Packaging Requirements For Fresh Fruits And Vegetables

Introduction(starch), and other materials to give it wet
Packaging fresh fruits and vegetables is one ofstrength and printability. Most fiberboard contains
the more important steps in the long andsome recycled fibers. Minimum amounts of
complicated journey from grower to consumer.recycled materials may be specified by law and
Bags, crates, hampers, baskets, cartons, bulk bins,the percentage is expected to increase in the
and palletized containers are convenient containersfuture. Tests have shown that cartons of fully
for handling, transporting, and marketing freshrecycled pulp have about 75 percent of the
produce. More than 1,500 different types ofstacking strength of virgin fiber containers. The
packages are used for produce in the U.S. and theuse of recycled fibers will inevitably lead to the
number continues to increase as the industryuse of thicker walled containers.
introduces new packaging materials and concepts.Double-faced corrugated fiberboard is the
Although the industry generally agrees thatpredominant form used for produce containers. It
container standardization is one way to reduceis produced by sandwiching a layer of corrugated
cost, the trend in recent years has movedpaperboard between an inner and outer liner
toward a wider range of package sizes to(facing) of paper-board. The inner and outer liner
accommodate the diverse needs of wholesalers,may be identical, or the outer layer may be
consumers, food service buyers, and processingpreprinted or coated to better accept printing.
operations.The inner layer may be given a special coating to
Packing and packaging materials contribute aresist moisture.
significant cost to the produce industry; thereforeHeavy-duty shipping containers, such as
it is important that packers, shippers, buyers, andcorrugated bulk bins that are required to have
consumers have a clear understanding of thehigh stacking strength, may have double- or even
wide range of packaging options available. Thistriple-wall construction. Corrugated fiberboard
fact sheet describes some of the many types ofmanufacturers print box certificates on the
packaging, including their functions, uses, andbottom of containers to certify certain strength
limitations. Also included is a listing, by commodity,characteristics and limitations. There are two
of the common produce containers standard totypes of certification. The first certifies the
the industry.minimum combined weight of both the inner and
The Function of Packaging or Why packageouter facings and that the corrugated fiberboard
Produce?material is of a minimum bursting strength. The
A significant percentage of produce buyer andsecond certifies minimum edge crush test (ETC)
consumer complaints may be traced to containerstrength. Edge crush strength is a much better
failure because of poor design or inappropriatepredictor of stacking strength than is bursting
selection and use. A properly designed producestrength. For this reason, users of corrugated
container should contain, protect, and identify thefiberboard containers should insist on ECT
produce, satisfying everyone from grower tocertification to compare the stackability of various
consumer.containers. Both certificates give a maximum size
PACKAGING POINTSlimit for the container (sum of length, width, and
Recyclability/Biodegradability.height) and the maximum gross weight of the
A growing number of U.S. markets and manycontents.
export markets have waste disposal restrictionsBoth cold temperatures and high humidities reduce
for packaging materials. In the near future, almostthe strength of fiberboard containers. Unless the
all produce packaging will be recyclable orcontainer is specially treated, moisture absorbed
biodegradable, or both. Many of the largest buyersfrom the surrounding air and the contents can
of fresh produce are also those most concernedreduce the strength of the container by as much
about environmental issues.as 75 percent. New anti-moisture coatings (both
Variety.wax and plastic) are now available to substantially
The trend is toward greater use of bulk packagesreduce the effects of moisture.
for processors and wholesale buyers and smallerWaxed fiberboard cartons (the wax is about 20
packages for consumers. There are now morepercent of fiber weight) are used for many
than 1,500 different sizes and styles of produceproduce items that must be either hydrocooled or
packages.iced. The main objection to wax cartons is
Sales Appeal.High quality graphics are increasinglydisposal after use- wax cartons cannot be
being used to boost sales appeal. Multi-colorrecycled and are increasingly being refused at
printing, distinctive lettering, and logos are nowlandfills. Several states and municipalities have
common.recently taxed wax cartons or have instituted
Shelf Life.rigid back haul regulations. Industry sources
Modern produce packaging can be customsuggest that wax cartons will eventually be
engineered for each commodity to extend shelfreplaced by plastic or, more likely, the use of ice
life and reduce waste.and hydrocooling will be replaced by highly
Containmentcontrolled forced-air cooling and rigid temperature
The container must enclose the produce inand humidity maintenance on many commodities.
convenient units for handling and distribution. TheIn many applications for corrugated fiberboard
produce should fit well inside the container, withcontainers, the stacking strength of the container
little wasted space. Small produce items that areis a minor consideration. For example, canned
spherical or oblong (such as potatoes, onions, andgoods carry the majority of their own weight
apples) may be packaged efficiently utilizing awhen stacked.
variety of different package shapes and sizes.Fresh produce usually cannot carry much of the
However, many produce items such asvertical load without some damage. Therefore,
asparagus, berries, or soft fruit may requireone of the primarily desired characteristics of
containers specially designed for that item.corrugated fiberboard containers is stacking
packages of produce commonly handled by handstrength to protect the produce from crushing.
are usually limited to 50 pounds. Bulk packagesBecause of their geometry, most of the stacking
moved by fork lifts may weigh as much as 1,200strength of corrugated containers is carried by
pounds.the corners. For this reason, hand holes and
Protectionventilation slots should never be positioned near
The package must protect the produce fromthe corners of produce containers and be limited
mechanical damage and poor environmentalto no more than 5 to 7 percent of the side area.
conditions during handling and distribution. ToInterlocking the packages (cross stacking) is
produce buyers, torn, dented, or collapseduniversally practiced to stabilize pallets. Cross
produce packages usually indicate lack of care instacking places the corner of one produce
handling the contents. Produce containers must bepackage at the middle of the one below it, thus
sturdy enough to resist damage during packaging,reducing its stacking strength. To reduce the
storage, and transportation to market.possibility of collapse, the first several layers of
Because almost all produce packages areeach pallet should be column stacked (one
palletized, produce containers should havepackage directly above the other). The upper
sufficient stacking strength to resist crushing in alayers of packages may be cross stacked as
low temperature, high humidity environment.usual with very little loss of pallet stability.
Although the cost of packaging materials hasThere are numerous styles of corrugated
escalated sharply in recent years, poor quality,fiberboard containers. The two most used in the
lightweight containers that are easily damaged byproduce industry are the one piece, regular slotted
handling or moisture are no longer tolerated bycontainer (RSC) and the two piece, full telescoping
packers or buyers.container (FTC). The RSC is the most popular
Produce destined for export markets requiresbecause it is simple and economical. However, the
that containers to be extra sturdy. Air-freightedRSC has relatively low stacking strength and
produce may require special packing, packagetherefore must be used with produce, such as
sizes, and insulation. Marketers who export freshpotatoes, that can carry some of the stacking
produce should consult with freight companiesload. The FTC, actually one container inside
about any special packaging requirements.another, is used when greater stack- ing strength
Additionally, the USDA and various state exportand resistance to bulging is required. A third type
agencies may be able to provide specificof container is the Bliss box, which is -
packaging information.constructed from three separate pieces of
Damage resulting from poor environmental controlcorrugated fiberboard. The Bliss box was
during handling and transit is one of the leadingdeveloped to be used when maximum stacking
causes of rejected produce and low buyer andstrength is required. The bottoms and tops of all
consumer satisfaction. Each fresh fruit andthree types of containers may be closed by glue,
vegetable commodity has its own requirementsstaples, or interlocking slots.
for temperature, humidity, and environmental gasAlmost all corrugated fiberboard containers are
composition.shipped to the packer flat and assembled at the
Produce containers should be produce friendly -packing house. To conserve space, assembly is
helping to maintain an optimum environment forusually performed just before use. Assembly may
the longest shelf life. This may include specialbe by hand, machine, or a combination of both.
materials to slow the loss of water from theEase of assembly should be carefully investigated
produce, insulation materials to keep out the heat,when considering a particular style of package.
or engineered plastic liners that maintain aIn recent years, large double-wall or even triple-
favorable mix of oxygen and carbon dioxide.wall corrugated fiberboard containers have
Identificationincreasingly been used as one-way pallet bins to
The package must identify and provide usefulship bulk produce to processors and retailers.
information about the produce. It is customaryCabbage, melons, potatoes, pumpkins, and citrus
(and may be required in some cases) to providehave all been shipped successfully in these
information such as the produce name, brand,containers. The container cost per pound of
size, grade, variety, net weight, count, grower,produce is as little as one fourth of traditional size
shipper, and country of origin. It is also becomingcontainers. Some bulk containers may be
more common to find included on the package,collapsed and re-used.
nutritional information, recipes, and other usefulFor many years, labels were printed on heavy
information directed specifically at the consumer.paper and glued or stapled to the produce
In consumer marketing, pack- age appearancepackage. The high cost of materials and labor has
has also become an important part of point ofall but eliminated this practice. The ability to print
sale displays.the brand, size, and grade information directly on
Universal Product Codes (UPC or bar codes) maythe container is one of the greatest benefits of
be included as part of the labeling. The UPCs usedcorrugated fiberboard containers. There are
in the food industry consist of a ten-digit machinebasically two methods used to print corrugated
readable code. The first five digits are a numberfiberboard containers:
assigned to the specific producer (packer orPost Printed. When the liner is printed after the
shipper) and the second five digits representcorrugated fiberboard has been formed, the
specific product information such as type ofprocess is known as post printing. Post printing is
produce and size of package. Although no pricethe most widely used printing method for
information is included, UPCs are used more andcorrugated fiberboard containers because it is
more by packers, shippers, buyers, and Exampleeconomical and may be used for small press runs.
of a UPC retailers as a fast and convenientHowever, postprinting produces graphics with less
method of inventory control and cost accounting.detail and is usually limited to one or two colors.
Efficient use of UPCs requires coordination withPreprinted. High quality, full-color graphics may be
everyone who handles the package.obtained by preprinting the linerboard before it is
Types of Packaging Materialsattached to the corrugated paperboard. Whereas
Woodthe cost is about 15 percent more than standard
Pallets literally form the base on which most freshtwo color containers, the eye catching quality of
produce is delivered to the consumer. Pallets werethe graphics makes it very useful for many
first used during World War II as an efficient waysituations. The visual quality of the package
to move goods. The produce industry usesinfluences the perception of the product because
approximately 190 of the 700 million palletsthe buyer's first impression is of the outside of
produced per year in the U.S.. About 40 percentthe package. Produce managers especially like high
of these are single-use pallets. Because many arequality graphics that they can use in super market
of a non-standard size, the pallets are built asfloor displays.
inexpensively as possible and discarded after aPreprinted cartons are usually reserved for the
single use. Although standardization efforts haveintroduction of new products or new brands.
been slowly under way for many years, theMarket research has shown that exporters may
efforts have been accelerated by pressure frombenefit from sophisticated graphics. The increased
environmental groups, in addition to the rising costcost usually does not justify use for mature
of pallets and landfill tipping fees.products in a stable market, but this may change
Over the years, the 40-inch wide, by 48-inch longas the cost of these containers becomes more
pallet has evolved as the unofficial standard size.competitive.
Standardization encourages re-use, which hasPulp Containers. Containers made from recycled
many benefits. Besides reducing cost becausepaper pulp and a starch binder are mainly used for
they may be used many times, most pallet rackssmall consumer packages of fresh produce. Pulp
and automated pallet handling equipment arecontainers are available in a large variety of
designed for standard-size pallets. Standard sizeshapes and sizes and are relatively inexpensive in
pallets make efficient use of truck and van spacestandard sizes. Pulp containers can absorb surface
and can accommodate heavier loads and moremoisture from the product, which is a benefit for
stress than lighter single-use pallets. Additionally,small fruit and berries that are easily harmed by
the use of a single pallet size could substantiallywater. Pulp containers are also biodegradable,
reduce pallet inventory and warehousing costsmade from recycled materials, and recyclable.
along with pallet repair and disposal costs. ThePaper and Mesh Bags. Consumer packs of
adoption of a pallet standard throughout thepotatoes and onions are about the only produce
produce industry would also aid efforts towarditems now packed in paper bags. The more
standardization of produce containers.sturdy mesh bag has much wider use. In addition
In the early 1950s, an alternative to the palletto potatoes and onions, cabbage, turnips, citrus,
was introduced. It is a pallet-size sheet (slipsheet)and some specialty items are packed in mesh
of corrugated fiberboard or plastic (or abags. Sweet corn may still be packaged in mesh
combination of these materials) with a narrow lipbags in some markets. In addition to its low cost,
along one or more sides. packages of produce aremesh has the advantage of uninhibited air flow.
stacked directly on this sheet as if it were a pallet.Good ventilation is particularly beneficial to onions.
Once the packages are in place, they are movedSupermarket produce managers like small mesh
by a specially equipped fork lift equipped with abags because they make attractive displays that
thin metal sheet instead of forks.stimulate purchases.
Slipsheets are considerably less expensive thanHowever, bags of any type have several serious
pallets to buy, store, and maintain; they may bedisadvantages. Large bags do not palletize well and
re-used many times; and they reduce the taresmall bags do not efficiently fill the space inside
weight of the load. However, they require the usecorrugated fiberboard containers. Bags do not
of a special fork-lift attachment at each handlingoffer protection from rough handling. Mesh bags
point from packer to retailer.provide little protection from light or contaminants.
Depending on the size of produce package, aIn addition, produce packed in bags is correctly
single pallet may carry from 20 to over 100perceived by the consumer to be less than the
individual packages. Because these packages arebest grade. Few consumers are willing to pay
often loosely stacked to allow for air circulation, orpremium price for bagged produce.
are bulging and difficult to stack evenly, theyPlastic Bags. Plastic bags (polyethylene film) are
must be secured (unitized) to prevent shiftingthe predominant material for fruit and vegetable
during handling and transit. Although widely used,consumer packaging. Besides the very low
plastic straps and tapes may not have completelymaterial costs, automated bagging machines
satisfactory results. Plastic or paper corner tabsfurther reduce packing costs. Film bags are clear,
should always be used to prevent the strapsallowing for easy inspection of the contents, and
from crushing the corners of packages.readily accept high quality graphics. Plastic films are
Plastic stretch film is also widely used to secureavailable in a wide range of thicknesses and
produce packages. A good film must stretch,grades and may be engineered to control the
retain its elasticity, and cling to the packages.environmental gases inside the bag. The film
Plastic film may conform easily to various sizematerial "breathes" at a rate necessary to
loads. It helps protect the packages from loss ofmaintain the correct mix of oxygen, carbon
moisture, makes the pallet more secure againstdioxide, and water vapor inside the bag.
pilferage, and can be applied using partialSince each produce item has its own unique
automation. However, plastic film severelyrequirement for environmental gases, modified
restricts proper ventilation. A common alternativeatmosphere packaging material must be specially
to stretch film is plastic netting, which is muchengineered for each item. Research has shown
better for stabilizing some pallet loads, such asthat the shelf life of fresh produce is extended
those that require forced-air cooling. Used stretchconsiderably by this packaging. The explosive
film and plastic netting may be difficult to properlygrowth of precut produce is due in part to the
handle and recycle.availability of modified atmosphere packaging.
A very low-cost and almost fully automatedIn addition to engineered plastic films, various
method of pallet stabilization is the application of apatches and valves have been developed that
small amount of special glue to the top of eachaffix to low-cost ordinary plastic film bags. These
package. As the packages are stacked, the gluedevices respond to temperature and control the
secures all cartons together. This glue has a lowmix of environmental gases.
tensile strength so cartons may be easilyShrink Wrap. One of the newest trends in
separated or repositioned, but a high shearproduce packaging is the shrink wrapping of
strength so they will not slide. The glue does notindividual produce items. Shrink wrapping has been
present disposal or recycling problems.used successfully to package potatoes,
Pallet Bins. Substantial wooden pallet bins of milledsweetpotatoes, apples, onions, sweet corn,
lumber or.plywood are primarily used to movecucumbers and a variety of tropical fruit. Shrink
produce from the field or orchard to the packingwrapping with an engineered plastic wrap can
house. Depending on the application, capacitiesreduce shrinkage, protect the produce from
may range from 12 to more than 50 bushels.disease, reduce mechanical damage and provide a
Although the height may vary, the length andgood surface for stick-on labels.
width is generally the same as a standard palletRigid Plastic Packages. packages with a top and
(48 inches by 40 inches). More efficientbottom that are heat formed from one or two
double-wide pallet bins (48 inches by 80 inches)pieces of plastic are known as clamshells.
are becoming more common in some produceClamshells are gaining in popularity because they
operations.are inexpensive, versatile, provide excellent
Most pallet bins are locally made; therefore it isprotection to the produce, and present a very
very important that they be consistent from lotpleasing consumer package. Clamshells are most
to lot in materials, construction, and especially size.often used with consumer packs of high value
For example, small differences in overallproduce items like small fruit, berries, mushrooms,
dimensions Pallet bin can add up to big problemsetc., or items that are easily damaged by crushing.
when several hundred are stacked together forClamshells are used extensively with precut
cooling, ventilation, or storage. It is also importantproduce and prepared salads. Molded polystyrene
that stress points be adequately reinforced. Theand corrugated polystyrene containers have been
average life of a hardwood pallet bin that istest marketed as a substitute for waxed
stored outside is approximately five years. Whencorrugated fiberboard. At present they are not
properly protected from the weather, pallets binsgenerally cost competitive, but as environmental
may have a useful life of 10 years or more.pressures grow, they may be more common.
Uniform voluntary standards for wood pallets andHeavy-molded polystyrene pallet bins have been
other wood containers are administered by theadopted by a number of growers as a substitute
National Wooden Pallet and Container Association,for wooden pallet bins. Although at present their
Washington, DC. Additionally, the Americancost is over double that of wooden bins, they
Society of Agricultural Engineers, St. Joseph,have a longer service life, are easier to clean, are
Michigan, publishes standards for agricultural palletrecyclable, do not decay when wet, do not harbor
bins (ASAE S337.1).disease, and may be nested and made collapsible.
Wire-Bound Crates. Although alternatives areAs environmental pressures continue to grow, the
available, wooden wire-bound crates are useddisposal and recyclability of packaging material of
extensively for snap beans, sweet corn andall kinds will become a very important issue.
several other commodities that requireCommon polyethylene may take from 200 to
hydrocooling. Wire-bound crates are sturdy, rigid400 years to breakdown in a landfill. The addition
and have very high stacking strength that isof 6 percent starch will reduce the time to 20
essentially unaffected by water. Wire-boundyears or less. packaging material companies are
crates come in many different sizes from half-developing starch-based polyethylene substitutes
bushel to pallet-bin size and have a great deal ofthat will break down in a landfill as fast as ordinary
open space to facilitate cooling and ventilation.paper.
Although few are re-used, wire-bound crates mayThe move to biodegradable or recyclable plastic
be dissembled after use and shipped back to thepackaging materials may be driven by cost in the
packer (flat). In some areas, used containers maylong term, but by legislation in the near term.
pose a significant disposal problem. WireboundSome authorities have proposed a total ban on
crates are not generally acceptable for consumerplastics. In this case, the supermarket of the early
packaging because of the difficulty in affixing21st century may resemble the grocery markets
suitable labels.of the early 20th century.
Wooden Crates and Lugs. Wooden crates, onceStandardization of Packaging
extensively used for apples, stone fruit, andProduce package standardization is interpreted
potatoes have been almost totally replaced bydifferently by different groups. The wide variety
other types of containers. The relative expenseof package sizes and material combinations is a
of the container, a greater concern for tareresult of the market responding to demands from
weight, and advances in material handling havemany different segments of the produce industry.
reduced their use to a few specialty items, suchFor example, many of the large-volume buyers of
as expensive tropical fruit. The 15-, 20-, andfresh produce are those most concerned with the
25-pound wooden lugs still used for bunch grapesenvironment. They demand less packaging and
and some specialty crops are being graduallythe use of more recyclable and biodegradable
replaced with less costly alternatives.materials, yet would also like to have many
Wooden Baskets and Hampers. Wire-reinforceddifferent sizes of packages for convenience.
wood veneer baskets and hampers of differentpackers want to limit the variety of packages
sizes were once used for a wide variety of cropsthey must carry in stock, yet they have driven
from strawberries to sweetpotatoes. They arethe trend toward preprinted, individualized
durable and may be nested for efficient transportcontainers. Shippers and trucking companies want
when empty. However, cost, disposal problems,to standardize sizes so the packages may be
and difficulty in efficient palletization have severelybetter palletized and handled.
limited their use to mostly local grower marketsProduce buyers are not a homogeneous group.
where they may be re-used many times.Buyers for grocery chains have different needs
Corrugated Fiberboardthan buyers for food service. For grocery items
Corrugated fiberboard (often mistakenly callednormally sold in bulk, processors want largest size
cardboard or pasteboard) is manufactured inpackages that they can handle efficiently - to
many different styles and weights. Because of itsminimize unpacking time and reduce the cost of
relativity low cost and versatility, it is thehandling or disposing of the used containers.
dominant produce container material and willProduce managers, on the other hand, want
probably remain so in the near future. Theindividualized, high quality graphics to entice retail
strength and serviceability of corrugatedbuyers with in-store displays.
fiberboard have been improving in recent years.Selecting the right container for fresh produce is
Most corrugated fiberboard is made from threeseldom a matter of personal choice for the
or more layers of paperboard manufactured bypacker. For each commodity, the market has
the kraft process. To be considered paperboard,unofficial, but nevertheless rigid standards for
the paper must be thicker than 0.008 inches. Thepackaging; therefore it is very risky to use a
grades of paperboard are differentiated by theirnonstandard package. packaging technology,
weight (in pounds per 1,000 square feet) and theirmarket acceptability, and disposal regulations are
thickness. Kraft paper made from unbleached pulpconstantly changing. When choosing a package for
has a characteristic brown color and isfresh fruits and vegetables, packers must consult
exceptionally strong. In addition to virgin woodthe market, and in some markets, standard
fibers, Kraft paper may have some portion ofpackages may be required by law.
synthetic fibers for additional strength, sizing