special adviser retail innovation team - food and drink ... barthel - presentation.pdf• bespoke...
TRANSCRIPT
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Integrity Seal
Case Study
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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 useImprove product quality Longer shelf life to maximize profitsImprove 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™ technologyNet Machine Efficiency Comparisons
Line 1 - Iceberg - Summer Salad - SpinachLine 2 - All other baggeds salads
0
10
20
30
40
50
60
70
80
90
09/10
/2007
16/10
/2007
23/10
/2007
30/10
/2007
06/11
/2007
13/11
/2007
20/11
/2007
27/11
/2007
04/12
/2007
11/12
/2007
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 oldPack 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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Thank you