SubscribeExcellent barrier quality is vital to maintaining product freshness over a long shelf life, but its value is not restricted to this: it is also an increasingly important aspect of a brand's image. Food that does not taste or look appetising, as the result of poor barrier protection, will be remembered by consumers for all the wrong reasons.
Similarly, whilst packaging needs to address shelf-life concerns, it must also be attractive and convenient in design, otherwise consumers may not notice the product in the first place.
As Europe’s leading rigid plastics packaging supplier and a major producer of food packs for a variety of markets, RPC leads the market in barrier technology, with a choice of materials and manufacturing processes.
RPC is able to concentrate on the development of innovative multi-layer solutions because of its autonomous structure, with individual sites within the Group being responsible for their own day-to-day operations.This enables each site to offer particular expertise and specialisation in specific markets and manufacturing technologies and means customers benefit from this focused approach.
The result is that RPC is a “one stop shop” for multi-layer needs, with expert sites devoted to thermoforming and blow moulding, as well as high barrier sheet for form fill seal applications. Close liaison between the sites ensures a regular exchange of ideas and technical developments and, very often, two or more sites will work together to provide a complete pack solution for a customer.
Available in standard and bespoke designs, RPC’s multi-layer packs can be augmented by a range of decoration options to help maximise individual brands’ image and appeal.And it is their advanced technology that ensures this appeal is maintained once the pack has been opened.
RPC Corby’s ‘Ultra’ Expertise in Blow Moulding
RPC Corby’s pioneering work in co-extruded blow moulding technology established the standard for multi-layer packaging, with its development of squeezy retail bottles and larger foodservice jar for sauces, ketchups and dressings. More recently, the site has further developed its multi-layer technology with the introduction of packs that can allow hot fill, pasteurisation, sterilisation and aseptic filling.
The benefits of multi-technology are particularly transparent in busy foodservice environments, with HACCP recommendations focusing on the need to reduce the use of glass packaging. Multi-layer polypropylene jars are lightweight and shatterproof while still providing extended product protection and preservation.
One example of RPC Corby’s innovation in this area is the new style of ‘thermic®’ ribbing for RPC Corby’s Ultra multi-layer polypropylene jar, which has been introduced across the entire Ultra jar range after the success of the ribs on the 500ml size.
Successful trials of the thermic technology have proved the jars’ ability to expand during the heating process and then contract to their original shape during cooling, without any panelling.
In addition, RPC Corby has developed a solution to allow crease-free labelling of the jars, a valuable addition to the range’s decoration options.
The expanded Ultra range now includes 1 litre and 2.4 litre sizes in addition to the original 500ml jar. In recognition of the significance of the thermic ribbing technology the range has been renamed Thermic Ultra.
The 500ml and 1 litre jars have been fully approved by two major customers in France, while the 500ml size has also successfully passed a complete transit and distribution test with a leading supermarket.
“Thanks to our pioneering work in co-extruded blow moulding technology, our multi-layer bottles and jars may now be regarded as genuine alternatives to glass for the packaging of high temperature processed foods,” comments Nick Meyrick, Sales and Marketing Manager, RPC Corby.
“Our new Thermic Ultra range and innovative labelling solution show our continuing commitment to the technology and this will be supported by further major investment in new production machinery in 2004 which, among many benefits, will improve the price competitiveness of our products.”
RPC Bebo Plastik – Enhancing Ready Meal Quality Through Thermoforming
RPC’s Bebo sites across Europe are leading the way in multi-layer thermoforming innovation. An extensive choice of tubs, trays and pots is available for ready meals, salads, fruit, snacks and functional foods, all available in multi-layer to offer an effective barrier against oxygen ingress.
This has been particularly critical as food markets have themselves developed and evolved to meet changing consumer demands.For example, the growth in convenience foods, ready meals and eating ‘on the go’ are a reflection of increasingly busy lifestyles.This has led in turn to pressure on space in chill cabinets.
Now RPC Bebo Plastik, in collaboration with its customers and raw material producer Ciba, is leading the development of a new generation of barrier films, incorporating oxygen scavengers, to further improve and maintain the quality of ready meal ingredients during their shelf life.
Proven barrier materials such as EVOH offer extended shelf life for products by impeding the entry of oxygen into a pack.Oxygen scavengers go one step further by “capturing” oxygen within the barrier layer of the sealed pack, ensuring that it never reaches and reacts with the product.This therefore further minimises any deterioration, particularly in colour or flavour.
Tests by two of RPC Bebo’s major customers have shown that ready meal ingredients in the new packaging, such as vegetables and mashed potatoes, offer clear flavour and colour advantages over those in conventional barrier packaging that does not contain oxygen scavengers. Importantly, consumers also noticed that overall ‘freshness’ had improved even after a six-month shelf life.
The photograph below shows an example of a product with (left) and without oxygen scavengers
Dishes featuring the new oxygen scavenger film have already been successfully adopted by both Unilever Bestfoods and HJ Heinz.
Barrier Sheet Extends Multi-Layer Possibilities
RPC is also the principal European producer of multi-layer high barrier sheet, used for both our own packs and for form-fill-seal technology, opening up our barrier capabilities to an even wider variety of applications.
For example, RPC Cobelplast developed a special multi-layer sheet for the “Easycup” development from Weasypack for form fill seal applications.
Easycup is a portion pack that features accordion-shaped sidewalls, achieved by utilising a special mould technology.This indicates to the consumer that a squeezing action is required which, combined with a simple to open tab, allows easy, controlled dispense of the product.
RPC Cobelplast worked closely with Weasypack in the development of the multi-layer PS sheet, which had to have a reduced thickness and the necessary elasticity in order to be moulded into this unique shape.
Easycup is ideal for all types of food portion packs, including mayonnaise, ketchup, mustard and syrups as well as milk and coffee creamers. The potential for other aseptic food packing applications is also being investigated.
In addition, the attractive packs are also suitable for a range of non-food products such as shampoos and bath gels.
Contacts:
RPC Corby
Tel: +44 (0) 1536 263 488
Fax: +44 (0) 1536 272 910
Email: sales@rpc-corby.co.uk
RPC Bebo Plastik
Tel: +49 (0) 4761 860 0
Fax: +49 (0) 4761 860 201
Email: info@rpc-beboplastik.de
RPC Cobelplast
Tel: +32 (0) 9340 9911
Fax: +32 (0) 9348 4965
Email: rpc.lokeren@cobelplast.be