Diverse and emerging demands ensure continuing variety and opportunities in packaging.
by Bryan Salvage, editor
Just as one package size will never fit all red meat needs, the same can be said about packaging systems. "Down the road, there may be just a few preferred packaging systems that will be in demand [for most fresh and processed meat products] as the cream rises to the top," says the manager of market development for one packaging systems manufacturer. "But for now, we'll continue to have quite a variety of packaging."
"Whether it's a regional vs. a national packer or processor-or steaks vs. ground beef-some [customers] will like modified atmosphere packaging (MAP) and others will like vacuum packaging," he adds. "There will continue to be options to choose from within both categories."
Case-ready fever
One executive at Ashville, N.Y.-based Fairbanks Farms, a manufacturer of fresh case-ready beef, ground beef, pork, sausage and value-added entrees, is among the increasing number of industry executives citing case-ready as a growing trend.
"We utilize two different packaging systems for case-ready beef and pork products," says Bill O'Neill, executive vice president and chief operating officer of Fairbank Farms. "We utilize the overwrap into a master bag system, and we also utilize what we call Fresh-Pak [a modified atmosphere package], which is used primarily for ground products or sausage.
"The technology preferred by retailers is the system that presents the product in a form similar to what consumers have recognized in the past," he adds. "The master bag is probably preferred at this point."
Regarding fresh red meat packaging, O'Neill says that high-oxygen, modified atmosphere packaging will be preferred over vacuum packaging because "consumers want red meat to be red."
O'Neill says the continuing move into case-ready will open new opportunities for regional packers and processors.
"Does [case-ready processing] need to be done closer to the market, or can it be done long distance from the Midwest?" he questions. "We have the technology to pre-package longer shelf-life products with a 21- or 30-day shelf life, which yields the necessary time to ship it across the country.
"Or will there be more decentralized production areas closer to customers?" he adds. "We believe there will ultimately be a large number of satellite facilities that are producing products through retailers and foodservice distributors within a 200-mile radius of the markets.
"The majority of these facilities will be [assembling and packaging] plants; some will slaughter," he says. "Up until now, [Fairbank Farms] has distributed products within a 200-mile radius from its Ashville processing plant. But we have plans to look at a satellite system and maybe establish other facilities that are closer to existing customers."
Kevin Ladwig, director of R&D and quality enhancement for Sheboygan Falls, Wis.-based Johnsonville Foods Co., predicts more case-ready fresh meat will employ high- and low-oxygen MAP technology. Johnsonville Sausage processes fresh and cooked sausage products; pre-cooked, sausage-based ingredient items; and refrigerated entrees.
"As retail stores attempt to take more labor out of meat departments, there will be more case-ready products in modified atmosphere packaging," Ladwig says.
He describes Johnsonville's packaging: "In the fresh category, we use both barrier film technology, and non-barrier shrink film and non-barrier stretch film," he says. "On the cooked side, we use traditional vacuum packaging, flexible gas flush packages, and we also have some gas flush/oxygen scavenger tray products. The latter has been on the market for only a year.
"It's a new area we ventured into," Ladwig points out. "It's doing well, but I can't divulge a lot because we're in a test market [phase]."
Case-ready fresh red meat is a building business for many packaging systems and materials suppliers.
"People are looking for longer shelf life with bloom in case-ready fresh red meats," claims the manager of market development for a packaging systems manufacturer. "That's one of the reasons we developed peelable barrier vacuum-skin packaging."
Designed to work with the company's skin-pack technology, the packaging machinery for the system is manufactured under license by a packaging equipment manufacturer. The machinery seals the package in a manner which allows the film to be laminated properly over the product without tearing.
"This system extends distribution life for red meat because the product is distributed in a barrier vacuum package," the manager says. "Once at retail, you trigger the bloom by peeling the external barrier away. A breathable skin layer remains in place over the meat so oxygen can permeate through to re-bloom the meat.
"This gives you 14 days for distribution and two to three days in the retail case-depending on the product," he adds. "A high-oxygen package for ground meat, for example, will give you only 12 days maximum."
The director of technical operations for the equipment manufacturer of this system says: "We're finally starting to see a lot of activity in the VSP-type package-a light, rigid tray with a skinned film over it in both a high-barrier form and now the peelable system.
"The one company that has been at it the longest and has expanded the furthest [with the peelable system in case-ready fresh beef] is Safeway's Lucerne operation in Calgary, Alberta," he adds. "The company has expanded it to all of its stores in Alberta and is in the process of deciding how much further and faster to go.
"The prospect of this system catching on in the United States is very good," he continues. "There are several [U.S.] red meat companies in the game already, but they're not willing to let us make it public yet."
Industry's move into fresh, value-added, case-ready red meat is evolving into more of a customization of products to satisfy certain niches, the development programs manager for a packaging film/materials manufacturer says.
"Fresh pork is certainly starting to emerge [as the leading product in that category]," he adds. "There are a number of companies, including Swift & Co. and Smithfield Foods Inc., that are offering marinated or seasoned products.
"Instead of placing product in a commodity-type package, they are going after specific consumers and customizing products [and packaging]," he says.
Case-ready packaging opportunities also exist for cooked meats, the sales and market development manager for a packaging systems manufacturer says. "We have [low-oxygen] MAP packaging systems to bring case-ready, pre-sliced deli meats to the store in a tray format similar to what the consumer is used to seeing," he stresses. "It could be a nitrogen or nitrogen/carbon dioxide mixture. One system is a BDF barrier overwrap; the other is a barrier foam system."
Harry Rubbright, president of Eagan, Minn.-based The Rubbright Group, says: "We're going to jump from case-ready all the way to oven-ready. Progressive retailers are offering their own line of marinated products that are ready to go into the oven."
Which type of packaging to use for which product depends on the product and how the customer wants it to be delivered to the consumer.
"Ground products don't look particularly appetizing in a vacuum package," the development programs manager says. "However, I know of several companies that are packing fresh ground pork into vacuum packages. Other companies prefer high-oxygen, modified atmosphere packaging."
The general manager for another packaging systems company sees a need and interest in developing large MAP case-ready foodservice trays that could go right onto the deli shelf; another for the steam table; and more packages that are divided into specific components.
Fairbank Farms' O'Neill says to expect more merchandising through packaging in the future.
"That trend actually began in Europe," he says. "If you look at Tesco and Marks & Spencer [two British supermarket chains], they do a lot of graphic work on their [meat] packages.
"For example, the Fresh-Pak packages are typically put into sleeves that have beautiful graphics and good explanations as far as handling and cooking instructions," O'Neill points out. "We're currently dealing with a major U.S. retailer on a plan to put all of its ground beef into that type of package."
Providing recipes on or within the package is also a growing trend, O'Neill says.
"[Fresh red meat products] ought to have cooking instructions so people feel at ease in buying and preparing these products for their families," he adds.
Merchandising through packaging is also important to Jac Pac Foods Inc.
"This is particularly true for the warehouse club segment where we are fairly strong," says Bob Smith, vice president of sales and marketing of the Manchester, N.H.-based company. "We are packaging products [including fully cooked loaves, pot roast, breaded patties, hamburger patties and steaks] that are marketable from that perspective; pre-printed corrugated facings that depict the product on the inside; or a window-style package where the customer can actually see the product inside."
Rubbright notes: "You're seeing more processed meat companies starting to look at marketing; how to move products off the shelf. Johnsonville Foods has done a super job in making its products 'pop' off the shelf."
Johnsonville's Ladwig, however, cautions processors about drastically changing packaging. "You want your package and product to look different, but not so different that the consumer starts to question what's in the package," he says. "We believe in tweaking, modifying and making small adjustments to enhance products and packaging vs. making a 'Star Wars-ish' jump."
Other trends, needs
More processors-including Sara Lee meat companies, Hormel Foods Corp. and Armour Swift-Eckrich Co.-are using MAP-either low oxygen with nitrogen or a combination of nitrogen and carbon dioxide-for packaging luncheon meats, the manager of market development says.
"Many companies are processing deli-sliced meats, very thin wafer products, which are difficult to separate in a vacuum package," he adds. "MAP offers a way to separate those slices easily."
Jac Pac's Smith says one of the biggest trends he is witnessing is the increase in customer demand for single-serve, portion-control, vacuum-packaged products evolving from his company's bulk-pack products.
"We vacuum package four strip steaks in such a way that you can cut between two steaks and have the remaining three steaks with unbroken packaging seals," Smith says. "Some customers would prefer us to pack these steaks in individual vacuum packages, but that's very expensive and few customers want to pay for that at this time."
Resealable packaging is also important to many companies. "We are packaging meatballs in a Ziplock-style bag, which has been popular," Smith says.
Johnsonville's Ladwig predicts: "You will see increased use of packaging/product enhancers, like product desiccants and shelf-life indicators. That's coming slowly, but we will see more of that within the next five years."
Products that liberate H2S (Hydrogen Sulfide gas, which has a rotten egg odor) could be used more inside packages of thinly-sliced processed meat items, adds the development programs manager.
As the intensity to enhance meat safety builds, revolutionary packaging concepts-such as using food-grade antiseptic ingredients that could be introduced to the packaging material-will continue to be tested. To date, no one has commercialized this particular process yet, Rubbright claims.
Work continues to enhance microwaveable packaging. "You have to design microwave packaging to take [product and oven temperature] variances into consideration; you have to design a smart package that controls energy," Rubbright says. "We're working on a couple now; controlling the energy coming into the packaging. That's where the future is going to be."
The general manager of a packaging systems company says there's a need to improve the quality and gauge of films and MAP barrier films so they can lower processors' packaging costs while enhancing some of the properties of the package. The range of packaging tray sizes should also increase, and cook-in packaging will grow, he adds.
The director of technical operations sees increased activity in high-oxygen and elevated carbon dioxide MAP Styrofoam tray-sealed packages for fresh hamburger. The meat stays red and it yields a seven- to 10-day shelf life vs. the traditional three or four days from the time it leaves the packing plant.
Johnsonville's Ladwig predicts: "You will also see a lot more barrier packaging designs for refrigerated, convenient, pre-cooked foods; foods that you can grab and run with. In order to do that, you will have to use barrier film packaging technology."
The director of market and press relations for a packaging systems manufacturer/supplier says there's a growing interest in uncooked beef and pork ribs packaged inside one of his company's special bags, which features a clear patch.
"Cooked pork ribs have always been around," he says. "In the past, you couldn't put uncooked ribs in retail vacuum packaging because the bones would punch holes in the bag. We're seeing more uncooked beef and pork ribs being packaged in [a special bag we designed], which now has a clear instead of cloudy patch so consumers can see the product.
"Vacuum-packed, uncooked beef ribs are relatively new," he adds. "We have two customers that are committed [to this product], and 10 more that look like they will come across."
Some packaging suppliers say work should not continue to extend shelf life while others say it should.
"If we want to lower the costs for the processor and the retail store-and if we can improve sanitation plus extend shelf life for the consumer-we ought to [extend shelf life]," the general manager of a packaging systems manufacturer says. "We can push it from two or three days to five or six days at the retail shelf. We don't need to push it up to two weeks."
International opportunities
As meat exports continue to grow, so do opportunities to enhance shipping systems.
For example, Salinas, Calif.-based TransFRESH, the self-proclaimed world leader in marine-controlled atmosphere shipments of fresh produce, has developed the Tectrol CA process which makes it possible to ship produce by sea, and get it to the customer as fresh as it would be shipped by air.
Meat is another candidate for this process; it's already possible to successfully handle pork shipments, according to the company.
Joint ventures between packaging companies will also keep the international packaging world simmering.
In November, W.R. Grace & Co. and Foshan Huan Yu Food Packaging Films Co. Ltd. formed a strategic packaging joint venture in Gaoming, Guandong Province, China.
The new venture is called Grace Packaging Gaoming Co. Ltd.
It will manufacture shrink films for packaging chub sausage-a cooked, non-refrigerated pork sausage staple that's popular throughout China.
Company officials estimate a total market potential of more than $70 million by the year 2000.
ASSOCIATED ARTICLE:
New Labeling Equipment Leaves Its Mark
Machinery utilizes software to control several applications
by Larry Aylward, managing editor
Labeling equipment has joined the computer age. Labelers have become number crunchers and thinking machines.
This is evident on the processing line, when a multitude of products are processed and packaged on a single shift.
Labeling equipment has kept up with the pace by instituting menu changeover technology.
Packers and processors are loving it, suppliers say. They want to be able to switch lines rapidly from hot dogs to bologna to sliced ham and back to hot dogs.
It's no secret that perishable products are more complex when it comes to labeling, what with weight and date considerations.
"To allow for quick label changeover, labeling equipment must utilize software-based control over as many of the labeling application variables as possible," a labeling expert explains. "These variables include package die layout dimensions, X and Y registration, labeling speeds and accelerations, label tamp and sensor settings."
Obviously, menu changeover allows for less downtime because formations are stored in a computer. The formations can be recalled with the press of a button, not with the manual realigning of the placement of the labeler.
"You can work back and forth in the menu between 10, 15 or any number of changeovers in an eight-hour shift," a supplier points out.
Packers and processors are happy about the quick change. They are asking for more programmability with labeling equipment, another supplier points out.
"The future is programmability," the supplier adds. "If you have a thousand products, you just load them into memory and recall them. This allows for a quick change."
Bar-code usage is also hot, especially as an answer to the need for tighter inventory control. "That requires more real-time labeling," says Mark Vignieri, MIS director for Kenosha, Wis.-based Kenosha Beef.
"In the past it was common to use a simple roll-on date code, low-resolution, ink-jet date coding or a pre-printed label that just had product information on it," Vignieri says. "Now, it's often desired and sometimes mandated by the customer that you put real-time information and variable information on the package."
There is also a trend in the industry to have labeling equipment function as part of a continuous packaging system.
"On form/fill/seal packaging equipment, the packages are held rigidly in place prior to the cutting section of the system," the labeling expert says. "To achieve the highest level of placement accuracy, labeling equipment should apply labels on the packaging system prior to the packages being cut free and dropped onto a conveyor.
"This can be accomplished by labeling the film [prior to seal] or by labeling the packages between the sealing section and the cutting section of the packaging system," he adds.
Currently, packers and processors have a choice of using labels or printed film on packages. The decision boils down to needs.
Some believe labels are of a higher quality and are easier to read. Others say printed film makes more sense and is more cost-effective if only one or two colors are involved. One supplier questions the quality of printed film. He has seen nutritional information on printed film of a package.
"By the time [the package] gets to the store, [the printed film] does not have the crisp, clear quality of print and text that is on a label," he says.
Consumers can be sold on labels, so there is the marketing aspect.
For instance, a supplier suggests a red label with white lettering detailing safe handling instructions.
"It would really stand out," the supplier adds. "It says: 'Mr. Consumer, take a look at this before you do anything.' Where as if you just try and put the information as black text on film, it gets lost."
Marketing through labels depends-again-on the needs and wants of processors and how much money they want to spend on spiffy packaging and labels.
"The supermarket shelf appeal of food products is predominantly influenced by packaging," a supplier says. "A label can provide superior graphics, color and contrast to a package while allowing a clear film area for display of the product."
There also may be a surge in use of ink jets, which are getting more high-tech and versatile.
"Changes in the world of ink jetting have given us the ability to print high-resolution graphics and bar codes with ink jets in a way that was not possible before," Vignieri points out.
Newer ink-jet printers are being used for a variety of applications, even to print images on designer clothes.
Processors may soon turn to the newer ink jets for their precision-and to save money.
"There is a trade-off that's brewing with the evolution of high-resolution ink-jet technology that may offer a lower cost solution than print-and-apply labeling," Vignieri says.
However, print-and-apply labeling is currently a better procedure for print quality and bar-code scannability, Vignieri adds.
"But the gap is narrowing and ink jetting will be coming more into play in the future," he says