Envalior, a global manufacturer of sustainable and high-performance engineering materials, and Dutch company PerfoTec, which specializes in smart packaging technologies for fruit, vegetables and flowers, have introduced a new film technology for packaging fresh produce. This solution eliminates the need for protective gas mixtures used in modified atmosphere packaging (MAP), because a natural, balanced atmosphere is created inside the pack. The film adapts to the respiration rate of the product, significantly extending its shelf life, quality and freshness.
The key element of the system is the combination of ultra-precise laser perforation with the permeability of the film based on Arnitel TPC thermoplastic copolyester elastomer produced by Envalior. Such a packaging design enables precise control of gas parameters around the packed product and effective moisture management. This next generation technology has already been implemented in PerfoTec BinLiner bags for lining and sealing large harvest containers and in PerfoTec pallet covers for transport.
PerfoTec reports that for bell peppers the new packaging design makes it possible to extend their natural shelf life fourfold. After two weeks of storage at 8°C there is no weight loss, fungal growth or color change. For peonies, storage of flowers for 14 weeks without signs of aging is possible. The solution is designed individually for specific crops, taking into account their respiration rate and gas permeability requirements.
Controlled atmosphere and humidity in the package
Microperforation of the film and its permeation properties make it possible to individually adjust the oxygen and carbon dioxide permeability of the packaging. Inside the pack, a low but stable oxygen concentration is created while excessive accumulation of CO2 is limited. The low oxygen content slows down metabolic processes in packed produce and inhibits the growth of aerobic microorganisms and oxidative reactions that accelerate aging and spoilage.
The BinLiner solution was developed for large bulk containers in which conventional film often fails to maintain product quality. In these bags the products remain dry and weight loss is limited. BinLiners are already used for cabbage, bell peppers, cut flowers and onions.
An important design element is moisture management inside the packaging. As explained by Dr Reimo Nickel, Key Account Manager at Envalior, the effectiveness of the solution is determined by the high water vapor permeability of the Arnitel TPC film with a thickness of around 40 micrometers combined with precise laser perforation tailored to the respiration of a given plant product. This configuration allows excess moisture to escape while maintaining the natural moisture level. It prevents water vapor condensation, mold growth and drying out of packed goods during storage and transport.
Applications: bulk liners and pallet covers
In addition to BinLiner bags, the same Arnitel TPC film is used in PerfoTec pallet covers developed to protect fresh produce on pallets during storage and transport. These solutions are used, among others, for strawberries and other berries, which are particularly sensitive to changes in atmospheric and humidity conditions. The controlled atmosphere and proper moisture management help reduce quality losses along the logistics chain and increase the likelihood of delivering products in a commercially acceptable condition.
Pallet covers are intended primarily for supply chains in which maintaining the quality of highly perishable and damage-prone products is crucial. They make it possible to extend the time window between harvest and sale and provide greater flexibility in planning transport and distribution.
Mechanical properties and recycling aspects
An important advantage of the Arnitel TPC film is its high mechanical strength and puncture resistance. Sharply ended stems and branches do not damage the packaging, so it remains sealed and maintains the designed internal atmosphere. The film can be laser perforated with holes of about 50–60 micrometers in diameter, which enables very precise adjustment of gas exchange parameters to the requirements of specific products.
The material is approved worldwide for food contact and does not contain components derived from genetic engineering. As a thermoplastic, it can be recycled, in contrast to chemically cross-linked packaging materials. As a result, the solution complies with the requirements for more sustainable packaging systems that combine functionality with the possibility of returning the material to the loop.
Impact on CO2 emissions and logistics costs
Extending the shelf life of fresh produce has a direct effect on the choice of transport modes in international supply chains. The use of Arnitel TPC film can make it possible, in selected routes, to switch from air transport to sea transport. According to data presented by PerfoTec, such a change can reduce the carbon footprint associated with transport by 80–90 percent and cut logistics costs by 70–90 percent, depending on the route and supply chain.
For many exporters of fresh produce this means the possibility of supplying more distant markets without the need to radically shorten transit times. At the same time, reduced quality losses and less product rejection can improve the economic efficiency of the entire value chain.
Reducing food waste and climate impact
According to the Food Waste Index 2024 report by the United Nations Environment Programme (UNEP), about one third of globally produced food is not consumed, mainly due to losses along the supply chain and consumers discarding spoiled food. This waste translates into inefficient use of resources such as land, water, energy, labor and investment capital. The Food and Agriculture Organization of the United Nations (FAO) further estimates that food waste is responsible for around 4.4 billion tons of greenhouse gas emissions per year.
The new gas-free packaging made from Arnitel TPC film can help to reduce food waste by extending the shelf life of fresh produce. Envalior and PerfoTec solutions are thus part of wider efforts to limit the negative climate impact of the food system by combining the protective function of packaging with the goal of reducing food losses and waste.
PerfoTec representatives emphasize that data on the scale of food waste and its contribution to greenhouse gas emissions indicate the need to develop highly functional and at the same time more sustainable packaging technologies. More information on breathable Arnitel TPC films for food packaging is available in Envalior's technical materials.
