Three key trends driving demand for vacuum skin packaging

Long renowned as an innovative packaging application for fresh red meat, there’s now fast-growing demand for vacuum skin packaging throughout food supply chains. The solution is also becoming a first choice for fish, seafood and poultry packaging.

Laurence Richard, EMEA Portfolio Director at Sealed Air, explains why the Packaging and Packaging Waste Regulation (PPWR), extending shelf life and a shared approach to improving sustainability are seeing food processors and retailers prioritising vacuum skin solutions.

Did you know?

Article 9 of the PPWR refers to ‘packaging minimisation by design and use’ and ranks as a high priority for food processors and retailers. From 1 January 2030, manufacturers and importers must ensure packaging is designed so that its weight and volume is reduced to the minimum necessary to ensure its functionality. There will also be a requirement for grouped packaging, transport packaging and e-commerce packaging to adhere to a maximum empty space ratio of 50%.

Trend #1
Packaging and Packaging Waste Regulation (PPWR)

In 1970, CRYOVAC^® Brand Darfresh^® was developed and patented by SEE^®. One of the reasons it quickly became a popular choice for fresh red meat packaging was because of its ability to reduce pack sizes. Modified Atmosphere Packaging (MAP) was widely used throughout the category, meaning there was a lot of empty space in each individual pack.

Skin vacuum solutions are specifically designed to wrap tightly around the shape of a food product, eliminating most the empty space that would be found in a MAP alternative. The PPWR is now driving growing awareness of this packaging minimisation performance.

Skin vacuum technology delivers a high abuse resistant skin that protects food against oxygen and potential contaminants, while minimising overall pack size. In some cases, CRYOVAC^® Brand Darfresh^® eliminates empty spaces to reduce packaging volume by around 50%, compared to MAP alternatives.

Skin top webs are applied gently during the packaging process, meaning the solution is being increasingly used in delicate food applications such as fresh fish, seafood, soft cheeses, minced meat and poultry.

Innovations in vacuum skin technologies also allow food retailers and processors to reduce plastic usage. Skins are becoming thinner and more lightweight, while maintaining high levels of abuse resistance and oxygen barriers. SEE^® has developed Darfresh^® skin top webs that are 80 microns thick and deliver performance comparable with skins ranging from 100 to 120 microns.

Trend #2

Extending shelf life

Fresh and frozen seafood supplier Lepore Mare is a good example of another key trend that’s driving the growing adoption of vacuum skin solutions: the extension of shelf life. The Italian company has been collaborating with SEE^® since 2022 and is among the first in the seafood sector to introduce single-material plastic trays.

CRYOVAC^® Brand Darfresh^® technology is used to seal a vacuum skin to a bottom tray, creating a high oxygen barrier that preserves seafood freshness for longer. Seafood product shelf life has been extended in some cases by up to 30%, versus prior packaging systems. This allows Lepore Mare and retailers to extend the shelf life of the products and reduce potential wastage.

The risk of food wastage is further minimised through customer satisfaction. Lepore Mare recognises that consumers are increasingly looking for fresh, high-quality products and place great importance on food safety. Packaging is crucial to influencing shopper perceptions in these areas and products must be presented in perfect condition. Crystal-clear, high-gloss skin packaging can improve product aesthetics, while high barrier resistance to oxygen can prevent food discolouration. Strong and reliable seals can avoid leaks and the risk of food cross-contamination.

Trend #3

Shared approach to sustainability

It’s increasingly important for operators throughout supply chains to collaborate and share responsibilities for improving sustainability. Legislation such as Scope 3 Emissions place greater onus on reducing environmental impact, from food sourcing right through to the point of sale. All parties, such as food retailers, processors, distributors must support each other’s sustainability goals and vacuum skin packaging helps achieve this.

Smaller packaging volumes can mean more food is transported per cubic metre of vehicle space. This can create an opportunity to reduce supply chain mileage, vehicle usage and carbon emissions. Furthermore, cube optimisation could allow retailers, wholesalers and distributors to reduce refrigeration requirements and energy usage by storing and displaying more food products in fridges, freezers and cold stores.

Process efficiencies and improved productivity during vacuum skin packaging are also contributing to supply chain wide efforts to minimise waste. Conventional skin packaging systems may have produced around 30% - 40% material scrap, while CRYOVAC^® Brand Darfresh^® on Tray systems are able to deliver packs with zero scrap. This is supported by faster cycles during packaging.

These three trends are driving the growing adoption of vacuum skin packaging, which shows little sign of slowing down. A fourth trend – recycled plastics and recyclability – is an important part of Europe’s transition to a circular economy. This is leading to new innovations in skin packaging, such as recycle-ready and recycled-content films, that is likely to enhance the solution’s sustainable performance and encourage greater demand throughout supply chains.

The fourth trend of recycled plastics and recyclability is the subject for a future blog post, where we’ll consider important parts of the PPWR, including Articles 6 and 7, and how these elements are creating new recyclability performance requirements for packaging. Stay Tuned!