BANANA PACKAGING FARM TO RETAIL NEXT GENERATION PACKAGING

KEY ISSUES At the Banana Industry Congress, held on the 1–4 June 11, a report commission by the Australian Banana Growers Council was table by Dr. Jenny Eckman’s identifying 5 key packaging issues causing downgrading of bananas and restricting sales growth. Input into this report was gathered from a group discussion involving Growers, Retailers, Marketing Agents, Transporting Companies and Supply Companies.

5 KEY ISSUES Carton rub (between fruit and carton). Transit rub (rub between fingers). Compression Bruising. Neck damage. Ventilation.

Carton rub Carton rub is the marks caused by the friction between the skin of the banana and the carton. The banana depends upon the plastic sticking to it so the friction is between the carton and the plastic and not between plastic and banana or between the banana and the carton.

Carton Rub This problem has been best resolved by use of plastic bag liner to fully enclose the fruit from the inner of the carton.

Transit Rub Transit rub is the friction marks caused during transit by ; 1.Dehydration of the bananas. 2.Loosely packed bananas in carton. 3.Excessive handling of fruit during transit (transhipping). 4.Rough ride during transit.

Transit rub - Hydration Avoiding excessive dehydration of freshly packaged bananas is critical to reducing transit rub. 1.Ensure packed cartons are pre-cooled in high humidity coolroom as soon as palletised. 2.Minimise time in low humidity environment. 3. use of bag liner for higher moisture retention compared to carton liner.

Transit rub - Hydration Carton liner Carton liner transit rub Bag liner

Transit Rub – Loosely packed Loosely packed carton can allow the approximately 15 clusters of fruit to move independently of each other, causing friction rub between the fingers of bananas. Particularly on the top 2 palletised layers of packaged bananas as they very load on the fruit allow for bananas to move or bounce. Possible solutions are; 1.Tighter packed carton with extra fruit and more attention to packing technique. 2.Tensioning of liner either by twisting of the bag liner or use of tape to tension, particularly on top layer. 3.Allow the packaged bananas to have a minimal load bearing (excessive load will compression bruise the bananas).

Transit Rub Tensioned by twisting bag liner Tensioned by using tape

Transit Rub - transport Other causes of transit rub during transport can be; 1.Poorly strapped allowing palletised cartons to move independently. 2.Lack of and or wrong palletising glue allowing palletised cartons to move independently.

Transit Rub - Transport Stretchable palletising tape can be used. The tape has a memory and keeps constant pressure on the whole pallet preventing cartons to move independently. Side wall locating lugs or corner locating lugs, in combination with layer locking pads, prevents one piece cartons moving independently of each other. Correct palletising glue prevents two piece cartons moving independently but allows the cartons to be depalletised without carton fibre tear.

Transit Rub - Transport Locating lug system Locking sheet

Compression bruising and Neck damage Compression Bruising and Neck Damage are caused by the excessive weight being carried by the banana, causes are; 1.Over packed cartons. 2.Collapsed packaging. 3.Packaging not supporting load above. 4.Damaged pallets and or damage to pallets by forklifts leaving cartons partially unsupported.

Neck Damage Neck Damage is break or a bruising of the neck of the banana and can be caused by the following. Poor handling at harvesting and packing. Transport. Carton failure. Different size carton above not stacked on the support structure of the carton below.

Compression bruising and Neck damage OVER PACKING

Compression bruising and Neck damage Over packing – With the introduction of the 175mm one piece carton the height lifted from 160mm, 6/layer 2 piece carton, to 175mm. Extra height in the lugs allow the next carton above to locate. Lifting the wall height of the carton (15mm or 9% higher) transfers the weight load from the bananas to the carton, however it is important for the fruit to carry some weight to prevent Transit Rub or fruit bounce.

Compression Bruising and Neck damage

Compression bruising and Neck damage By lift the height of the carton, places increased loading on the carton. By taking board used for the lid has allow a cost effective strengthening of the carton to avoid carton collapse. 3 layers laminated together & double corner post. Partial 2 layers & single corner post.

Compression bruising and Neck damage Compression bruising is caused by the banana supporting excessive weight, generally this is caused by carton failure or over packing of the carton. Carton failure can be either collapsing of the carton side wall or a smaller carton placed on top of the carton inside the perimeters of the support structure of the carton.

Compression bruising and Neck damage When different size cartons are palletised together, if a smaller carton above isn’t supported by the carton structural supports below it can cause compression bruising and neck damage.

Compression bruising and Neck damage Currently we are under taking testing on a developmental ledge support one piece carton.

Compression bruising and Neck damage

Compression bruising and Neck damage - Transport New pallet stoppers attached to the forklift will prevent forklifts from breaking the leading edge pallet boards.

Compression bruising and Neck damage - Transport

Ventilation Good ventilation is important at all stages of the life cycle of the packaged bananas;  Pre-cooling once first packaged.  Transportation.  Ripening.  Back of store storage. Over ventilation, particularly in low humidity environments, can cause the bananas to dehydrate.

Ventilation Incorrect ventilation can cause uneven ripening of the bananas. Excessive ripening of the bananas. The fruit to boil. Reduce self life.

Ventilation Once the bananas are forced ripen the heat is generated by the banana inside of the carton. It is critical, for longer self life, the heat is allowed to ventilate. Normal back of retail store practise is to removed lid and pull back plastic and restack.

Ventilation Standard 6/layer carton2 piece 6/layer stacked at back of store to allow for greater ventilation for longer self life of bananas.

Ventilation One piece carton has 4 way ventilation, allowing rising heat to escape through each side wall panel. No lid allows heat to vent upwards through the stacked cartons. Superior venting system could allow for staff to stack the packaged bananas away with the need to lift lids and fold back plastic. Eliminating a procedure for store staff.

Ventilation

SUMMARY Carton rub eliminated – Use of bag liners. Transit rub reduced – Keeping bananas hydrated through the use of bag liners. – Early pre-cooling of packaged bananas. – Tensioning of bag liner either by twisting or tape particularly on top 2 layers. – Use of correct palletising glue (2 piece carton). – Palletising stretchtape with memory to contain palletised cartons as one.

SUMMARY Compression Bruising and Neck damage reduced – Transferring load from bananas to carton by lifting height of side wall by 15mm, still allowing some load on bananas to prevent bouncing or transit rub of the bananas. – Strengthening of the carton side wall and structure load bearing points to handle extra load and prevent carton collapse. – Increasing structure load bearing points to accommodate cross stacking at Distribution Centre with different size cartons. – Forklift fitted with attachment to prevent pallet board damage.

SUMMARY Ventilation issues resolved – Use of 4 way venting system of one piece carton. – Removal of lid, with one piece carton, allows for vertical ventilation of stacked packaged bananas. – Combination of one piece and bag liner eliminates need for removal of lid, folding back of plastic and restacking of cartons at back of store.

Perceived Benefits to Retailer Reduced waste from Distribution Centre to Back of Store provided by superior supporting structural strength and extra height of carton – Reduced compression bruising and neck damage. One less critical staff procedure to be performed – with the bag liner and 4 way venting open tray carton providing ‘portable shelving system’ that provides superior venting eliminating the need to remove lids, fold back liners and space stack inners.