New Horizons in Produce Packaging

The future of produce packaging is sustainable, but must address the unique needs of the industry.

Packaging plays an integral role in the fresh produce supply chain and sales.

“Key drivers for packaging growth are numerous benefits, such as protection, identification/traceability, ease of transportation, consumer convenience, company promotion and product communication,” says Leah Lex, sustainability manager at Volm Companies in Antigo, WI. “These factors are not only driving the industry forward, but also ensuring the quality and freshness of produce for consumers.”

Packaged produce is perceived as more hygienic and easier to handle, appealing to busy consumers, says Victoria Lopez, marketing and business development manager at Fox Packaging in McAllen, TX.

“Historical sales trends in food packaging reveal a dynamic market influenced by demographic shifts, changes in household size, disposable income, and food preferences for convenience or organic,” she says.

Even before the public scrutiny of plastic became daily chatter, there have been many successes in fresh produce packaging worthy of celebration, says Marsha Pozza, director of marketing and communications at Volm. “For as long as packaging has been used in this industry, we have been focused on ensuring products make it to market safely, are easily traceable, and promote shelf life.”

Increasingly, packaging must marry convenience and function with sustainability considerations. Martindale’s Natural Market in Springfield, PA, takes its stewardship of the planet seriously through packaging, says Tracy McDonald, produce department head.

“Promoting a sustainable environment is a key part of our company’s mission statement,” McDonald explains. “As a produce department, we do our utmost to promote sustainability, in both our front and back-end operations. We would like vendors to offer more recyclable, compostable and biodegradable packaging.”

INCREASING ALTERNATIVES

As large retail grocers hone their sustainability missions and enact vendor mandates,Teri Gibson, director of marketing at Peri & Sons Farms in Yerington, NV, notes “it’s important the packaging they are mandating be attainable material-wise and affordability-wise.”

The industry continues to develop options. “Several packaging materials balance convenience, sustainability and cost, including recyclable poly bags/pouches and non-wet strength paper,” says Lex.
Other flexible packaging designs include polyethylene-based mesh that allows for greater breathability, and light blocker film that prevents greening, Lex says, adding both options lead to longer shelf life.

Lopez explains increasing trends include the use of recyclable materials, innovative designs enhancing produce visibility and protection, and smart solutions with traceability features.

Fox offers a range of flexible packaging solutions, including mesh bags, film bags and stand-up pouches, that can be tailored to meet specific needs of different types of produce, she says.

“The produce packaging market is also seeing a shift toward more innovative and value-added options, such as resealable pouches, which offer ease of use and storage, a segment in which we are actively invested and able to produce for a range of commodity types.”

Some incredible innovations are coming through the pipeline, according to John Paap, sustainability director at Jac. Vandenberg in Tarrytown, NY. “We just have to be willing to try them and be open to change.”

“We continue to encourage our retail partners to pivot to our tree-fiber netting bags for citrus — a material that’s 100% responsibly sourced from nature and returned back to nature,” Paap says. “Solutions are out there; they may not look exactly like what we’re used to, but we need to be open to these differences.”

Though pouch bags are the primary vehicle for apples and pears, Stemilt of Wenatchee, WA, introduced a four-pack banded tray, called EZ Band, to help merchandise larger-sized organic apples. “It’s a concept common in Europe and made of 100% paper products for ease in recyclability,” says Brianna Shales, marketing director.

Yoke’s Fresh Markets in Spokane, WA, with 19 stores, carries the Stemilt EZ Band apples. “During the summer, we also get totes with apricots from Family Tree Farms,” says Jim Sullivan, produce merchandiser. “Kings River offers heirloom navels and blood oranges in totes as well.”

On the cherry side, Stemilt offers bags and clamshells with top seal film. “This reduces the amount of plastic used in comparison to traditional clamshells with a lid and label,” says Shales.

Reseal film allows for multiple uses, keeping the product fresh after each use for convenient opening and closing. Top seal provides 40% less plastic when replacing a clamshell lid with film on a 100% recyclable PET tray, according to Kaitlin Wyatt, marketing and communications manager for JBT Proseal in Richmond, VA.

Paperboard and fiber options are gaining in popularity and can also be top-sealed, Wyatt says. “Food safety is another concern to consumers, and top seal provides a full tamper-evident hermetic seal.”

Peri & Sons has been successful with an all-paper, eco-friendly solution called Earthbag that is 100% plastic-free, and biodegradable/compostable, says Gibson. “This unique bag, with paper/bamboo mesh, has a large window offering ample product visibility.”

Working with Warren Packaging, Peri & Sons has also produced 100% biodegradable/compostable paper clamshells with a clean soy-based window for its organic shallots and cipollinis.

As a retailer, Martindale’s would love to see more alternatives to plastic clamshells for salads, sprouts, herbs, commercial berries and plastic carrot bags, McDonald says. “It would be a dream to see commercial companies use the corrugated cardboard containers for their berries because the local option is only available in summer,” she says. “This would extend sustainability to other seasons.”

SEEKING SUSTAINABILITY

Environmental concerns remain a major driver for packaging innovation. “From a packaging standpoint, there are many different avenues to approach sustainability, including overall package reduction, selective raw materials, and recyclable packaging,” says Belinda Heidebrink, product marketing lead at Bedford Industries in Worthington, MN. “Each has its own advantages and caveats. It’s truly up to each individual to determine priorities and choose packaging that helps them meet their objectives.”

The shift away from plastics and toward eco-friendly/sustainable materials and automation is not just a passing trend, asserts Brant Carman, West Coast sales for 4HM Solutions in Yakima, WA.

“Earth-friendly packaging is becoming the new standard,” Carman says. “By adopting biodegradable, truly recyclable, and innovative materials, the industry is making significant strides toward a more sustainable future.”

“By adopting biodegradable, truly recyclable, and innovative materials, the industry is making significant strides toward a more sustainable future.”

— Brant Carman, 4HM Solutions, Yakima, WA

Volm offers a range of sustainable options, such as recyclable, compostable and biodegradable packaging. “Our light blocker film, for instance, extends the shelf life of potatoes by 12 to 17 days,” says Lex. “We are also actively working to incorporate post-consumer recycled (PCR) content into our packaging line, a move that not only reduces plastic pollution, but also supports the recycling infrastructure.”

Fox collaborates with brands and retailers to foster packaging innovation addressing both cost efficiency and sustainability. “Our recent elimination of PFAS from all flexible packaging options is a testament to our environmental commitment and customer health,” says Lopez. “We believe in the importance of supply chain relationships, helping support one another in decision-making with consideration to the impacts of such decisions.”

Bedford empowers consumers and retailers to return produce ties and tags to be processed through Bedford’s equipment and upcycled into other usable materials. “Our TagBack program gives growers the unique opportunity to communicate how they’re part of the solution directly on their packaging by printing the logo and return instructions,” says Heidebrink. “Shoppers drop the ties/tags into drop box locations or mail directly to Bedford.”

Kevin Kelly, chief executive of Emerald Packaging in Union City, CA, points to Europe as a forecast of what’s to come.

“We see more fiber-based offerings, especially in Europe, where paper packaging has replaced plastics for certain dry items such as potatoes,” Kelly says. “In Germany, paper is also being used in salad packaging as a replacement for film. And, I think you’ll see efforts to replace clamshells with fiber in the U.S., something we already see in Europe.”

A BALANCING ACT

Balancing multiple factors is crucial to new packaging. “We have a perishable product that can’t be harmed during transport,” says Shales. “In any package development work we do, product integrity is our top priority before we move forward. Partnering on a new packaging trial and in a test retail environment is a great way for retailers and suppliers to work together on new ideas.”

Several notable trends in produce packaging emphasize security and freshness, says Carrie Cline, senior brand manager at Inline Plastics in Shelton, CT. “Inline pioneered patented tamper protection technology with its Safe-T-Fresh brand, which now offers over 100 options,” she says. “This technology also provides a leak-resistant seal, enhancing freshness. Inline recently expanded Safe-T-Fresh to include a family of 7-inch round tubs, ideal for produce applications.”

For materials such as fiber or post-consumer resin, Kelly says companies can take creative actions to reduce cost increases by thinning packages and eliminating zippers.

“D’Arrigo Bros. of California took this route when it rolled PCR out across its product lines,” he says. “With D’Arrigo, we found a way to deploy 30% post-consumer recycled resin in their packaging by making it cost-neutral. We thinned the package without giving up protection and shelf-life extension.”

Packaging/identification products such as Bib Ties, Produce Ties, ElastiTag and PushTag are great options for growers and consumers alike concerning convenience, sustainability and cost, suggests Heidebrink. “These solutions offer a significant plastic reduction when compared to other alternatives such as single-use bags, plastic overwrap, or shrink,” she says.

The 4HM Eco-Tray is an example of balancing the need for convenience, sustainability and cost, explains Carman. “It comes in many shapes and sizes, and with multiple fully-automated sealing options,” he says. “These trays/packs accommodate size and shape variations inherent in fresh produce. The Eco-tray is a zero-plastic package comprised of affordable micro-flute corrugated cardboard.”

The balancing act of packaging also takes into account register accuracy. Yokes’ Sullivan points out packaging helps ensure organic is rung up correctly. “Especially with increased self-checkout, it’s easier for the customer and more accurate for us,” he says.

“Sustainable options such as paperboard tie in better with organic produce, since many organic customers look at plastic containers as the enemy.”

PAYING THE PRICE

As with the development of any new product, new packaging options yield higher costs.

“There are numerous reasons for this, including the costs of R&D, limited supply of new materials, testing and required certifications,” says Volm’s Pozza. “It’s crucial that our plastic food packaging, including PCR, operates as effectively and efficiently as traditional materials. In the case of PCR in film, we should expect the price to decrease as supply increases and material manufacturers make equipment modifications.”

Sustainable packaging options are more expensive due to their complex manufacturing processes, explains Cline. “Inline navigates this cost balance by designing packaging using less plastic and incorporating PCR content,” she says. “As more companies invest in sustainable practices and technologies, the cost gap between sustainable and non-sustainable packaging is expected to narrow.”

Sustainable packaging costs 5% to 100% more than traditional packaging, explains Kelly. “Compostable offerings have never come down in price and easily remain double to triple the cost of plastics,” he says. “PCR for plastics has emerged as the least costly of the alternatives, only 3% to 10% more than virgin plastics, though availability remains a challenge.”

Looking to the future, Carman expects sustainable packaging to become even more cost-effective.

“Increased investment in research and development, coupled with stricter environmental regulations and heightened consumer awareness will drive further advancements,” he says. “Companies are likely to benefit from reduced waste disposal costs and enhanced brand loyalty, offsetting initial investments.”

Competitive variables further influence the balance between sustainability and cost, notes Lopez. “Packaging types such as stand-up pouches and plastic containers, despite their higher initial costs, can offer benefits such as ease of restocking, improved display aesthetics, and consumer convenience, which may lead to overall cost savings and increased sales.”

Some package innovations may help reduce costs in other ways. For example, Wyatt explains the weight savings in the actual packaging when changing from a clip-on or clamshell lid to a film lid.

“A clip-on lid for a pack of strawberries weighs 13.4 grams whereas a film lid only weighs 1.14 grams,” she says. “This weight savings is not only in materials but also transportation, factory space and other important factors throughout the supply chain.”

Cost is certainly one of the pain points in solving the packaging problem, says Paap of Jac. Vandenberg. “Consumers want brands and companies to be environmentally responsible without a significant change in product cost,” he says. “We have to be willing to compromise on cost of goods in the short term to protect ourselves in the future where the cost will be inevitably higher — not just for the goods, but for our overall livelihoods and environment.”

The tough part is the ticket price, agrees Yokes’ Sullivan. “Price can be a sticker shock,” he says. “It’s hard to get shoppers to pay the extra premium for the product. We must overcome consumer perception.”

One solution, according to Paap, is education. “On the front end of the supply chain, we need to do a better job telling the story about these packaging innovations. Retailers then need to take this information and share the story, in partnership with their suppliers, at the store level.

“The worst thing you can do is put something that looks completely different on the shelves without any explanation.”