Ice-free: StePac launches “climate positive” packaging for fresh produce long-haul transit

22 Jul 2019 --- MA/MH (Modified Atmosphere/Modified Humidity) packaging technology, Xtend Iceless, eliminates the need for ice and non-recyclable wax cartons in the transport of fresh vegetables, such as broccoli. The new launch by StePac Ltd. seeks to integrate sustainability into long-haul transport of vegetables, as well as to enhance food safety. According to the Food & Agriculture Organization, 1.3 billion tons of food worldwide is wasted annually, with 40 to 50 percent of this being lost post-harvest due to spoilage in transit.

In certain countries, such as the US, broccoli and other produce items are typically packed in waxed cartons filled with ice to keep the produce cool and maintain freshness. However, melting ice can create a mess, and more importantly, encourages the growth of plant and human pathogens. Waxed cartons also are non-recyclable. Stepac explains how this generates untenable disposal problems for supermarkets, many of which are seeking greener alternatives in the wake of new laws imposed to tackle this problem.

“Xtend Iceless offers a dry – and much leaner and greener – means of transporting fresh produce, wholly eliminating the need for ice,” says Gary Ward, Ph.D., Business Development Manager for StePac. “Moreover, it makes waxed cartons totally unnecessary. Xtend Iceless MA/MH packaging is fully recyclable and offers an affordable solution suitable for land or sea freight. The packaging is ‘climate positive,’ generating net savings in carbon emissions as a result of significantly extending the shelf life of fresh produce and reducing supply chain waste.”

A significant challenge faced by the company when developing the product was in integrating modified atmosphere packaging into the field-packed process. Much of the broccoli in the US is field-packed in cartons, palletized and then ice is added upon arrival at the packing house.

“We developed a solution that enables the broccoli to be field-packed in Xtend packaging and then forced air and/or vacuum cooled in the sealed packaging. This seamlessly integrates the packaging into the existing packing process,” explains Ward, noting that the system is patented in the US and Mexico.

Research demonstrates lower bacteria counts 
The company also touts Xtend Iceless as being able to significantly slow down the growth of microorganisms on broccoli, effectively abating produce deterioration and – more importantly – reducing the risk of foodborne illness associated with human pathogens such as E. coli.

In a study carried out at the Agricultural Research Organization in Israel, Xtend Iceless packaging was shown to be a superior alternative to ice for preserving all-around quality, as well as for mitigating against bacterial growth on produce during prolonged storage. 

The move to iceless packaging
The shift to iceless packaging is already gaining momentum among distributors of fresh produce globally. In the US, where broccoli is transported by land on trucks, road traffic accounts for 50 percent of air pollution, notes the company. 

Transport of broccoli from Salinas, California, to New York City in Xtend Iceless packaging allows 33 percent more broccoli to be packed in the same container space, yet results in a 30 percent reduction in gross weight. This translates into 40 percent lower logistical costs as well as a reduction in carbon footprint.

Innovating for sustainability
Earlier this year, a report by Fruit Logistica anticipated “significant innovation” in fresh produce packaging and supply chain management in the coming years. The prediction was based on increased consumer awareness of the environmental damage caused by food packaging and the need for greater shelf-life and efficiency in the supply chain.    

Fruit Logistica expected to see “significant innovation” in three key areas:

• “Firstly, while minimizing the overall use of plastic, we expect to see increased use of recycled plastics in the packaging of easy-healthy convenience products.
• Secondly, we expect the introduction of modified production processes in combination with new forms of stable packaging, including packaging within a protective atmosphere.
• Thirdly, we expect innovative forms of supply, such as the increased use of urban (vertical) farming.” 

StePac’s previous launches also touted sustainable profiles. In December it developed a proprietary, polyamide-based packaging technology for ensuring long-lasting freshness in long-distance bulk deliveries of blueberries. Earlier in 2018, the manufacturer also launched Xflow, a flowpack solution for blueberries as a cost-saving alternative to traditional preformed bulk packaging. 

Edited by Laxmi Haigh