A large Israeli food conglomerate redesigns its flexible packaging for improved sustainability

Major players in the fresh produce industry increasingly realize their responsibility to engage in more sustainable practices, especially when developing and choosing packaging for their products. They understand that their packaging must contribute to minimizing greenhouse gas emissions and soil contamination by becoming completely recyclable or reusable—all while delivering fresh produce safely, maintaining freshness, extending shelf life, and continuing to be cost-effective.

To this end, Strauss, a major Israeli food distributor, enlisted the help of Shay Zeltzer along with polymer engineers at ROP Ltd. to redesign its entire line of flexible packaging. The project team from Strauss consisted of representatives from the production plant, packaging procurement, and quality assurance. Five goals were defined:

1. Decrease total amount of plastic used

2. Improve presentation

3. Reduce costs

4. Design packaging that was 100% recyclable

5. Maintain or exceed produce quality and shelf life of the company’s packed salads and fresh leafy greens

The multi-stage project, which included the design and testing of various films, lasted nearly three years. The winning film, a Cast Polypropylene-based film named FC-SP/AF 50 was selected after extensive testing in ROP’s postharvest lab, Strauss’s QC testing facilities, and external food-safety labs. Logistic chain simulations were also conducted with a variety of products including washed romaine, washed rocket, mixed greens, shredded cabbage, and carrot mix.

A 28% reduction in plastic weight was achieved by reducing the film gauge to 50 microns. Film cost remained the same even though global resin prices rose during the development period. Due to the lower film gauge, savings in transportation and storage were also realized as each roll could hold more impressions.

The new mono-polymer film is super clear with exceptional antifog properties resulting in superb presentation. Produce shelf life now surpasses the 11 days proclaimed on the “Sell-by-date” on the packed salads. Most importantly, the new film helps Strauss meet its goal to reach 100% recyclability/reusability by 2025.

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