Iceless packaging to aid in vegetable transportation

Modified Atmosphere/Modified Humidity (MA/MH) packaging developed by StePacPPC aims to facilitate the transition away from ice-filled polystyrene and waxed carton boxes for packaging fresh broccoli and other vegetables for long-haul shipments in both the US and Japan.

The Otofuke Agricultural Cooperative in Japan (JA Otofuke) —a major broccoli producer—is benefiting from StePacPPC's Xtend MA/MH bulk bags for shipping broccoli on its land journey from Hokkaido to Yokohama.

Polystyrene foam boxes filled with ice have been widely used for the domestic transport of many vegetables in Japan. While such packaging has excellent insulation properties and helps maintain low temperatures, it is not an environmentally friendly packaging material. Polystyrene foam is becoming increasingly shunned by retailers concerned about the ease with which it fragments, its persistence in the environment, and the fact that it is non-recyclable. Polystyrene generates significant disposal challenges, prompting calls for it to be phased out and replaced with more eco-friendly alternatives.

Many countries have already banned polystyrene entirely. Japan is placing growing regulatory emphasis on reducing the use of non-recyclable materials including certain types of polystyrene foam.

Likewise, in the U.S., waterproofed waxed carton boxes used for iced broccoli shipments are increasingly unwelcome. Their wax coating renders them unsuitable for paper recycling, relegating them to general waste. Worse, landfilled waxed cardboard can produce methane, a potent greenhouse gas. Certain states, such as California, have placed local bans on non-recyclable containers.

From a food safety standpoint, as the ice in the boxes melts, it is also conducive to microbial decay. Studies have shown that at any point in time, the amount of microbial colony-forming units on iced broccoli is higher than on broccoli packed in MA/MH packaging. And, numerous studies have shown that as the ice melts, vitamin C from the broccoli leaches out. It also can be physically unsafe: Melting ice is not only messy, but it also creates potential slipping hazards.

"In our efforts to move away from polystyrene foam with ice and its inherent contamination risks, we considered various alternatives for maintaining freshness without using ice," explains Akio Yamagishi, Manager of the Fruit and Vegetable Sales Department of JA Otofuke. "We tested various modified atmosphere packaging films, including the Xtend films from StePacPPC. After inspecting the condition of the broccoli upon arrival, Xtend outperformed the rest in both appearance and quality."

The Xtend packaging films are built with modified atmosphere and moisture control properties. These work to slow respiration inside the packaging, inhibit ethylene (a plant hormone that promotes the yellowing of broccoli), remove excess moisture, delay the aging processes, and slow the growth of microorganisms on broccoli. Its mode of action may also reduce the risk of foodborne illness associated with pathogens such as E. coli.