Speaker 9 Mr Mark Barthel Special Adviser Retail Innovation Team WRAP mark.barthel@wrap.org.uk
Integrity Seal Case Study
Drivers for change • Why does the fresh cut produce industry need a superior seal system on bagged fresh produce? � Reduce packaging material use � Improve product quality � Longer shelf life to maximize profits � Improve operational efficiencies and lower manufacturing costs
Current sealing technology
Typical cross seal failures • Creases and folds on crimp seals are not hermetic, so the film barrier is impaired
New Integrity Seal™ technology • Bead weld cross seal which produces a hermetic seal
New Integrity Seal™ technology • Produces a hermetic seal even when creases are present
The commercial system • Control unit • Jaw system • Water chiller
New Integrity Seal™ technology • Extensive 3 year development programme • Engineering partners Ceetak Ltd • System Engineering and Development • Bespoke Installation and Field Service • Funding through WRAP’s Innovation Fund • Marks & Spencer • Tilmanstone Salads (Geest, Vitacress Salads, Exotic Farm Produce) • United Biscuits (KP) • Successful commercial trials • Technically proven to give longer shelf life • Positive consumer research and in-store acceptance • • •
Successful commercial trials • Over 600,000 packs made during the recent 3 month trial for Marks & Spencer: • Products packed : • Block Bottom - Iceberg and Summer Salad • Pillow pack - Spinach • Machine used – intermittent motion Sandiacre bagging machine • Line speeds consistently 10 -15 % faster • No packs leave the factory with product trapped in the seal • Integrity Seal cuts through fleshy leaves and still makes an hermetic seal • Integrity Seal does not make a seal if larger leaves or stalks are present – the bag remains open so easily seen and removed from the line • Rework down to between 1 and 5 % depending on ingredient characteristics • • •
New Integrity Seal™ technology Net Machine Efficiency Comparisons Line 1 - Iceberg - Summer Salad - Spinach Line 2 - All other baggeds salads 90 80 70 60 50 40 30 20 10 0 7 7 7 7 7 7 7 7 7 7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 2 2 2 2 2 2 2 2 2 / / / / / / / / / / 0 0 0 0 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 / / / / / / / / / / 9 6 3 0 6 3 0 7 4 1 0 1 2 3 0 1 2 2 0 1 Line 1 Integrity Seal Line 2 Crimp Seal
Benefits - Extended shelf life • Oxygen sensitive varieties • 50 % increase • Iceberg - extended from 5 to 8 days • Potential for 10 days plus • Baby leaf non-sensitive varieties • 30% increase • Spinach – extended from 7 to 9 days Offers improved supply chain flexibility
Benefits- extended shelf life Pack on left 5 days old Pack on right 11 days old
• Benefits - block bottom or pillow pack style
Benefits - a perfect seal • Better appearance, no folds, no wrinkles or ripples
Benefits- less packaging • The bag is shorter giving typically 10% - 15% saving in film usage
Other benefits (1) • 10 - 15% faster line speed and efficiencies • Less product reworking – potential savings > 10% • Easy to open • Reduced in-store spoilage and shrink • Improved appearance – no over heated seals • Easier maintenance and less down time • Wipe clean jaws – no burn on • Ready to use – no preheat time required • IP 65 rated electrics - low voltage elements
Other benefits (2) • Works on straight or gusseted seals • Works on all Polymer film types OPP, OPP/PE, metallised PET, PLA • Gusseted bags stand better • Easily retrofitted to existing bagging machines • Can be fitted to any new bagging machines • Safer to operate – jaw cooling after every cycle
Other applications
Thank you
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