Value stream mapping (VSM) has been used to justify the additional costs of switching to a new type of shrink lidding case ready packaging, which is much shallower than conventional trays and uses up 40% less material by weight.
Trials for an unnamed UK fresh meat processor, which handles 10M trays a year, were conducted using a new type of lidded modified atmosphere packaging (MAP) called Mirabella, which is just being launched into the UK by Seal Air Cryovac.
Unlike conventional MAP of meat, which has around three times the volume of modified atmosphere to that of product, Mirabella comes in a much shallower tray with reduced pack height. As a result it cuts costs for storage, distribution and display.
The VSM exercise, which seeks to maximise operations along the supply chain that add value while minimising those that do not, proved the benefits of using the new packaging, despite costing up to 30% more. The additional costs result from the special double-skinned lidding used in Mirabella. “The benefits far outweighed the extra costs,” said a Seal Air Cryovac spokesman.
“You’re selling almost double the amount in those crates [with Mirabella]”, said Laura Bryant, European supply chain analysts for Seal Air Cryovac, who carried out the VSM exercise. While the packer witnessed a 30% reduction in crate usage, said Bryant, the benefits for retailers were even greater.
Much of the manual handling necessary with traditionally packaged products at regional distribution centres (RDCS) and in store were removed; truck movements from RDC to stores were cut by 160 (30%) and more product could be displayed in less space in store. “100% more packs were on display at any one time,” said Bryant.
With Mirabella, even though the lid is in contact with meat, discolouration of meat is avoided by the use of novel double-skinned polymer. This has an impermeable ethylene vinyl alcohol polymer (EVOH) outer gas barrier layer and an inner permeable membrane, which allows oxygen to diffuse through and maintain a microscopically thin oxygen layer between the two. The flow of oxygen over the surface of the meat helps maintain the rich red colour desired by retailers and consumers.