Vacuum packaging technologies heighten hygiene and lower energy amid industry disruptions

30 Mar 2022 --- Vacuum seal technologies are essential for preserving F&B shelf life for home, hospitality and other non-food sectors like the pharmaceutical industry. Over the past several years, new machinery and product design has hit the market, enabling stakeholders to make important developments that can protect consumer hygiene and lower energy output in line with global environmental sustainability goals.

However, serious problems have arisen due to force majeures, such as disruptions caused by the COVID-19 pandemic, damage to infrastructure caused by extreme weather, and cyberattacks on some of the world’s largest energy and food providers. 

These issues, coupled with the recent invasion of Ukraine, have combined to create one of the most difficult periods in history for these interwoven industries. Energy and material prices are skyrocketing throughout the world, and shortages of basic supplies are threatening supply chains for essential goods. 

PackagingInsights looks at some of the most recent technological developments in vacuum seal technologies and speaks to Dutch manufacturer Henkelman to discuss how these leaps in progress could transform industry, how current global calamities are hindering advances, and what this could mean for consumers around the world. 

We also look back at some of the latest policy recommendations and political contentions on how governments can aid industry in overcoming these difficulties. 

Koen van den Heuvel.Henkelman’s technology 
Henkelman has been producing vacuum packaging machinery since 1994. The company’s international sales manager and marketing & communications manager Koen van den Heuvel says its machines have several important functions of which consumers and policymakers are often unaware. 

“A vacuum package ensures optimal protection against external influences, such as dirt and dust. An airtight package prevents corrosion because moisture is being kept away from the product.”

“Furthermore, with our machines, we extend the shelf life of products in the F&B industry. But next to that, we have several interesting options available, such as marinating and tenderizing produce on some of our machines,” he explains. 

These functions all have vital ramifications for environmental sustainability, he adds. By combining operations like sealing and marinating or tenderizing on F&B products, supply chains can be streamlined, and transportation costs cut down. 

“During the vacuum packaging cycle, all air is being extracted from the product and the vacuum bag, so the final, vacuum-packed result will be more compact than the original product. As a consequence, this results in significant savings on storage and transport. This can also be profitable for a wide variety of non-food products, such as cash receipts, money, documents and textile fabrics.” 

“For the pharmaceutical industry, our machines are being used for the protection of the products, volume reduction and for optimizing the production process.” 

New designs hit the market 
Henkelman has installed solar paneling, which will help it overcome rising energy costs.Van den Heuvel says new designs of Henkelman’s machines are also reaching the market, with a new series coming on display this year. 

“At the upcoming IFFA show in Frankfurt, Germany, we will launch a new tabletop series. This series has a more elegant and modern design, comes with a three programs panel and options included such as soft-air and sensor control.” 

Soft air is a design whereby air is “gradually and gently” returned into the machine chamber. This gradual process is based on the pre-set time. In a controlled way, the vacuum bag envelopes the product for optimal protection of both the product and the bag. It is particularly applicable for products such as meat. 

Sensor control calculates when a pre-set percentage has been achieved for vacuum packaging. The desired end vacuum is always reached, regardless of the volume, says the company. 

“The main objective here was to produce a new modern table top line which is easy-to-use and ‘dummy-proof,’” says Van den Heuvel. 

Material advances 
Henkelman is not the only industry player making strides in the vacuum packaging space. Last year, Sealed Air began making its range of thermoformable food packaging webs – branded TM-Ply – 100% recyclable as it targets a fully recyclable or reusable product portfolio by 2025. 

TM-Ply webs are designed for a range of vacuum or modified atmosphere packaging (MAP) applications, including refrigeration, freezing, pasteurization and cooking. 

Rising steel prices are impacting machine manufacturers.Similarly, Ulma Packaging last year presented new solutions for cereal packaging that can minimize waste and material use in cereal packs by removing excess air. Branded The Tight Bag, its air extraction process 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.

Also, GEA unveiled a new version of its skin thermoforming packaging technology – the PowerPak Skin.50 – which can perform vacuum and MAP packing on the same machine. 

Fighting inflation and supply issues 
Currently, the packaging industry as a whole is facing a series of crises due to high inflation, soaring energy costs and supply chain disruption. 

Van den Heuvel says most recently, the Russian invasion of Ukraine is a key concern for machinery producers like Henkelman as gas and oil supplies are coming under massive pressure due to sanctions. 

“We hope the war in Ukraine will end soon,” he says. “In terms of energy costs, we are happy to have placed solar panels on our production plants roof last year.” 

However, other long-term issues are threatening the industry, he explains, particularly the cost of metals. “The increase in raw material pricing such as stainless steel definitely has its consequences. All our suppliers raised their prices. Therefore last year we were forced to increase our prices as well, and we are looking at another price increase again.” 

Last year, the US and EU agreed to a new Transatlantic trade deal, ending Trump-era tariffs for steel and aluminum. This move comes as China has long established a monopoly over the global market on these raw materials – something Western leaders and industry associations say is largely due to illegal dumping. With China facing its own energy crisis, prices have risen, and companies in the EU have no choice but to shoulder higher prices. 

By Louis Gore-Langton