top of page

Search General Films

Search this site

59 results found with an empty search

  • Employee Spotlight | United States | General Films

    At General Films, we celebrate our most valuable assets – our employees. EMPLOYEE SPOTLIGHT EMPLOYEE SPOTLIGHT David Cathie-Atkins Day Shift Supervisor, Extrusion David grew up in the Phoenix, Arizona, area. He served in multiple branches of the US military, both active and reserve, for 11 years before transitioning to a federal & tribal law enforcement officer in Arizona. He then entered the private sector working at Abbott Nutrition for 10 years, starting in production and later elevated to production supervisor. While at Abbott, David was fortunate to see the country and experience different regions of the United States. One of the locations was Troy, Ohio, where he fell in love with the area and the people. Seizing the opportunity, David and his family moved to Troy in 2017 to work full-time at Abbott. Due to health reasons, David left Abbott and after a long recovery period, was ready to rejoin the workforce. Although he enjoyed large companies, he looked for an opportunity with a smaller and more intimate environment to work in. After doing a significant amount of research, David discovered General Films and the rest, as they say, is history. He brings the skills that he honed in the military and corporate America to GF, including discipline, leadership, people skills, and problem-solving, to name a few. David currently leads a team in the extrusion department. “I really like the challenge of the 2nd shift. We work more cohesively and independently, solving our own problems and navigating through challenges.” David states that many of the GF job requirements and skills are similar to Abbott's. However, the company environment at GF, the people, and the motivations are different. The company has an open and transparent environment while focusing on its people and customers. David sights a positive example of the company culture as the “Sunshine Committee,” which helps where and when necessary to make sure co-workers are taken care of in times of need. David is married and enjoys his growing family, which includes four sons, three daughters, ten grandchildren, and six great-grandchildren, including their newly arrived-first granddaughter. Together they enjoy the outdoors, including kayaking and rolling down the highway on their Harley. David is also a member of the Improved Order of the Red Men in Troy and is especially active in their Alzheimer's research. BACK

  • Flexible Film Solutions for Food Packaging | General Films

    General Films specializes in flexible film solutions for various types of food packaging including cheese, fresh meat, frozen foods, cereal, produce and more. OTHER FOOD A FRESH LOOK AT FOOD PACKAGING Preserving quality and extending shelf life are critical to the success of food packing companies. The ability to deliver higher quality products that stay fresher longer is a tremendous competitive advantage and a necessity for demanding consumers. At General Films, we provide flexible film solutions for various types of food packaging, including cheese, fresh meat and crackers, cookies, cakes, cereal, frozen foods, and other goods that require a barrier bag . We specialize in flexible packaging for institutional cheese applications including short- and long-hold bags for 40 lb. to 640 lb. cheese blocks and liners for 500 lb. cheese barrels. Our product is stiff, abrasion-resistant, and won’t stretch. Plus, our flexible film solutions are designed to support your operations by increasing throughput and reducing downtime. Produce Film Precut lettuce, salad mix, and other produce enjoy longer shelf life, excellent taste, color, and freshness with General Films coextruded film or bag produce packaging. We can design each product's oxygen, carbon dioxide, and water vapor barriers. Plus, a wide heat seal range assures quick and tight vacuum closures. We have a complete vertical form fill and seal film line for precut produce packaging. Contact Freezer plate/Crust Films Our coextruded freezer plate/crust films are ideal for demanding IQF applications. FDA-approved for poultry to seafood, our freezer plate/crust film exhibits exceptional stiffness and toughness with less elongation and tear. When you ask me what I would tell others about General Films, I'd say they have good quality products, they listen to the customer, they help us solve problems, they react quickly, and their prices are fair. " " Craig Colonno, Purchasing Director & Ice Cream Mix Manager, Anderson Erickson Dairy Savings Focus Can I use coextruded films in laminations or replace laminated films to lower packaging costs? > READ MORE We Meet or Exceed Government Standards Third-party auditors regularly inspect General Films to ensure compliance with Good Manufacturing Practices and all applicable HAACP program requirements. We submit film samples to independent laboratories each month for microbiological testing. And we are inspected by the Ohio Department of Agriculture to ensure compliance with the Interstate Milk Shippers standards, as prescribed by the U.S. Food and Drug Administration. For these reasons, you can depend on General Films fluid milk dairy packaging to meet the highest industry standards. > CLICK HERE to learn more about how our packaging solutions are suited to meeting your processing needs.

  • Bag-In-Box Success Story: Anderson Erickson Dairy

    Anderson Erickson Dairy discusses how their relationship with General Films is based on mutual respect, problem solving, and quality customer service. ANDERSON ERICKSON DAIRY Success Story ANDERSON ERICKSON DAIRY FINDS BUSINESS RELATIONSHIPS NOT JUST BUSINESS AS USUAL When you ask me what I would tell others about General Films, I'd say they have good quality products, they listen to the customer, they help us solve problems, they react quickly, and their prices are fair. I like to say that this is a business relationship that has also become a great business friendship. So says Craig Colonno, Purchasing Director & Ice Cream Mix Manager for Anderson Erickson Dairy in Des Moines, Iowa. Mr. Colonno recalls his first encounter with General Films over 15 years ago: "We were dealing with another supplier that couldn't make delivery on some of the plastic fluid bags we use. Even though we weren't one of their regular customers, General Films got us out of a bind for several months by supplying bags that worked with our filling equipment. Frankly, I don't know what we would have done without them stepping in." "We returned to our regular supplier out of a sense of loyalty, but a few years later we went back to General Films for our bags. Soon after, we worked closely with them to develop an automated web filler that would meet our specific needs. You might say we participated in the design of that filler and General Films was great to work with. They took me to see various fillers at other facilities and the prototypes they developed. Then they listened to what I had to say and acted on it." Although everyone's prices for plastic bags have gone up recently, General Films has remained very competitive and informative on all increases. They've had to raise some prices over the years, of course, but we feel they have been fair about it. " " Craig Colonno, Purchasing Director & Ice Cream Mix Manager for Anderson Erickson Dairy Keith Nichols, Century Furniture’s Plant Three operations manager "In the same way, if I have a problem, they listen and quickly act to help us get back on track. Occasionally you have a panic situation as if we landed a new account that wants to get started tomorrow and requires a lot more bags than we have on hand. We can't tell a new customer they have to wait a week so that we can stock up on bags. But I can call General Films and they respond quickly to our needs; that's the real key. And from a quality standpoint, we haven't had any issues I can think of for the past several years." The Anderson Erickson Dairy was founded in 1930 and continues to be family owned and operated. The third generation of family owners continues to live by the values of founder Iver Erickson while continuously investing in new technology to produce a full range of Quality You Can Taste dairy products. To learn how General Films can help your operation realize greater efficiency, more secure packaging, and labor cost savings, contact Tom Granata or submit a Start Your Solution form, or call 1.888.436.3456 today!

  • VFFS Films Case Study | General Films

    VFFS Films Case Study Stepping Up to the Plate Americans consume more chicken than any other consumer in the world. Per capita consumption of chicken is expected to total 96.5 lbs. this year and to increase to 97.8 lbs. in 2021, according to the National Chicken Council. Fueling this increase is product variety. As a result, chicken packaging formats vary widely to meet specific processor and product needs and include bags, films, and vacuum roll stock packaging, among others. "Packaging advances have improved the safety and quality of poultry products," said Scott Russell, professor of poultry processing and products microbiology at the University of Georgia, in discussing a study on the effects of packaging on the value chain for the chicken industry titled "Chicken and Packaging: A Sustainable Partnership," from AMERIPEN (American Institute for Packaging and the Environment). We have seen a trend of vacuum-packed, individually wrapped products [i.e., Perdue's boneless, skinless individually wrapped chicken breasts]," says Gwen Venable, vice president of communications with the US Poultry & Egg Association. "We have also seen more value-added packaging [i.e., drumsticks that are packaged two per pack and marinated], as well as a reduction in the amount of packaging to protect the product." Packaging must lure hurried shoppers to the refrigerated case, plus it must allow labeling that is helpful to consumers, among other things. But most importantly, all packaging must ensure maximum product integrity. Innovation never sleeps. Powertray LLC, Mackville, NC, was conducting a test with a supermarket chain and major chicken processor, says Huston Keith, principal of Marietta, GA-based Keymark Associates. The refrigerated chicken was packaged in a coated, pressed paperboard tray that was biodegradable. "Bell & Evans is using a PET tray they say is fully recyclable and uses the native barrier of PET," he adds. "It's a vacuum-skin package and it's sold at Whole Foods and other chains." Providing Solutions General Films Inc. (GFI), Covington, Ohio, recognized for years that the vertical form/fill/seal "space" for fresh chicken suffered from high leaker rates. This realization led to the development of BG/2M film, says Tim Weikert, president. BG/2M is a coextruded film with a nylon barrier, featuring two-sided sealing, Octene LLD PE sealant layers, and a nylon interior ply. It is a nine-layer structure, so it provides excellent physical properties, ranging from the sealant to impact strength, says Tom Granata, vice president of sales. This film was designed for fresh poultry packaged on a vertical form/fill/seal machine. GFI began BG/2M trials with a medium-sized US chicken processor. Although experiencing good results, the customer initially balked at its higher pricing. "But we kept sampling and they kept trialing. Finally, they replaced their previous film with our product," Weikert says. Pricing of the new product (on a mil-to-mil basis) resulted in a price increase of about 70 percent more when compared to more traditional packaging. But when factoring in downgauging opportunities this new film affords, the price goes down. Granata explains the processor was using a 3.25 mil film at one plant that was replaced with a 2.5 mil film that still reduced leaker rates. And the processor achieved much more yield compared to previous yields. With the printing cost factored in, the increase is closer to 40 percent. The film prints well and labels designed for PE films readily adhere. On this processor's line, each 10-lb. sealed, formed pouch of fresh chicken now withstands the rigors of rugged processing and distribution. After making the switch, leaker rates greatly diminished. Overall profitability grew substantially through enhanced productivity, fewer product rejects, and increased customer satisfaction. The processor is seeing a minimum leaker reduction of 50 percent. " " Tom Granata, Vice President, General Films Keith Nichols, Century Furniture’s Plant Three operations manager "BG/2M features higher impact strength, higher tensile strength, a substantially wide-ended heat seal window, the film is about 50 percent stiffer than the traditional solution, which benefits the vertical form/fill/ seal machines," he adds. This processor banked a 20-percent throughput improvement on its packaging lines. This allowed expanded production with a lower footprint on labor. Increased throughput allowed the temperature on the seal to increase so it runs a little faster yielding increased productivity. Start A Solution or call 1.888.436.3456 today! BACK TO VFFS FILM

  • Custom Flexible Film Packaging for Food & Industrial Applications

    General Films products are competitively priced and designed to fulfill exact customer needs. View Co-Extruded, Bag-In-Box, VFFS, and Industrial Film products. PRODUCTS CUSTOM FLEXIBLE FILM SOLUTIONS Founded in 1947, General Films manufactures flexible film for an extensive range of food packaging and industrial applications. Our films are customized to meet the exact needs and specifications of our customers. We produce a wide variety of sizes and formulations that are expertly produced to ensure that the exact features and attributes are matched to your specific packaging or industrial application. We use top quality resins and advanced blown film technology to produce high quality results. Our employees are knowledgeable and well-trained to operate and monitor the manufacturing process with precision and attention to detail. Our Products Include: CoEx and Barrier Films Monolayer Films CoEx Poly Films Bag-in-Box Systems One of the key advantages and strengths of General Films is our ability to analyze your needs and develop a solution for your exact situation. We operate an in-house laboratory to test and recommend formulations that often offer unexpected benefits and cost savings for our customers. We are experienced with an impressive range of resins which further contributes to our versatility and ability to customize your film. For more than 75 years, General Films has mastered the art of flexible film manufacturing. Whether you need a fairly routine product or a complicated technical challenge, we can produce your film with a timely and resourceful approach. , Our service is attentive and personalized - from your first inquiry, to quotes, trials, orders, and delivery of your custom film solution. Industrial Films • SMC • Furniture • Other Industrial Industrial Films Food Packaging Food Packaging • Chicken • Cheese • Dry Mixes • Other Foods Bag-in-Box Bag-in-Box Gain More Value with a Family-Owned Bag-in-Box Partner

  • Savings Focus | General Films

    SAVINGS FOCUS CAN I USE COEXTRUDED FILMS IN LAMINATIONS OR REPLACE LAMINATED FILM TO LOWER PACKAGING COSTS? The quick answer is YES, and in two significant ways. The first way would be to substitute or replace coextruded barrier film in what was formerly a plain laminated structure without printing. The barrier need should be examined to match up the oxygen barrier requirement and whether the film needs to have nylon on the outside of the web for automatic FFS or in pouch making a conversion. If the OTR (Oxygen Transmission Rate) barrier can be attained and package optics is not a concern, then there can be significant cost savings by switching to a coextruded film to replace a lamination. The second way to save money is to use the barrier coextruded film as the sealant layer in a lamination. For instance, NYLON or EVOH & Nylon, or some other possible barrier combinations, such as Nylon and, or HDPE (high-density polyethylene) for added moisture barrier; whatever the specific barrier requirement is needed in the finished lamination. But it is worth examining coextruded flexible films as a cost-savings alternative. With the correct use of coex films and careful evaluation of the packaging equipment and barrier testing, these coex films can be a great way to offset the rising cost and uncertainty of material pricing fluctuations in today’s competitive marketplace.

  • Modified Atmosphere Packaging (MAP) for Fresh Chicken | General Films

    General Films Modified Atmosphere Packaging (MAP) film for poultry fresh chicken unique barrier properties, excellent sealing, impact resistance & leaker reduction. POULTRY CHICKEN & PROTEINS MODIFIED ATMOSPHERE PACKAGING (MAP) FOR FRESH CHICKEN ON VFFS MACHINES Customized 9 Layer Coextrusions offer the ability to custom design and manufacture packaging films. We can precisely provide the right solution for your food processing needs. Whether you are looking for unique barrier properties, transmission rates, excellent sealing, impact resistance, or other performance criteria, General Films delivers. DOWNLOAD OUR BROCHURE Learn More About General Films Custom Barrier Films for Fresh, Frozen or Processed Proteins. DOWNLOAD OUR BROCHURE Learn More About General Films Custom Barrier Films and Bag-In-Box Solutions for Chicken and Liquid Egg Products. Key Benefits for Fresh Chicken Include: Excellent physical properties, ranging from the sealant to impact strength, significant reduction in leaker rates Increased profitability through enhanced productivity Fewer rejects and increased customer satisfaction Higher impact strength, higher tensile strength, a substantially wide-ended heat seal window Approximately 50 percent stiffer than the traditional solution Significant throughput improvement allows for expanded production and a lower labor footprint Ideal for high-speed large-volume poultry packaging production > VFFS Machine < After making the switch, leaker rates greatly diminished . Overall profitability grew substantially through enhanced productivity, fewer product rejects, and increased customer satisfaction. " " CUSTOMER FOCUS Stepping Up to the Plate Americans consume more chicken than any other consumer in the world. Per capita consumption of chicken is expected to total 96.5 lbs. this year and to increase to 97.8 lbs. in 2021, according to the National Chicken Council. > READ MORE > Dry Pack CVP Bags on a CVP Machine > > General Films Product on a VFFS Machine < > CLICK HERE to learn more about how our packaging solutions are suited to meeting your processing needs.

  • General Films: A Custom Manufacturer of Flexible Packaging Films

    For more than 65 years, General Films has delivered custom-designed, competitively priced packaging that precisely matches customer requirements. ABOUT GF YOUR PACKAGING PARTNER SINCE 1947 With decades of experience and a long term commitment to our customers, General Films is a leading manufacturer of custom-designed, flexible films combined with personalized service, on-time delivery and exceptional customer support. General Films combines in-depth expertise and experience with advanced manufacturing capabilities to craft everything from simple, one-layer films to complex custom packaging requiring up to 9 layers. Our custom films include a wide range of barrier, mono and co-ex products for industrial applications and food packaging. Our Bag-in-Box systems offer quality packaging for liquid food and dairy. It’s more than just our products and service. Our customers appreciate the added value of our personalized approach to analyze your needs and work together to create the best solution made for your exact specifications. VISION General Films will be a trusted leader, focused on customization & extensive product capabilities key to our customer's success. MISSION Our mission is to safely manufacture flexible film products with a commitment to satisfy our customer’s quality and delivery expectations. VALUES Accountability Honesty Passion Family Respect

  • Community | United States | General Films

    Since 1947, we have been a fixture in our community and active supporters of local schools, charities, and civic outreach organizations. From employee clothing drives that help the less fortunate to sponsoring youth sports and scholarship programs, we take our responsibility to our community seriously. COMMUNITY CHRISTMAS SPIRIT AND INNOVATION SHINES BRIGHT AT GENERAL FILMS Covington, OH— Sunday, November 29, 2020 The General Films Christmas party is typically a time for our associates to gather and celebrate the holidays with a festive dinner. Due to the coronavirus, this annual tradition was reformatted to ensure everyone could stay safe, healthy, and socially distanced. The new format was initially planned as an outdoor gathering, like an old-fashioned Christmas Market, but the pandemic issues continued...which required us to change the event once again. This time, we created a Drive-thru experience, with several individual tents arranged around the GF facility for our associates and their families to enjoy. The Drive-thru included many stops with gift items, kettle corn, hot cocoa, a food truck, Santa, holiday lights, and more. GF employees, including the senior leadership team and the Sunshine Committee, staffed each tent. The event provided a great opportunity to individually thank our associates for their dedication to GF and express appreciation for their outstanding effort during such a challenging year. Although it was a different approach, we were pleased to continue our annual GF Christmas tradition - and It was a wonderful day to celebrate and enjoy the holiday season! Clicked to Enlarge, View and Scroll the Full Gallery COVINGTON SCHOOL BOARD OF EDUCATION RECOGNIZES GENERAL FILMS FOR LEGACY OF COMMUNITY SUPPORT Covington, OH—October 9, 2020 General Films was awarded the Ohio School Board Association’s Business Honor Roll at the September 16, 2020, Covington Exempted Village Schools Board of Education meeting. For 75 years, General Films has been honored to partner with our community on education initiatives. The OSBA Business Honor Roll program recognizes just that—areas where businesses and schools are able to collaborate, ensuring that schools receive the support and real-world experience they need today while businesses are able to share the workforce skills students needs for tomorrow. General Films Founder Roy J. Weikert began his education in a single-room schoolhouse before eventually graduating from Covington High School. Following graduation, Roy attended Columbia University in New York City and completed his Bachelor of Science Degree at The Ohio State University in Columbus. Roy’s passion for learning was reflected not only in his formal education but also in his profession. A lifelong learner, it was Roy’s insatiable curiosity and inventiveness that led to General Films. Prior to WWII, Roy invented a manufacturing process that pioneered the Company’s first product; a plastic protector for men’s hats. Following service in the war—and along with his brother, Wayne—Roy’s curiosity and energy turned to creating new products and building a manufacturing business. It was then that General Films was officially founded, making Roy an industry icon and flexible film leader. Today, General Films’ commitment to education and invention continues. Through the RJW Foundation, General Films presented Covington EVS with a gift that funded computers, plus a business education initiative. Later donations supported renovations and improvements to the school’s theatre. It was Roy’s nephew and current General Films CEO Tim Weikert who accepted the award. “Covington continues to be the setting for our company and family’s story,” said Tim Weikert. “We are honored to help support a new generation of learners and innovators, who we hope will look to Roy and General Films as their inspiration.” AT HOME IN OUR COMMUNITY Since 1947, we have been a fixture in our community and active supporters of local schools, charities, and civic outreach organizations. From employee food and clothing drives that help the less fortunate to sponsoring youth sports and scholarship programs, we take our responsibility to our community seriously, and so do our employees. Many members of our General Films family freely devote their time and energy outside of work to help improve the quality of life for others. On a national scale, the company has made large equipment donations to support several educational institutions, including Food Sciences in the College of Agriculture at Purdue University and the dairy programs at Penn State University and Cornell University. Our founder, Roy J. Weikert, also made significant donations in his lifetime and through his estate to the American Red Cross and the Salvation Army. Several local and regional organizations have also been beneficiaries of Roy’s generosity. General Films recently hosted an event for community leaders to share information about the company and distribute additional philanthropic gifts to several local groups. Some organizations that received funds from Roy’s estate include the Village of Covington, Covington Exempted Village Schools, Covington Fire & Rescue, Covington-Newberry Historical Society, Covington Church of the Brethren, and the Brethren Retirement Community in Greenville. The event provided a wonderful opportunity to reflect on Roy’s life, recognize the impact that he had on General Films and the local community, and celebrate more than $500,000 of donations over the past two years

  • Custom-Engineered SMC Films | General Films

    Custom-engineered Sheet Molding Compounds water shield and laminating films for fabrics, non-wovens, and noise non-attenuation components create the ultimate driving experience. SMC DEPENDABLE INDUSTRIAL PACKAGING FOR ALL APPLICATIONS We're your source for tough, affordable industrial packaging that protects your products. General Films offers a wide range of custom films from economically priced material for non-FDA regulated applications, to a single layer and coextruded films for special uses. We make linear, a low-density film from 7" tubing to large pallet covers and sheeting and offer a wide range of custom colors as well as a broad assortment of bags on rolls or separated. Coextruded Film Products Some industrial packaging applications require the enhanced strength that only a coextruded film product provides. General Films uses multiple layers of different materials to greatly improve impact resistance and tear strength versus standard films or bags. And our Modified Atmosphere Packaging (MAP) films and bags are the perfect solutions for molding compounds, circuit boards, metal products, and other items that must be protected from environmental forces. Box and Barrel Liners Give us your requirements and we'll help size and specify liners for corrugated or drums. Because General Films is a custom resource, you'll get precisely the size and strength you need for your application. Top Sheets Available as individually cut or perforated on rolls, top sheets protect pallets from dirt and moisture. We can help you package your product for maximum durability. Shrink Bundling Films Custom-made to your specifications, our shrink bundling film provides an economical industrial packaging system. The high shrink force and contact clarity protect against in-transit damage, pilferage, and product tampering. Pallet Covers General Films produces dependable polyethylene pallet covers with excellent puncture resistance, so your products arrive safely at their destination. They're available inside seal, bottom seal, and flat or gusseted bags so you get the best fit and most protection possible. Also available is a high-grade shrink version for tight product utilization and to reduce load shifting. Machine Films Made from prime resin, our machine films offer the ultimate flexibility. You can use centerfold films on most L-sealers, and our single wound sheeting is standardized for shrink wrappers. Mattress manufacturers benefit from several grades of machine wrap films. General Films machine films are perfect for use on vertical form/fill/seal equipment. Performance Products Our packaging films can be formulated to meet rigorous requirements like automotive standard 302 or NFPA flame retardancy. Our antistatic films can meet military specifications or other static-resistant requirements. For sunlight exposure, UVI film provides a substantially longer use life. Light-sensitive products require our photo black film; impervious to sunlight. Many other performance attributes can be met with our ability to custom formulate various packaging film Being proactive and exceptionally responsive is what sets General Films apart from the typical supplier. " " Linda Cleveland, CEO, Industry Products Company CUSTOMER FOCUS Profiting From Team Spirit "Being Proactive and exceptionally responsive is what sets General Films apart from the typical supplier," according to Linda Cleveland, CEO of Industry Products Company, a 42-year-old Piqua, Ohio enterprise that serves the automotive industry. > READ MORE > CLICK HERE to learn more about how our industrial packaging solutions are suited for protecting your products.

  • | General Films

    Stepping Up to the Plate Americans consume more chicken than any other consumers in the world. Per capita consumption of chicken is expected to total 96.5 lbs. this year and to increase to 97.8 lbs. in 2021, according to the National Chicken Council. Fueling this increase is product variety. As a result, chicken packaging formats vary widely to meet specific processor and product needs and include bags, films, and vacuum roll stock packaging, among others. ​ "Packaging advances have improved the safety and quality of poultry products," said Scott Russell, professor of poultry processing and products microbiology at the University of Georgia, in discussing a study on the effects of packaging on the value chain for the chicken industry titled "Chicken and Packaging: A Sustainable Partnership," from AMERIPEN (American Institute for Packaging and the Environment). ​ We have seen a trend of vacuum-packed, individually wrapped products [i.e., Perdue's boneless, skinless individually wrapped chicken breasts]," says Gwen Venable, vice president of communications with the US Poultry & Egg Association. "We have also seen more value-added packaging [i.e., drumsticks that are packaged two per pack and marinated], as well as a reduction in the amount of packaging to protect the product." ​ Packaging must lure hurried shoppers to the refrigerated case, plus it must allow labeling that is helpful to consumers, among other things. But most importantly, all packaging must ensure maximum product integrity. ​ Innovation never sleeps. Powertray LLC, Mackville, NC, was conducting a test with a supermarket chain and major chicken processor, says Huston Keith, principal of Marietta, GA-based Keymark Associates. The refrigerated chicken was packaged in a coated, pressed paper­board tray that was biodegradable. ​ "Bell & Evans is using a PET tray they say is fully recyclable and uses the native barrier of PET," he adds. "It's a vacuum-skin package and it's sold at Whole Foods and other chains." ​ Providing Solutions General Films Inc. (GFI), Covington, Ohio, recognized for years that the vertical form/fill/seal "space" for fresh chicken suffered from high leaker rates. This realization led to the development of BG/2M film, says Tim Weikert, president. ​ BG/2M is a coextruded film with a nylon barrier, featuring two-sided sealing, Octene LLD PE sealant layers, and a nylon interior ply. It is a nine-layer structure, so it provides excellent physical properties, ranging from the sealant to impact strength, says Tom Granata, vice president of sales. This film was designed for fresh poultry packaged on a vertical form/fill/seal machine. ​ GFI began BG/2M trials with a medium-sized US chicken processor. Although experiencing good results, the customer initially balked at its higher pricing. "But we kept sampling and they kept trialing. Finally, they replaced their previous film with our product," Weikert says. ​ Pricing of the new product (on a mil-to-mil basis) resulted in a price increase of about 70 percent more when compared to more traditional packaging. But when factoring in down­gauging opportunities this new film affords, the price goes down. Granata explains the processor was using a 3.25 mil film at one plant that was replaced with a 2.5 mil film that still reduced leaker rates. And the processor achieved much more yield compared to previous yields. With the printing cost factored in, the increase is closer to 40 percent. The film prints well and labels designed for PE films readily adhere. On this processor's line, each 10-lb. sealed, formed pouch of fresh chicken now withstands the rigors of rugged processing and distribution. After making the switch, leaker rates greatly diminished. Overall profitability grew substantially through enhanced productivity, fewer product rejects, and increased customer satisfaction. ​ The processor is seeing a minimum leaker reduction of 50 percent, Granata says. ​ "BG/2M features higher impact strength, higher tensile strength, a substantially wide-ended heat seal window, the film is about 50 percent stiffer than the traditional solution, which benefits the vertical form/fill/ seal machines," he adds. ​ This processor banked a 20-percent throughput improvement on its packaging lines. This allowed expanded production with a lower footprint on labor. Increased throughput allowed the temperature on the seal to increase so it runs a little faster yielding increased productivity. ​ Close

bottom of page