In today’s fresh produce industry, the severe shortage of labor coupled with rising labor costs is driving a push toward automation. This shift is particularly prevalent in the food service sector, where operational efficiency and product freshness directly impact the bottom line.

StePacPPC, a supplier of advanced modified atmosphere/modified humidity (MA/MH) packaging solutions, has responded to this challenge with innovative technology specifically designed for bulk automated packing that addresses these workforce challenges while extending shelf life.

When automation meets preservation
Foodservice contributes to nearly 30% of global food waste (290 million tons). Approximately half of this waste is linked to raw fruits and vegetables, with items like mushrooms and green beans being especially vulnerable. StePacPPC’s Xflow™ films offer a breakthrough for addressing this waste with patented sealing technology for both HFFS and VFFS operations.

“Our technology simultaneously addresses labor reduction and shelf-life extension, creating a compelling value proposition as labor costs rise,” said Dr. Gary Ward, CTO of StePacPPC.

Customized preservation through science
StePacPPC’s approach to packaging is product preservation. Each film is customized to address the specific needs of different produce types, considering key factors including respiration rates, moisture sensitivity, dehydration risk, required atmospheric conditions, post-harvest handling, and supply chain considerations,

StePacPPC’s food packaging tech in a nutshell
The technology’s power lies in the relatively high water vapor transmission rates (WVTR) of the films used, which help prevent moisture buildup — the primary culprit behind microbial decay and quality degradation in highly perishable items. This targeted moisture management, combined with modified atmosphere properties, significantly extends shelf life while maintaining product quality.

Real-world success: green beans
In collaboration with Windham Packaging, PEA King Produce saw impressive results with StePacPPC’s films for five-pound green bean bundles. Operations Manager Miguel Ibarra reported a 5% reduction in scrap rate, faster sealing times, and improved efficiency. The film’s superior humidity management and modified atmosphere also increased shelf-life by 10%, enhancing customer satisfaction and reducing waste.

Mushroom packaging: extending the shelf life from days to weeks
The impact of StePacPPC’s technology is notably evident in the mushroom sector, traditionally limited to days of shelf life. Once again in collaboration with their USA partner, Windham Packaging, StePacPPC’s customer; Basciani Foods*, achieved remarkable results despite mushrooms’ high metabolic activity and moisture generation.

Fred Recchiuti reported on “freshness preservation for as long as 18 days!” This extension from days to weeks represents a paradigm shift for the industry. CEO Michael Basciani, whose company directs 80% of production to foodservice, also noted:

“StePacPPC’s Xflow™ Technology improved food safety through tamper-proof packaging in addition to a 94.7% reduction in plastic use compared to previous packaging,” said Michael Basciani, CEO of Basciani Foods.

Sustainability by design
In an era of increasing environmental consciousness, StePacPPC’s lean packaging delivers sustainability benefits precisely aligned with industry goals, such as reduced plastic usage compared to traditional packaging, availability of up to 30% chemically recycled material with RedCert2 accreditation, less food waste through extended shelf life as well as optimized logistics that reduce carbon footprint.

The future of fresh produce packaging
As the labor crisis continues to challenge the fresh produce industry, automation solutions that simultaneously enhance product quality will become increasingly essential. StePacPPC’s Xflow™ technology represents a significant advancement in this direction, providing a solution that addresses operational efficiency, food waste reduction, and sustainability goals while helping companies navigate workforce shortages. Win-Win.

Picture sourced from UMDIS

Bottom line
For food service operations grappling with rising costs and quality concerns, the ability to extend shelf life while reducing labor requirements offers a compelling path forward. By integrating cutting-edge materials science with practical automation solutions, StePacPPC is helping to shape a more efficient and sustainable future for fresh produce packaging.

References
* Basciani Foods quotes and photos are sourced from the article ‘Interview and lots of photos from American mushroom farm Basciani’ published by UMDIS Mushroom Agency on April 4, 2024.