A groundbreaking approach to packaging fresh produce is reshaping the logistics of long-haul vegetable shipments in both the United States and Japan.
Modified Atmosphere/Modified Humidity (MA/MH) packaging, developed by StePacPPC, is providing an eco-friendly alternative to traditional ice-filled polystyrene foam and wax-coated carton boxes. This shift is particularly evident in the broccoli supply chain, where environmental, safety, and efficiency concerns have driven the adoption of StePacPPC’s Xtend packaging.
In Japan, the Otofuke Agricultural Cooperative (JA Otofuke), a prominent broccoli producer, has already transitioned to using Xtend MA/MH bulk bags for transporting broccoli from Hokkaido to Yokohama. Historically, polystyrene foam boxes filled with ice were the standard for such shipments.
Despite their effective insulation and cooling properties, these boxes have faced mounting criticism. Polystyrene foam’s non-recyclable nature, its tendency to fragment into persistent environmental pollutants, and the logistical challenges of disposal have prompted growing regulatory and commercial disapproval. Japan, following the global trend, is tightening restrictions on non-recyclable materials, including certain types of polystyrene foam.
The U.S. has witnessed a parallel trend. Waterproofed waxed carton boxes, another traditional option for transporting iced broccoli, are increasingly out of favor. The wax coating not only makes these boxes unsuitable for recycling but also contributes to greenhouse gas emissions when discarded in landfills. States such as California have implemented bans on non-recyclable containers, further accelerating the search for sustainable alternatives.
Concerns about traditional packaging extend beyond environmental issues. The use of ice in transport poses food safety challenges, as melting ice can foster microbial decay. Research has consistently shown that broccoli packed with ice harbors higher levels of microbial contamination compared to that stored in MA/MH packaging. Melting ice also leads to nutrient loss, particularly vitamin C, while creating hazards from slippery surfaces and leaks.
Akio Yamagishi, Manager of the Fruit and Vegetable Sales Department at JA Otofuke, highlights the cooperative’s motivation to explore alternatives. “In our efforts to move away from polystyrene foam with ice and its inherent contamination risks, we considered various alternatives for maintaining freshness without using ice,” he explains. “We tested various modified atmosphere packaging films, including the Xtend films from StePacPPC. After inspecting the condition of the broccoli upon arrival, Xtend outperformed the rest in both appearance and quality.”
StePacPPC’s Xtend packaging leverages advanced technologies to maintain the freshness of broccoli and other vegetables. By creating a controlled atmosphere with precise humidity levels, the packaging slows respiration, reduces ethylene production (a hormone that accelerates yellowing), removes excess moisture, and inhibits microbial growth. These features not only preserve the produce’s quality but also reduce the risk of foodborne illnesses caused by pathogens like E. coli.
Environmental and Economic Gains
The benefits of this transition extend far beyond food safety. According to Yamagishi, the adoption of Xtend packaging has led to substantial cost savings and environmental benefits. “We discovered multiple benefits to iceless Xtend packaging,” he says. “First, it eliminates the space ice occupies, allowing us to transport 66% more broccoli per container. This slashes carbon emissions and transport costs, especially significant given the recent rises in shipping costs. With ice, each box holds only 6kg of broccoli; without it, we can pack around 10kg. In addition, one Xtend bag can hold 10kg of broccoli, making it more resource-efficient and eliminating the need for extra handling. The ability to transport ice-less fresh broccoli across the continent on weight-constrained trucks has led to a net reduction in costs of more than 30%.”
In the U.S., Xtend packaging has also gained traction, particularly in the food service sector. Gary Ward, Ph.D., StePacPPC’s Chief Technology Officer, emphasizes its role in reducing environmental impact. “At a time when flexible plastic packaging is under the spotlight, we have, together with researchers at the Agrotechnology & Food Sciences Group at Wageningen University, demonstrated that our functional ‘lean and green’ packaging solution reduces the carbon footprint by approximately 40% in shipments from Salinas Valley on the West Coast of California to New York on the East Coast, demonstrating a positive environmental impact,” Ward explains.
The packaging’s ability to extend shelf life and maintain nutritional quality minimizes food waste while offering superior logistics performance. “Our Xtend bulk packaging also successfully preserves other produce traditionally shipped on ice, such as bok choy and green onions,” Ward adds.
StePacPPC has established itself as a leader in functional packaging for fresh produce. Its innovative solutions, including Xtend, Xgo, Xflow, and Xbloom, are designed to reduce weight loss, slow respiration and aging, and inhibit microbial decay. Backed by extensive post-harvest expertise, these technologies are helping the agricultural industry meet growing demands for sustainability while improving supply chain efficiency.
As the global push for environmentally friendly and cost-effective packaging intensifies, technologies like Xtend offer a glimpse into the future of fresh produce logistics. For broccoli growers and consumers alike, the benefits are clear: fresher produce, lower costs, and a cleaner planet.