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Chicken packaging do-over

New software-assisted tooling for vacuum skin packaging brings a number of advantages, while a switch in lidding material and new thermoformed trays complete the upgrade.

The TraySkin xplus tooling now available in the Model A4 tray sealer takes a less aggressive approach to film handling th
The TraySkin xplus tooling now available in the Model A4 tray sealer takes a less aggressive approach to film handling th

Refrigerated chicken parts vacuum packaged in unsupported film has been a staple for some time at Locust Point Farms in Elkton, MD. But about two years ago the firm decided to add a tray to its vacuum skin packaged offerings because the in-store appearance was so much better, says company owner Timothy Detweiler.

To make the switch to trays, the firm installed a Model A4 from Sealpac. A chamber-style machine, it packages trays two up, which is perfectly adequate for the kind of volumes Locust Point has in mind.

A conventional CPET tray and equally conventional vacuum skin pack film were selected when Locust Point got launched with this package format. But in the past few months, both tray and film have been changed. Trays are now supplied by CPT-Go Green and SkinFreshTop lidding material is from Schur Flexibles.

The change in lidding material—described by Schur Flexibles as a seven-layer coextrusion that includes EVOH for oxygen barrier—came about as Locust Point sought to optimize its packaging from a cost perspective. The new material has all the performance characteristics required. And because it’s less robust, it costs less. Unfortunately, as Locust Point began trials with the new material, they discovered that as it went through the rigors of being softened and stretched up into the vacuum heat seal tooling of the Sealpac machine, a gap in the barrier material could occasionally be produced, which in turn could compromise shelf life.

As luck would have it, Sealpac had only recently introduced its TraySkin xplus technology, which is designed to be gentler on cost-optimized lidding materials like the one Locust Point had switched to. When Sealpac’s previous tooling closed on a package, the lidding material was rather aggressively drawn up into a dome where heat and a predetermined dwell time conditioned the film so that it could be blown down out of the dome and onto the product-filled tray. Heat-seal tooling would then close on the flange of the tray as vacuum was applied, thus producing a vacuum skin-packed tray.

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