Benefits for beans: StePac’s Xtend packaging reduces food loss in US post-harvest production

23 Jan 2020 --- StePac’s automated bulk packaging solutions have reduced food loss in the US foodservice sector, most recently witnessed in packaged green beans. The fresh produce packaging supplier’s modified atmosphere bulk packaging – under the brand name Xtend – is custom engineered for each individual fruit or vegetable type. This innovation marks a significant step toward eliminating food waste and loss (FWL) in the post-harvest production cycle, the 12th of the UN’s Sustainable Development Goals (SDG 12).

“Over the years, StePac has designed tailor-made packaging solutions in various formats for over 50 different fresh produce items,” Dr. Gary Ward, Business Development Manager for StePac, tells PackagingInsights.

“One of the biggest obstacles in developing any modified atmosphere bulk packaging (MAP) solution is to ensure that the packaging provides the value that the customer seeks and at the same time is robust enough to tolerate real life supply chain conditions. This requires a combination of basic research in our post-harvest lab to determine optimal film properties for the application, followed by rigorous applied research to test the packaging,” he continues.

A multifaceted problem, food waste affects the entire global food value chain, says Dr. Ward. Amid rising environmental concerns regarding FWL, StePac unveiled its four-pillared strategy for greener packaging last October to support climate-positive plastic packaging. 

Moreover, supermarkets rejecting approximately 25 percent of crops produced by farms, poor post-harvest handling practices, handling damage at stores and depots, poor supply chain management and household waste are all contributors to the problem.

Fresh taste preserved
The green beans’ Xtend packaging delivers on preserving the quality, crispiness and glossy green color of fresh green beans. Likewise, it prevents excessive weight loss caused by dehydration while maintaining full flavor and nutritional value, the company notes. 

“Xtend packaging is typically thinner than conventional packaging. The mechanical properties of the films that we employ often allow us to go down to thicknesses of as low as 17 micron for certain applications. As such, our films can be considered as lean,” Dr. Ward explains.

StePac’s automated bulk packaging solutions have reduced food loss in the US foodservice sector.The company's solutions are also not limited to green beans, but extend to a range of other vegetables, such as peas, carrots, broccoli, brussels sprouts and others that are freshly bulk packed exclusively for the foodservice sector. 

Xtend Modified Atmosphere/Modified Humidity packaging is engineered so that the packed produce equilibrates within the optimal range of O2 and CO2 concentrations for that specific fruit or vegetable. This slows senescence and ripening processes and inhibits the growth of pathogens, thereby reducing decay. In addition, the relative humidity in Xtend packaging increases to 90-95 percent.

StePac affirms that this kind of packaging technology holds the potential to reduce logistical costs associated with land and sea freight, offers brand enhancement and season extension, as well as expanding product market reach.

Product packaging challenges
In the US, peak season for green beans takes place during November and May. As green beans have a short shelf-life of eight to 12 days, it is important to get the produce packed and shipped quickly, while reducing as much food loss and waste as possible. 

A common post-harvest problem, dehydration causes the bean pods to shrivel and become limp. StePac’s modified atmosphere packaging films are inbuilt with ideal water vapor transmission rates (WVTR). These eliminate the excess moisture from fresh green bean packaging that can aggravate russeting – reddish-brown spots that result from chilling injury when beans are stored at 5-7.5°C (41-45°F). 

In terms of recyclability, StePac has a broad portfolio of film structures in its portfolio, which can be recycled. While some are fully recyclable, supporting a circular economy, others can only be used for downstream applications, Dr. Ward explains. 

All Xtend packaging films are manufactured with raw materials that comply with international regulations and are suitable for direct contact with whole fruits and vegetables, fresh or chilled and processed fruits and vegetables.

By Anni Schleicher