Controlled Environment Agriculture (CEA) has transformed fresh food production by reducing land and water use. However, sustainability challenges remain, especially in packaging waste and food spoilage.
Proseal, a JBT Marel brand specializing in tray-sealing technology, is making strides in reducing plastic waste and extending the shelf life of fresh produce. With the growth of vertical farming and increased consumer demand for sustainability, Proseal's packaging solutions offer a forward-thinking approach to reducing waste while ensuring fresh, high-quality produce reaches consumers.
Cutting plastic waste while keeping produce fresh
Traditional packaging solutions like plastic clamshell containers have long been the industry standard for leafy greens and fresh produce, but they generate significant amounts of plastic waste. Proseal's top-seal technology replaces these clamshells with a peel-and-reseal film, which it says uses up to 42% less plastic per package.
"For every million trays sealed with our equipment, up to 10 tons of plastic is saved," says Thomas Reimann, Proseal Account Manager. "Customers who have implemented Proseal technology have seen a sizable decrease in unnecessary plastic use." 
Proseal's GT1e tray sealer
A prime example is Greenswell Growers, a large-scale indoor farm that has successfully implemented Proseal's packaging solutions, achieving a 40% reduction in plastic use compared to similar brands.
"We achieved a major reduction in plastic use for Greenswell Growers by implementing an automated tray-sealing system that replaces traditional plastic clamshells with a peel and reseal film," Reimann says.
"This solution not only minimizes plastic usage but also extends the shelf life of leafy greens, helping to reduce food waste. Additionally, by optimizing space and weight, Proseal's packaging contributes to lower transportation emissions and an overall reduced environmental footprint." 
Greenswell Growers' leafy greens being packaged in Proseal's GT1e tray sealer
Modified Atmosphere Packaging (MAP)
Extended shelf life is achieved through Modified Atmosphere Packaging (MAP) technology, which regulates the oxygen and carbon dioxide levels within a package to slow down spoilage.
"Proseal's automation capabilities streamline the packaging process to enable increased throughput while keeping products fresher for longer through MAP technology, reducing food waste by allowing the product to stay fresher throughout the entire supply chain journey," Reimann says. "Without MAP, some fresh produce has a shelf life of 2 to 7 days in ambient air. With MAP, fresh produce shelf life is almost doubled from 5 to 35 days." 
Proseal's CP3rs
Scalability
Reimann says that one of the key advantages of Proseal's packaging technology is its scalability.
"From startups to large-scale indoor facilities, we offer customizable solutions that adapt to different operational needs. The technology is designed to be energy-efficient and cost-effective, making it an attractive investment for growers looking to optimize their packaging processes and meet sustainability goals."
Proseal's automation features also streamline production, reducing labor requirements and packaging errors, further contributing to operational efficiency.
Inside Proseal's CP3rs
Meeting the demand for sustainable packaging
Consumers are becoming increasingly eco-conscious, demanding less plastic and more sustainable packaging in their grocery choices. Retailers are also looking for suppliers who meet environmental standards without compromising on freshness and food safety.
"Proseal ensures that its packaging solutions meet both environmental standards and the rigorous requirements of fresh food safety by prioritizing the development and integration of sustainable materials and technologies," Reimann says. "We work closely with material suppliers to offer packaging options that are recyclable, biodegradable, or compostable, aligning with consumer demand for eco-friendly products."
The future of packaging in CEA
Reimann says that looking ahead, Proseal is committed to further reducing environmental impact through continuous innovation, which includes making more energy-efficient machinery, developing new sustainable materials, and expanding the use of MAP technology.
"We are continuously exploring new ways to reduce the environmental impact of food packaging," Reimann says. "This will come in the form of making our machines even more energy efficient as well as utilizing more sustainable materials and manufacturing locations. We also endeavor to transform the future of food by bringing MAP and other shelf life extension technologies to the forefront of our innovation."
For more information:
Proseal
Thomas Reimann, Proseal Account Manager
www.proseal.com
Dittoe Public Relations
Claire Graham
claire.graham@dittoepr.com
www.dittoepr.com