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."
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.