph, Michigan, publishes standards for agricultural pallet bins (Asae S337.1).
Wire-Bound Crates. Although alternatives are available, wooden wire-bound crates are used extensively for snap beans, sweet corn and several other commodities that want hydrocooling. Wire-bound crates are sturdy, rigid and have very high stacking force that is essentially unaffected by water. Wire-bound crates come in many separate sizes from half- bushel to pallet-bin size and have a great deal of open space to facilitate cooling and ventilation. Although few are re-used, wire-bound crates may be dissembled after use and shipped back to the packer (flat). In some areas, used packaging may pose a considerable disposal problem. Wirebound crates are not ordinarily suitable for buyer packaging because of the strangeness in affixing suitable labels.
Wooden Crates and Lugs. Wooden crates, once extensively used for apples, stone fruit, and potatoes have been approximately totally supplanted by other types of containers. The relative price of the container, a greater concern for tare weight, and advances in material handling have reduced their use to a few specialty items, such as high-priced tropical fruit. The 15-, 20-, and 25-pound wooden lugs still used for bunch grapes and some specialty crops are being gently supplanted with less high-priced alternatives.
Wooden Baskets and Hampers. Wire-reinforced wood veneer baskets and hampers of separate sizes were once used for a wide range of crops from strawberries to sweetpotatoes. They are durable and may be nested for Sufficient transport when empty. However, cost, disposal problems, and strangeness in Sufficient palletization have severely tiny their use to mostly local grower markets where they may be re-used many times.
Corrugated Fiberboard
Corrugated fiberboard (often mistakenly called cardboard or pasteboard) is artificial in many separate styles and weights. Because of its relativity low cost and versatility, it is the dominant produce box material and will probably remain so in the near future. The force and serviceability of corrugated fiberboard have been enhancing in new years.
Most corrugated fiberboard is made from three or more layers of paperboard artificial by the kraft process. To be carefully paperboard, the paper must be thicker than 0.008 inches. The grades of paperboard are differentiated by their weight (in pounds per 1,000 quadrilateral feet) and their thickness. Kraft paper made from unbleached pulp has a characteristic brown color and is exceptionally strong. In addition to virgin wood fibers, Kraft paper may have some portion of synthetic fibers for further strength, sizing (starch), and other materials to give it wet force and printability. Most fiberboard contains some recycled fibers. Minimum amounts of recycled materials may be specified by law and the ration is imaginable to increase in the future. Tests have shown that cartons of fully recycled pulp have about 75 percent of the stacking force of virgin fiber containers. The use of recycled fibers will inevitably lead to the use of thicker walled containers.
Double-faced corrugated fiberboard is the renowned form used for produce containers. It is produced by sandwiching a layer of corrugated paperboard in the middle of an inner and outer liner (facing) of paper-board. The inner and outer liner may be identical, or the outer layer may be preprinted or coated to great accept printing. The inner layer may be given a special coating to resist moisture.
Heavy-duty shipping containers, such as corrugated bulk bins that are required to have high stacking strength, may have double- or even triple-wall construction. Corrugated fiberboard manufacturers print box certificates on the bottom of packaging to warrant clear force characteristics and limitations. There are two types of certification. The first certifies the minimum combined weight of both the inner and outer facings and that the corrugated fiberboard material is of a minimum bursting strength. The second certifies minimum edge crush test (Etc) strength. Edge crush force is a much great predictor of stacking force than is bursting strength. For this reason, users of corrugated fiberboard packaging should insist on Ect certification to assess the stackability of various containers. Both certificates give a maximum size limit for the box (sum of length, width, and height) and the maximum gross weight of the contents.
Both cold temperatures and high humidities reduce the force of fiberboard containers. Unless the box is specially treated, moisture absorbed from the surrounding air and the contents can reduce the force of the box by as much as 75 percent. New anti-moisture coatings (both wax and plastic) are now ready to substantially reduce the effects of moisture.
Waxed fiberboard cartons (the wax is about 20 percent of fiber weight) are used for many produce items that must be either hydrocooled or iced. The main objection to wax cartons is disposal after use- wax cartons cannot be recycled and are increasingly being refused at landfills. several states and municipalities have recently taxed wax cartons or have instituted rigid back haul regulations. business sources suggest that wax cartons will at last be supplanted by plastic or, more likely, the use of ice and hydrocooling will be supplanted by very controlled forced-air cooling and rigid climatic characteristic and humidity maintenance on many commodities.
In many applications for corrugated fiberboard containers, the stacking force of the box is a minor consideration. For example, canned goods carry the majority of their own weight when stacked.
Fresh produce normally cannot carry much of the vertical load without some damage. Therefore, one of the primarily desired characteristics of corrugated fiberboard packaging is stacking force to protect the produce from crushing. Because of their geometry, most of the stacking force of corrugated packaging is carried by the corners. For this reason, hand holes and ventilation slots should never be positioned near the corners of produce packaging and be tiny to no more than 5 to 7 percent of the side area.
Interlocking the packages (cross stacking) is universally practiced to stabilize pallets. Cross stacking places the projection of one produce box at the middle of the one below it, thus reducing its stacking strength. To reduce the possibility of collapse, the first several layers of each pallet should be column stacked (one box directly above the other). The upper layers of packages may be cross stacked as usual with very tiny loss of pallet stability.
There are numerous styles of corrugated fiberboard containers. The two most used in the produce business are the one piece, quarterly slotted box (Rsc) and the two piece, full telescoping box (Ftc). The Rsc is the most popular because it is uncomplicated and economical. However, the Rsc has relatively low stacking force and therefore must be used with produce, such as potatoes, that can carry some of the stacking load. The Ftc, categorically one box inside another, is used when greater stack- ing force and resistance to bulging is required. A third type of box is the Bliss box, which is - constructed from three cut off pieces of corrugated fiberboard. The Bliss box was industrialized to be used when maximum stacking force is required. The bottoms and tops of all three types of packaging may be accomplished by glue, staples, or interlocking slots.
Almost all corrugated fiberboard packaging are shipped to the packer flat and assembled at the packing house. To conserve space, assembly is normally performed just before use. Assembly may be by hand, machine, or a aggregate of both. Ease of assembly should be carefully investigated when inspecting a particular style of package.
In new years, large double-wall or even triple- wall corrugated fiberboard packaging have increasingly been used as one-way pallet bins to ship bulk produce to processors and retailers. Cabbage, melons, potatoes, pumpkins, and citrus have all been shipped successfully in these containers. The box cost per pound of produce is as tiny as one fourth of former size containers. Some bulk packaging may be collapsed and re-used.
For many years, labels were printed on heavy paper and glued or stapled to the produce package. The high cost of materials and labor has all but eliminated this practice. The capability to print the brand, size, and grade information directly on the box is one of the greatest benefits of corrugated fiberboard containers. There are basically two methods used to print corrugated fiberboard containers:
Post Printed. When the liner is printed after the corrugated fiberboard has been formed, the process is known as post printing. Post printing is the most widely used printing formula for corrugated fiberboard packaging because it is prudent and may be used for small press runs. However, postprinting produces graphics with less information and is normally tiny to one or two colors.
Preprinted. High quality, full-color graphics may be obtained by preprinting the linerboard before it is attached to the corrugated paperboard. Whereas the cost is about 15 percent more than suitable two color containers, the eye catching capability of the graphics makes it very beneficial for many situations. The optic capability of the box influences the perception of the product because the buyer's first impression is of the face of the package. produce managers especially like high capability graphics that they can use in super market floor displays.
Preprinted cartons are normally reserved for the introduction of new products or new brands. market explore has shown that exporters may benefit from sophisticated graphics. The increased cost normally does not account for use for mature products in a garage market, but this may convert as the cost of these packaging becomes more competitive.
Pulp Containers. packaging made from recycled paper pulp and a starch binder are mainly used for small buyer packages of fresh produce. Pulp packaging are ready in a large range of shapes and sizes and are relatively cheap in suitable sizes. Pulp packaging can discharge face moisture from the product, which is a benefit for small fruit and berries that are categorically harmed by water. Pulp packaging are also biodegradable, made from recycled materials, and recyclable.
Paper and Mesh Bags. buyer packs of potatoes and onions are about the only produce items now 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 benefit of uninhibited air flow. Good ventilation is particularly beneficial to onions. Supermarket produce managers like small mesh bags because they make challenging displays that stimulate purchases.
However, bags of any type have several serious disadvantages. Large bags do not palletize well and small bags do not efficiently fill the space inside corrugated fiberboard containers. Bags do not offer protection from rough handling. Mesh bags furnish tiny protection from light or contaminants. In addition, produce packed in bags is correctly perceived by the buyer to be less than the best grade. Few consumers are willing to pay premium price for bagged produce.
Plastic Bags. Plastic bags (polyethylene film) are the renowned material for fruit and vegetable buyer packaging. Besides the very low material costs, self-operating bagging machines further reduce packing costs. Film bags are clear, allowing for easy inspection of the contents, and effortlessly accept high capability graphics. Plastic films are ready in a wide range of thicknesses and grades and may be engineered to operate the environmental gases inside the bag. The film material "breathes" at a rate considerable to claim the spoton mix of oxygen, carbon dioxide, 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. explore has shown that the shelf life of fresh produce is extended considerably by this packaging. The explosive increase of precut produce is due in part to the availability of modified atmosphere packaging.
In addition to engineered plastic films, various patches and valves have been industrialized that affix to low-cost ordinary plastic film bags. These devices riposte to climatic characteristic and operate the mix of environmental gases.
Shrink Wrap. One of the newest trends in produce packaging is the shrink wrapping of private produce items. Shrink wrapping has been used successfully to box potatoes, sweetpotatoes, apples, onions, sweet corn, cucumbers and a range of tropical fruit. Shrink wrapping with an engineered plastic wrap can reduce shrinkage, protect the produce from disease, reduce mechanical damage and furnish a good face for stick-on labels.
Rigid Plastic Packages. Packages with a top and bottom that are heat formed from one or two pieces of plastic are known as clamshells. Clamshells are gaining in popularity because they are inexpensive, versatile, furnish perfect protection to the produce, and gift a very pleasing buyer package. Clamshells are most often used with buyer packs of high value produce items like small fruit, berries, mushrooms, etc., or items that are categorically damaged by crushing. Clamshells are used extensively with precut produce and ready salads. Molded polystyrene and corrugated polystyrene packaging have been test marketed as a substitute for waxed corrugated fiberboard. At gift they are not ordinarily cost competitive, but as environmental pressures grow, they may be more common.
Heavy-molded polystyrene pallet bins have been adopted by a number of growers as a substitute for wooden pallet bins. Although at gift their cost is over double that of wooden bins, they have a longer service life, are easier to clean, are recyclable, do not decay when wet, do not harbor disease, and may be nested and made collapsible.
As environmental pressures continue to grow, the disposal and recyclability of packaging material of all kinds will come to be a very leading issue. common polyethylene may take from 200 to 400 years to breakdown in a landfill. The addition of 6 percent starch will reduce the time to 20 years or less. packaging material associates are developing starch-based polyethylene substitutes that will break down in a landfill as fast as ordinary paper.
The move to biodegradable or recyclable plastic packaging materials may be driven by cost in the long term, but by legislation in the near term. Some authorities have proposed a total ban on plastics. In this case, the supermarket of the early 21st century may resemble the grocery markets of the early 20th century.
Standardization of Packaging
Produce box standardization is interpreted differently by separate groups. The wide range of box sizes and material combinations is a supervene of the market responding to demands from many separate segments of the produce industry. For example, many of the large-volume buyers of fresh produce are those most concerned with the environment. They examine less packaging and the use of more recyclable and biodegradable materials, yet would also like to have many separate sizes of packages for convenience. Packers want to limit the range of packages they must carry in stock, yet they have driven the trend toward preprinted, individualized containers. Shippers and trucking associates want to standardize sizes so the packages may be great palletized and handled.
Produce buyers are not a homogeneous group. Buyers for grocery chains have separate needs than buyers for food service. For grocery items normally sold in bulk, processors want largest size packages that they can deal with efficiently - to minimize unpacking time and reduce the cost of handling or disposing of the used containers. produce managers, on the other hand, want individualized, high capability graphics to entice retail buyers with in-store displays.
Selecting the right box for fresh produce is seldom a matter of personal option for the packer. For each commodity, the market has unofficial, but nevertheless rigid standards for packaging; therefore it is very risky to use a nonstandard package. packaging technology, market acceptability, and disposal regulations are constantly changing. When selecting a box for fresh fruits and vegetables, packers must consult the market, and in some markets, suitable packages may be required by law.
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