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POLYOLEFIN FILM TRIALS
Perfect Automation has recently undertaken groundbreaking trials with our existing customers to eliminate PVC film from their mushroom packaging processes, aligning with the Australian Packaging Covenant Organisation (APCO) standards. This initiative aims to completely remove PVC film and replace it with a new Japanese polyolefin film, offering an eco-friendly solution tailored for the produce sector.
The customers participating in the trials are utilising Omori STN-8500 Tray Stretch Wrappers, which required only minor adjustments to accommodate the new polyolefin film. These changes were implemented under the supervision of our skilled technicians, who not only made the necessary adjustments but also trained operators and maintenance staff to ensure they could manage future modifications themselves.
Minor adjustments were made to allow for the adaptability of the polyolefin film which proved effective, and the trials continued smoothly across various formats, including 500g and 250g mushroom cups, as well as 500g and 250g sliced mushroom packs. An integral part of the trials involved rigorous micro-testing, including colour measurements, weight assessments, and controlled lab testing to monitor colouration and water weight. Customer testing was conducted on days 3, 5, and 8, all within the target range with no observed weight loss. We also conducted a comparison between perforated and non-perforated films. Perforated films are known to achieve breathability by allowing gases such as CO2 and ethylene to escape, while non-perforated films demonstrate moisture retention, a critical factor in preventing dehydration. Given mushrooms’ sensitivity to both moisture loss and gas exchange, this balance is a key consideration in maintaining product quality throughout the packaging process.
The trials included an evaluation of packed mushrooms in standard refrigeration compared to a chillvac process over a 16-day period. The chillvac method employs vacuum cooling to rapidly reduce the packaging temperature, effectively slowing microbial growth and improving shelf life without chemical preservatives — essential for long distance transportation.
ACHIEVING OUTSTANDING RESULTS IN CONTROLLED TRIALS
RESULTS
Standard Refrigeration Process: In the standard refrigeration test, mushrooms packaged in Asahi Japanese polyolefin film were stored for 16 days. Day 9 results showed minor condensation buildup at the base of the packages outside the container, but no condensation inside or on the mushrooms. Both colour and shape remained intact, meeting retail aesthetic standards. By Day 16, condensation levels remained consistent, with slight discolouration noted but firmness preserved, meeting key texture and freshness criteria. While the trial highlighted some opportunities for improvement in minimising condensation, the overall results were promising. The mushrooms maintained their quality throughout the test period, and the minor adjustments made to the packaging machine facilitated seamless use of the new polyolefin film without the need for major modifications.
Chillvac Process: In the Chillvac trial, our customers utilised the chillvac process, designed to extend shelf life for interstate transportation. Key findings indicated no condensation throughout the test period, with mushrooms maintaining their colour, firmness, and texture—fully meeting customers’ requirements for product quality. So far, the initial trials have successfully demonstrated that Asahi polyolefin film can effectively replace PVC film in the produce sector. With ongoing testing and support from Perfect Automation, our customers are well on their way to eliminating PVC film from their mushroom packaging, aligning with sustainability goals while delivering high-quality products to consumers and significantly reducing environmental impact.
Next Steps The next step is to expand the trials to encompass the entire supply chain of distribution, evaluating how the film performs in real-time scenarios for Australian growers. While the Japanese film has shown success in Japan, our unique environmental factors will play a crucial role in its performance here. With promising initial results and our approach to delivering both sustainable packaging solutions and optimal results for our customers, we aim to complete these expanded trials by early 2025.
