Ulma Packaging delivers cereal pack material savings with excess air removal tech

27 May 2021 --- Ulma Packaging UK is presenting solutions for minimizing waste and material use in cereal packs by removing excess air.

The move comes as leading cereal brand Kellogg’s announces plans to cut 700 tons of carbon from its operations annually.

Ed Williams, sales director for Ulma Packaging UK, hopes Kellogg’s actions are replicated in packaging lines across other food sectors.

However, he also stresses the need to consider packaging technology making these benefits possible without logistical and operational challenges compromising product integrity.

“The news from Kellogg’s is a big step in the right direction when it comes to meeting waste reduction targets around the globe,” he says.

“One of the largest concerns in packaging is excess air, as this can lead to excess financial and material costs.”

“Decreases in the volume of packages using certain packaging machinery, for example, increases the number of packs per pallet by approximately 20 percent, which could save companies up to 25 percent on fuel miles when getting packs to retailers.”

“It is therefore clear that exploring the technology available to achieve this is critical to improving sustainability.”Ed Williams, sales director for Ulma Packaging UK: “One of the largest concerns in packaging is excess air, as this can lead to excess financial and material costs.”

Avoiding product sealing damage
However, the mechanical “pushing” motion used by some packaging machinery to remove air can damage product sealing, while perforation techniques could reduce product quality.

“While it is clear food manufacturers stand to make significant gains by following Kellogg’s lead and extracting air during the packaging process, innovative solutions are required to avoid other potential pitfalls around vacuum packaging,” continues Williams.

Ulma Packaging’s investigative report – “Food Packaging: Air, The Hidden Cost” – published in 2019, explains how newer technologies, such as vertical form fill sealing (VFFS) and air extraction (Tight Bag) methods, can help to reduce the problem of excess air.

Tight Bar air extraction
The Tight Bag air extraction packaging solution works by pulling air from the individual bags in a precise (programmable) and controlled way, with no speed reduction, using a patented jaw arrangement in the cross-seal area.

The bag is sealed while air is drawn out and packaged vertically.

“While traditional forms of air removal have served production lines for many years, the challenges around product damage and contamination risk can be overcome by using newer air extraction technologies, such as Tight Bag,” explains Williams.

“This technology reduces packaging waste and lessens the risk of product damage in transit, due to significant reduction in product movements, meaning both logistical and sustainability benefits can be realized.”

“For Bag in Box applications, which are prevalent in cereal packaging, Tight Bag, for example, eases the insertion of the filled bag into an outer carton.”

“The automatic sealing means full seal integrity is maintained and the risk of content contamination is also significantly reduced, negating another common issue in this arena.”

Williams says innovations like the Tight Bag show it is possible for food manufacturers to make changes – regardless of their size – to significantly improve their operations’ environmental sustainability, like Kellogg’s.The Tight Bag air extraction packaging solution works by pulling air from the individual bags in a precise and controlled way, with no speed reduction, using a patented jaw arrangement in the cross-seal area.

Ulma Packaging developments
In other Ulma Packaging developments, the supplier recently released the LeafMap pack for sliced products, reducing plastic use by up to 80 percent.

The solution replaces conventional packaging’s structural plastic with a paper fiber structure based on fully recyclable flat cardboard trays. The cardboard trays can be printed on both sides, giving the packaging options in visual communication.

The company has also developed an innovative leak-proof and fully-hygienic packaging solution for the poultry sector. The Tight-Chicken solution ensures bags fit the product like a second skin, eliminating the risk of leaks and ensuring the product arrives at stores in compliance with the applicable hygiene regulations.

Edited by Joshua Poole