About 32 million Americans are reported to have food allergies. This translates to about 1 in 10 adults and 1 in 13 children. Allergens, the root cause of these allergies, have been a major factor in inciting produce recalls in the recent past.
Allergen contamination of fresh produce may come from poor hygiene during production or repacking. Additionally, mislabeling, another trigger for produce recalls, can also happen during repacking.
Tracing the source of contamination can be difficult when inventory control is manually performed using pen and paper or basic spreadsheet programs. Sorting produce according to lot numbers can also be tricky if the lot information is not encoded in an automated system. In situations like these, This is where Enterprise Resource Planning (ERP) users have an advantage over their peers.
With an ERP platform like Silo, wholesalers as well as growers and shippers can maintain bidirectional visibility over the supply chain. An ERP can be used to trace the contaminated produce back to its lot location and supplier, and it may also help in adhering to labeling requirements and sorting produce during repacking processes.
What is repacking?
The process of repacking takes place when grower-shippers receive a shipment, where they usually repackage the perishables to adhere to the packaging standards of the fresh produce industry. This includes using eco-friendly packaging, appropriate labeling, and including warnings where necessary as required by the FDA.
Repacking is done to ensure that fruits and vegetables supplied to customers are in good condition and free from allergens. The repacking materials are usually designed to protect the fresh produce from physical damage and help it retain optimum temperature, light, and moisture conditions during handling and transportation.
Here are some things to note about repacking. The packaging material must be:
- Moisture-proof to prevent drying of the produce;
- Physically resistant to damage so that the produce is not bruised, punctured, or squashed during transportation;
- Properly sealed and arranged on pallet bins.
Most commonly used materials for repacking food produce
Paper and mesh bags
While widespread at one point, paper bags are no longer as commonly used as they used to be. In fact, onions and potatoes are usually the only produce items that still use this type of packaging these days. The sturdier mesh bags are more versatile and can be used in repacking several types of produce, such as cabbages, citrus fruits, and garlic in addition to potatoes and onions. While mesh bags are becoming more widely accepted and utilized in the industry, it’s still possible to find a majority of onion and potato products still being packaged in paper bags.
Film plastic bags
Plastic bags are one of the most commonly used materials for repacking fruits and vegetables. The fact that they are low-cost and reduce packing costs is one of the most likely reasons for this.
The film plastic bag is a particular variant that sees use for perishables like tomatoes. Since they’re clear and allow for easy inspection of their contents, they’re a popular choice when you need to verify if the contents are still fresh.
They also conveniently accept high-quality graphics like branding images, barcodes, and labels. Film plastic bags are made in different thicknesses and of various grades, all of which are engineered to control the amount of environmental gases getting into the bag.
Shrinkwrap
Shrinkwrap is one of the newest and emerging packaging packs for fresh produce. As the name suggests, it is designed to prevent the shrinking of its contents and prevents moisture exchange between the inside and outside of the packaging. It’s commonly used in repacking cucumbers, onions, apples, and some other fruits and vegetables.
In addition to reducing the shrinkage of its contents, it protects them from physical damage and provides a good surface for stick-on labels.
Clamshells
They are packages with heat-formed plastic tops and bottoms. They have become increasingly popular for repacking berries, mushrooms, small fruit, and other such fresh produce that can be easily damaged during handling and transportation. They are incredibly versatile and relatively inexpensive for packaging produce.
Corrugated fiberboard
Just like clamshells, corrugated fiberboards are also incredibly versatile and can be used for packing most vegetable produce. They may be made of styrofoam or plastic and are recyclable, which makes them a great environmentally friendly option.
6 ways to simplify the repacking process for grower-shippers
Streamlining the repacking process is an essential aspect of any grower-shipper’s business, since it directly corresponds to the efficiency and effectiveness of their functions. After you’ve selected the right category of packaging for your produce items, here are some factors to consider that can greatly simplify your repacking procedures.
Ensure a clean work environment
Disorganized and dirty working environments increase the potential for contamination, and having a lot of clutter and misplaced items within the repackaging environment can also slow your operations down. It’s important to ensure that the environment is always kept clean and hygienic, and that unnecessary materials are removed from the area after use.
You can promote better organization by:
- Removing unused materials to the repacking area
- Regularly mobilizing workers to clean the production line or repacking area
- Optimizing repacking area for the tasks in each station
- Organizing inventory to be closer to the repacking area
Utilize custom labeling
Custom labeling is a valuable investment in the food repacking process because it allows you to streamline your produce packaging operations. Custom labels make for consistency in your labeling procedures.
By making liberal use of custom labels, you can be sure you’re not missing out essential information that comply with FDA standards. You’ll also reduce the chances of mislabeling that can lead to expensive recalls.
Incorporate automated packaging machines and MAP
With automated packaging machines, you can repack several lines of produce items within minutes.
Modified Atmosphere Packaging (MAP) technologies play the role of ‘preservers’ in fresh produce.
Since fresh produce is minimally processed and does not usually contain any preservatives, using MAP helps maintain the right oxygen and nitrogen levels in the package to delay the oxidation and spoilage of the freshly picked produce.
Establish quality control and safety standard metrics
By establishing quality control and safety standard metrics, you ensure consistency across various factors that need to be considered for all packaging. Common quality control metrics to consider are the moisture content of produce before packaging, the temperature of the carrying container, and the size and thickness of the carrying material.
It’s also necessary to establish standards for hygiene in washing the perishables, gear to be worn by employees when handling produce, and pest control protocols when applicable.
Make use of real-time inventory
During repacking, a lot of information about the repackaged produce needs to be tracked, including price and weight of produce, lot number, supplier information, date of order received, and expiry date. Collecting this manually slows down the repacking process greatly and reduces the scale at which you can function. It can also lead to more errors and incorrect values due to the higher chance of human error.
Even manual data entry into spreadsheets, though more convenient and efficient than pen and paper, is still largely inefficient and time-consuming. ERP software is much more efficient and accurate in inventory keeping, as it allows businesses to track and manage all relevant details about their repacking in real-time.
The ultimate solution: ERP software
ERP solutions are the foremost solution for managing the number of units of each type of produce, cartons or plastic bags per cast, lot information, and other shipping details are accurately reflected on the produce label.
It also makes the process of barcoding, labeling, and inventory management much simpler, which are all mandatory for efficient repacking.
In addition to aiding regulatory compliance, an ERP solution can also help in accurately calculating weights for truck packing. For the best results, aim to utilize platforms that offer advanced features like traceability, temperature control, and seamless communication options with relevant stakeholders across the supply chain.
