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Speaker 9
Mr Mark Barthel Special Adviser Retail Innovation Team
WRAP
mark.barthel@wrap.org.uk
Speaker 9 Mr Mark Barthel Special Adviser Retail Innovation Team - - PowerPoint PPT Presentation
Speaker 9 Mr Mark Barthel Special Adviser Retail Innovation Team - - PowerPoint PPT Presentation
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?
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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
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Current sealing technology
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Typical cross seal failures
- Creases and folds on crimp seals are not
hermetic, so the film barrier is impaired
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New Integrity Seal™ technology
- Bead weld cross seal which produces a
hermetic seal
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New Integrity Seal™ technology
- Produces a hermetic seal even when
creases are present
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- Control unit
- Jaw system
- Water chiller
The commercial system
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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
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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
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New Integrity Seal™ technology
Net Machine Efficiency Comparisons Line 1 - Iceberg - Summer Salad - Spinach Line 2 - All other baggeds salads
10 20 30 40 50 60 70 80 90 9 / 1 / 2 7 1 6 / 1 / 2 7 2 3 / 1 / 2 7 3 / 1 / 2 7 6 / 1 1 / 2 7 1 3 / 1 1 / 2 7 2 / 1 1 / 2 7 2 7 / 1 1 / 2 7 4 / 1 2 / 2 7 1 1 / 1 2 / 2 7 Line 1 Integrity Seal Line 2 Crimp Seal
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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
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Benefits- extended shelf life
Pack on left 5 days old Pack on right 11 days old
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- Benefits - block bottom or pillow pack style
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Benefits - a perfect seal
- Better appearance, no folds, no wrinkles or ripples
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- The bag is shorter giving typically 10% - 15% saving in film usage
Benefits- less packaging
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- 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 (1)
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- 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 benefits (2)
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Other applications
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