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. Heavy-duty shipping containers,
significant cost to the produce industry; thereforesuch as corrugated bulk bins that are required to
it is important that packers, shippers, buyers, andhave high stacking strength, may have double- or
consumers have a clear understanding of theeven triple-wall construction. Corrugated fiberboard
wide range of packaging options available. Thismanufacturers print box certificates on the
fact sheet describes some of the many types ofbottom of containers to certify certain strength
packaging, including their functions, uses, andcharacteristics and limitations. There are two
limitations. Also included is a listing, by commodity,types of certification.
of the common produce containers standard toThe first certifies the minimum combined weight
the industry.of both the inner and outer facings and that the
The Function of Packaging or Why packagecorrugated fiberboard material is of a minimum
Produce?bursting strength. The second certifies minimum
A significant percentage of produce buyer andedge crush test (ETC) strength. Edge crush
consumer complaints may be traced to containerstrength is a much better predictor of stacking
failure because of poor design or inappropriatestrength than is bursting strength. For this reason,
selection and use. A properly designed produceusers of corrugated fiberboard containers should
container should contain, protect, and identify theinsist on ECT certification to compare the
produce, satisfying everyone from grower tostackability of various containers. Both certificates
consumer.give a maximum size limit for the container (sum
PACKAGING POINTSof length, width, and height) and the maximum
Recyclability/Biodegradability.gross weight of the contents.
A growing number of U.S. markets and manyBoth cold temperatures and high humidities reduce
export markets have waste disposal restrictionsthe strength of fiberboard containers. Unless the
for packaging materials. In the near future, almostcontainer is specially treated, moisture absorbed
all produce packaging will be recyclable orfrom the surrounding air and the contents can
biodegradable, or both. Many of the largest buyersreduce the strength of the container by as much
of fresh produce are also those most concernedas 75 percent. New anti-moisture coatings (both
about environmental issues.wax and plastic) are now available to substantially
Variety.reduce the effects of moisture.
The trend is toward greater use of bulk packagesWaxed fiberboard cartons (the wax is about 20
for processors and wholesale buyers and smallerpercent of fiber weight) are used for many
packages for consumers. There are now moreproduce items that must be either hydrocooled or
than 1,500 different sizes and styles of produceiced. The main objection to wax cartons is
packages.disposal after use- wax cartons cannot be
Sales Appeal.High quality graphics are increasinglyrecycled and are increasingly being refused at
being used to boost sales appeal. Multi-colorlandfills. Several states and municipalities have
printing, distinctive lettering, and logos are nowrecently taxed wax cartons or have instituted
common.rigid back haul regulations. Industry sources
Shelf Life.suggest that wax cartons will eventually be
Modern produce packaging can be customreplaced by plastic or, more likely, the use of ice
engineered for each commodity to extend shelfand hydrocooling will be replaced by highly
life and reduce waste.controlled forced-air cooling and rigid temperature
Containmentand humidity maintenance on many commodities.
The container must enclose the produce inIn many applications for corrugated fiberboard
convenient units for handling and distribution. Thecontainers, the stacking strength of the container
produce should fit well inside the container, withis a minor consideration. For example, canned
little wasted space. Small produce items that aregoods carry the majority of their own weight
spherical or oblong (such as potatoes, onions, andwhen stacked. Fresh produce usually cannot carry
apples) may be packaged efficiently utilizing amuch of the vertical load without some damage.
variety of different package shapes and sizes.Therefore, one of the primarily desired
However, many produce items such ascharacteristics of corrugated fiberboard containers
asparagus, berries, or soft fruit may requireis stacking strength to protect the produce from
containers specially designed for that item.crushing. Because of their geometry, most of the
packages of produce commonly handled by handstacking strength of corrugated containers is
are usually limited to 50 pounds. Bulk packagescarried by the corners. For this reason, hand holes
moved by fork lifts may weigh as much as 1,200and ventilation slots should never be positioned
pounds.near the corners of produce containers and be
Protectionlimited to no more than 5 to 7 percent of the
The package must protect the produce fromside area.
mechanical damage and poor environmentalInterlocking the packages (cross stacking) is
conditions during handling and distribution. Touniversally practiced to stabilize pallets. Cross
produce buyers, torn, dented, or collapsedstacking places the corner of one produce
produce packages usually indicate lack of care inpackage at the middle of the one below it, thus
handling the contents. Produce containers must bereducing its stacking strength. To reduce the
sturdy enough to resist damage during packaging,possibility of collapse, the first several layers of
storage, and transportation to market.each pallet should be column stacked (one
Because almost all produce packages arepackage directly above the other). The upper
palletized, produce containers should havelayers of packages may be cross stacked as
sufficient stacking strength to resist crushing in ausual with very little loss of pallet stability.
low temperature, high humidity environment.There are numerous styles of corrugated
Although the cost of packaging materials hasfiberboard containers. The two most used in the
escalated sharply in recent years, poor quality,produce industry are the one piece, regular slotted
lightweight containers that are easily damaged bycontainer (RSC) and the two piece, full telescoping
handling or moisture are no longer tolerated bycontainer (FTC). The RSC is the most popular
packers or buyers.because it is simple and economical.
Produce destined for export markets requiresHowever, the RSC has relatively low stacking
that containers to be extra sturdy. Air-freightedstrength and therefore must be used with
produce may require special packing, packageproduce, such as potatoes, that can carry some
sizes, and insulation. Marketers who export freshof the stacking load. The FTC, actually one
produce should consult with freight companiescontainer inside another, is used when greater
about any special packaging requirements.stack- ing strength and resistance to bulging is
Additionally, the USDA and various state exportrequired. A third type of container is the Bliss box,
agencies may be able to provide specificwhich is - constructed from three separate pieces
packaging information.of corrugated fiberboard. The Bliss box was
Damage resulting from poor environmental controldeveloped to be used when maximum stacking
during handling and transit is one of the leadingstrength is required. The bottoms and tops of all
causes of rejected produce and low buyer andthree types of containers may be closed by glue,
consumer satisfaction. Each fresh fruit andstaples, or interlocking slots.
vegetable commodity has its own requirementsAlmost all corrugated fiberboard containers are
for temperature, humidity, and environmental gasshipped to the packer flat and assembled at the
composition. Produce containers should be producepacking house. To conserve space, assembly is
friendly - helping to maintain an optimumusually performed just before use. Assembly may
environment for the longest shelf life. This maybe by hand, machine, or a combination of both.
include special materials to slow the loss of waterEase of assembly should be carefully investigated
from the produce, insulation materials to keep outwhen considering a particular style of package.
the heat, or engineered plastic liners that maintainIn recent years, large double-wall or even triple-
a 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.
produce and size of package. Although no pricePost printing is the most widely used printing
information is included, UPCs are used more andmethod for corrugated fiberboard containers
more by packers, shippers, buyers, and Examplebecause it is economical and may be used for
of a UPC retailers as a fast and convenientsmall press runs. However, postprinting produces
method of inventory control and cost accounting.graphics with less detail and is usually limited to
Efficient use of UPCs requires coordination withone or two colors.
everyone who handles the package.Preprinted. High quality, full-color graphics may be
Types of Packaging Materialsobtained by preprinting the linerboard before it is
Woodattached to the corrugated paperboard. Whereas
Pallets literally form the base on which most freshthe cost is about 15 percent more than standard
produce is delivered to the consumer. Pallets weretwo color containers, the eye catching quality of
first used during World War II as an efficient waythe graphics makes it very useful for many
to move goods. The produce industry usessituations. The visual quality of the package
approximately 190 of the 700 million palletsinfluences the perception of the product because
produced per year in the U.S.. About 40 percentthe buyer's first impression is of the outside of
of these are single-use pallets. Because many arethe package. Produce managers especially like high
of a non-standard size, the pallets are built asquality graphics that they can use in super market
inexpensively as possible and discarded after afloor displays.
single use. Although standardization efforts havePreprinted cartons are usually reserved for the
been slowly under way for many years, theintroduction of new products or new brands.
efforts have been accelerated by pressure fromMarket research has shown that exporters may
environmental groups, in addition to the rising costbenefit from sophisticated graphics. The increased
of pallets and landfill tipping fees.cost usually does not justify use for mature
Over the years, the 40-inch wide, by 48-inch longproducts in a stable market, but this may change
pallet has evolved as the unofficial standard size.as the cost of these containers becomes more
Standardization encourages re-use, which hascompetitive.
many benefits. Besides reducing cost becausePulp Containers. Containers made from recycled
they may be used many times, most pallet rackspaper pulp and a starch binder are mainly used for
and automated pallet handling equipment aresmall consumer packages of fresh produce.
designed for standard-size pallets. Standard sizePulp containers are available in a large variety of
pallets make efficient use of truck and van spaceshapes and sizes and are relatively inexpensive in
and can accommodate heavier loads and morestandard sizes. Pulp containers can absorb surface
stress than lighter single-use pallets.moisture from the product, which is a benefit for
Additionally, the use of a single pallet size couldsmall fruit and berries that are easily harmed by
substantially reduce pallet inventory andwater. Pulp containers are also biodegradable,
warehousing costs along with pallet repair andmade from recycled materials, and recyclable.
disposal costs. The adoption of a pallet standardPaper and Mesh Bags. Consumer packs of
throughout the produce industry would also aidpotatoes and onions are about the only produce
efforts toward standardization of produceitems now packed in paper bags. The more
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. Since
pilferage, and can be applied using partialeach 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