Stand-up resealable pouches are among the fastest-growing packaging formats for fresh fruits and vegetables, thanks to their attractive, user-friendly design. However, achieving effective moisture control while maintaining a modified atmosphere has remained a challenge, particularly for moisture-sensitive produce such as cucumbers. Addressing this gap, StePacPPC introduces a new generation of the popular retail pouches engineered for high-performance shelf-life preservation and convenience.
The groundbreaking Xgo™ PAZ Pouch applies advanced flexible-film technology to optimize moisture and atmosphere control for maintaining the freshness of moisture-sensitive produce. Packers and retailers of cucumbers, which are particularly susceptible to excess moisture, are already reaping the benefits of this innovative patent-pending retail packaging. Whether for home use or enjoyment as a snack on the go, the PAZ pouches help preserve the quality of the cool vegetable for up to 16 days, maintaining their crisp texture, flavor and vibrant color from harvest, through retail display to home refrigeration.
There are several challenges in the cucumber supply chain that can limit the use of modified atmosphere packaging. Cucumbers are often packed and sold in laminated stand-up pouches, whose low water vapor transmission rate (WVTR) restricts the release of excess moisture, creating conditions that accelerate microbial decay. To prevent moisture build-up, the packaging is often macro-perforated.
However, this sacrifices modified atmosphere, accelerates dehydration and shortens shelf life, and even with macro-perforations, there is likely to be condensation in the package. These issues become more pronounced when cucumbers cannot be sufficiently cooled before packing, are subject to unstable supply chains or are displayed at ambient conditions at the retailer before refrigeration in the consumer’s home.
3 in 1 solution
The Xgo™ Modified Atmosphere (MAP) films work by incorporating three functions in one pouch: modified atmosphere, modified humidity, and condensation control.
“With traditional laminated pouches, achieving modified atmosphere for shelf-life extension comes at the expense of optimal moisture control,” explains Gary Ward, Ph.D., CTO for StePacPPC. “Conversely, if you want optimal moisture control, you need to macro-perforate, which is at the expense of modified atmosphere and increases the risk of dehydration. This is the balance fresh produce packagers struggle to reach. Xgo™ PAZ pouch’s three-in-one design successfully overcomes this limitation and offers a comprehensive solution that effectively maintains appearance and quality of the produce, extends the marketability window, and ultimately reduces food waste and costs.”
The patent-pending pouch is already establishing its presence in North America. Fresh produce providers there are leveraging the pouches’ unique ability to manage moisture during unstable supply chains. They keep produce dry, crisp, and free of microbial decay all the way to the consumers’ refrigerators where they continue to preserve quality and freshness.
Wholesum packs mini cucumber snacks in Xgo™ pouches
Wholesum Family Farms, Inc. recently debuted its Lil’ Ones™ Organic Baby Cucumbers snack packs using 8 oz. portable Xgo™ pouches. The appealing compact packaging offers a convenient format for on-the-go snacking of fresh organic vegetables. Before commercial expansion, the company conducted 16-day shelf-life tests under simulated supply chain conditions. At day 16, the PAZ pouch delivered a 29 percentage-point advantage in overall quality for organic baby cucumbers compared with a top-seal alternative, and a 10 percentage-point advantage for organic mini cucumbers compared with traditional macro-perforated packaging. The improved performance was reflected in reduced moisture, decay and mold, together with better product visibility, appearance and overall quality.
“At Wholesum, we're always looking for ways to remove barriers between consumers and fresh, healthy produce,” adds Joanna Jaramillo, marketing manager for Wholesum. “Excess moisture may seem like a small challenge, but it can have a significant impact on how consumers perceive freshness. Through our partnership with StePacPPC, we've been able to bring a solution that helps cucumbers maintain the clean, fresh appearance shoppers expect, creating a better experience and bringing more joy to healthy snacking.”
The new Xgo™ pouches are also being adopted by packagers of exotic fruits, including lychee, pitaya, rambutan, and longan for maintaining their quality, vibrant appearance and fruity flavor while extending their shelf life. The pouch keeps the produce dry during unstable supply chains and is a more suitable alternative to clamshells which typically must be opened in order to wipe the underside of the lid of the condensation after such temperature fluctuations. Florida-based Freshway Produce, Inc. employs the innovative PAZ pouch exclusively for its exotic fruit line, enabling packing at source in the final retail format and eliminating the high cost of repacking upon arrival in the U.S.
“We offer Xgo™ PAZ pouches with variable WVTR films that can provide precisely the required level of moisture control and modified atmosphere properties for specific produce items,” adds Ward. “This makes the packaging adaptable for a range of fresh fruits and vegetables. We tweak the film in accordance with the unique preservation requirements of the produce being packed and the prevailing supply chain conditions.”
The Xgo™ stand-up pouches are available in a range of sizes and feature a convenient resealable closure. The visually appealing structures stand upright on the supermarket shelves as they showcase with clear visibility (thanks to its condensation control properties) the freshness and quality of the produce inside.
StePacPPC will be showcasing at the upcoming IFPA in Orlando, Oct 15-16, Booth #2933