Click here to Gal`s presentation.

New shelf-life extending
films for fresh produce
packaging
London Produce Show
June 3-5, 2015
Gal Wollach, VP International Sales
Synopsis
• R.O.P corporate overview
• Fresh Produce food losses
• Packing fresh produce
• Fresh produce physiology
• EMAP and MHP in fresh produce
TM
• ExtendCast Banana case study
• Solutions for additional fruits and vegetables
• Conclusion
3
R.O.P corporate overview
• Founded on 1970
• Privately owned
• 2 production sites –
• Israel, Czech Republic
• Casting multilayer PP, PE, PA,
PS - 12μ to 200μ
Slitting, Printing, Bags
• ISO 9001:2008; ISO 22000
4
R.O.P markets served
• Fresh Produce
• Processed food
• Bread and Pastry
• Stationary
• Industrial film
5
Global yearly food loss
UNEP 2013
6
Produce loss in the value chain
FAO 2011
Loss not incl. consumers
Retail chains
Depots
facilities
Harvest
Apple
Citrus
Grapes
Bananas
Cucumbers Peppers Potatoes
Packing
Tomatoes
IL Ministry
of Ag.
8
% loss in retail
Loss in retail
Apple
Peppers
Citrus
Potatoes
Grapes
Bananas
Tomatoes
Cucumbers
IL Ministry
of Ag.
9
Wastage
Direct wastage
• Weight loss
• Aging, “Use by” dates,
bundling
• Produce bruising
• Package breakage
Indirect wastage
• transportation and logistics
• Inflexibility
• Consumer claims
10
Motivations for packing produce
• Minimizing wastage
• Extending the product’s shelf
life
taste, texture, looks, nutritious
values; Inhibit Fungus and
Bacteria
• Protect from mechanical
bruising
• Hygienic & health concerns
• Retail drives
11
Fresh Produce
At the moment of harvest, produce is at its
‘absolute freshness’
/ From this point on produce begins to deteriorate.
/ This process is irreversible.
- By using proper post-harvest protocols, this process
may be dramatically slowed.
12
Fresh Produce physiology
Preharvest
Heat
13
Fresh Produce physiology
Post Heat harvest
C2H
C2H4
H4
v
Ethyle
ne
e
14
Deterioration of produce
• Oxygen - nutrient loss, change in color and
taste
• Carbon dioxide – discoloration of damaged
tissue,
fungus suppression, anaerobic respiration
• Ethylene – maturing speed, texture and flavor
change
• Moisture – wilting and shriveling, loss of
crispiness,
leathering, splitting, microbial
growth,
accentuation of pitting and other
chilling injuries
15
Deterioration of produce
Produce
Optimal conditions for preserving post-harvest
produce
Ethylene
Temp C
% Relative
humidity
% O2
% CO2
Expels
Sensitive
12-15
90-100
8-15
3-10
+
+
Bean sprouts
0
90-98
5
15
+
Mushrooms
0-5
90-98
5
10
12-20
90-98
3-5
5-10
+
+
Cauliflower /
Broccoli
0-5
90-95
2
5
+
++
Cucumber
8-12
90-95
3-5
0
++
Head of
lettuce
0-5
95
2-5
0
++
Capsicums
8-12
90-95
3-5
2
Grape fruit
10-15
85-90
3-10
5-10
Peach
0-5
90
1-2
Apple
0-5
90
Pear
0-5
Plum
Strawberry
Banana
Tomato
+
+
+
5
+++
+
2-3
1-2
+++
+
90-95
2-3
0-1
+++
+
0-5
90-95
3
8
0-5
85-95
10
15-20
Source: Danish Technological Institute - Packaging and Transport, 2008
+
16
Deterioration of produce
Temperature impact on respiration rate - ml. CO2 per 1 Kg.
of produce per 1 hour
Temperature (°C)
0
Apricot
5
2-4
Avocado
10-25
10
15
20
6-10
15-25
25-80
40-150
Banana
12-40
20-70
Blackberry
11
31
78
Blueberry
3
9
34
Cantaloupes
2-3
4-5
7-8
Cherries
3-5
5-9
15-17
22-28
Grapes
1-2
3-4
5-8
12-15
3-5
7-9
12-16
20-27
3-4
5-7
9-12
15-20
3-5
5-8
6-10
Honeydew
Kiwi
1.5-2
Lime
Litchi
5-8
Mango
Strawberry
Watermelon
10-15
12-16
6-10
3-4
17-20
23-33
25-40
19-28
35-80
25-50
50-100
6-9
17-25
17
*
EMAP and MHP for produce
Equilibrium Modified Atmosphere
Packagingpassively balancing of gases inside the
package by engineering selectively “breathable” films
Modified Humidity Packaging –
passively balancing of humidity levels
inside the package by engineering
selectively water
vapor transmitting films
18
EMAP and MHP for produce
The film / bag needs to be:
• Selectively permeable to different gases
• Selectively permeable to water vapor
• High tear strength and elongation; Ease of
handling
• Non reactant with Produce; Nontoxic
• Have AF properties
• Lightweight
• Good transparency, gloss and printability
• Good heat sealability; Good machinability
• Recyclable
19
Cast Polypropylene
• High transparency and gloss
• Exceptional sealing and durability
Lamina
te
• Controllable OTR and MVTR
BOPP
CPP
PE
• Embedded AF
• Good machinability and handling
PA
• 100% recyclable
20
EMAP and MHP key factors
Understanding the post-harvest process
•
•
•
•
•
Harvest
Cleaning, packing, storage
Shipping
Ripening, repacking, distribution
Retail storage and display
Analyzing the content
•
•
•
•
Volume of content
Shape/ surface area of content
Maturity of content
Package form factor
21
EMAP and MHP key factors
Gas and Moisture control
•
•
•
•
•
Film composition
Film diffusion characteristics
Film gauge
Perforation size, density and location
ation
Additives and Coatings
22
TM
ExtendCast Banana case study
23
TM
ExtendCast Banana case study
Background:
harvest + pack 1-7
days
retail 3-7
days
ripening + repacking 38 days
transportation 421 days
24
TM
ExtendCast Banana case study
Goals:
• Slow down the aging progress up to 12 days
post-ripening
• Minimize weight loss
• Maintain high levels of flavor, texture and
appearance
• Ripen through retail bags (replacing box
liners)
25
TM
ExtendCast Banana case study
Protocol:
• Green bananas were cut off the tree and
washed
• Packing 1 Kg in bag variants – 30 specimens
each
• A – Control unpacked
• C – ExtendCast Banana
• E – PP Macroperf. *
• Ripening for 3-4 days in a ripening facility at
* Types B and D not presented for simplification reasons
13C
26
TM
ExtendCast Banana case study
Parameters:
» Organoleptic evaluation – aroma and taste
by a digital refractometer and a focus group.
» Firmness –FT-327 penetrometer with 11mm
SS plunger tip.
» Atmosphere in bag – CheckPoint gas analyzer
nalyyzer
» Ripening stage – visual, universal standard
stan
ndard
ripening chart
» Skin condition – visual
27
TM
ExtendCast Banana case study
Banana ripening chart
TM
ExtendCast Banana case study
Experiment days 1 and 6 post - ripening
Extend
Cast
PP
Macroperf.
Cont
rol
Day
1
Day
6
29
TM
ExtendCast Banana case study
Experiment days 8 and 11 post - ripening
Extend
Cast
PP
Macroperf.
Cont
rol
Day
8
Day
11
30
ExtendCast Banana case study
31
TM
ExtendCast Banana case study
Gas composition @ retail conditions by days
25.0
O2
CO2
O2 / CO2 (%)
20.0
15.0
10.0
CO2
criteria
5.0
0.0
0
5
Days after ripening
10
32
TM
ExtendCast Banana case study
Banana weight loss post-ripening after 10 days in
retail conditions
Extend
XC-6,
62PH 150umPPXC-6, 8PH 9mm Cont
Unpacked
Cast
Macroperf. rol
-1%
Weight Loss (%)
-4%
-0.6%
-3.5%
-7%
-10%
-13%
-16%
-19%
-22%
-21.5%
33
TM
ExtendCast Banana case study
Banana ripening chart according to skin color
8
Ripening stage
7
6
5
4
3
2
1
0
0
2
4
6
8
Days after ripening
ExtendCast
PP Macroperf.
10
12
34
TM
ExtendCast Banana case study
firmne
ss
Ripe
Over
ripe
Unripe
flavor
Ripe
Over
ripe
Firmness (Relative units)
Un-rip
e
Taste (Relative units)
Correlation between ripening stage and
firmness / flavor
1
2
1
2
Ripening Stage (color index)
3
4
5
6
7
6
7
1
2
3
4
5
3
4
5
1
2
3
4
5
ExtendCast
35
TM
ExtendCast Banana case study
Synchronized ripening parameters
Normal Ripening Process - Firmness
8
Firmness (Kg)
7
6
5
4
3
2
1
0
1
2
3
4
Ripening Stage
5
6
7
36
TM
ExtendCast Banana case study
Synchronized ripening parameters
Yellow unripe banana
Green soft banana
37
TM
ExtendCast Banana case study
Respiration control effect on harvest-stage
bruising
Day 6
Day
10
38
TM
ExtendCast Banana case study
conclusion:
• XC-Banana extends banana retail shelf life up to
double compared to un-packed (naked) and PP
microperfirated bagged bananas.
• XC-Banana keeps all marketing - required banana
values
• XC-Banana prevents weight loss up to 21.5%
21..5%
• XC-banana delays manifestation of bruising
ng
discoloration,
39
ExtendCast Asparagus
TM
Weight loss 3%
Weight loss 27%
40
ExtendCast Cauliflower
TM
41
TM
ExtendCast Broccoli
42
TM
ExtendCast Cabbage
18 days postharvest
28 days postharvest
43
Thank You
[email protected]