DARFRESH®

ON TRAY

The Economic
and Sustainability
Impact of Meat
Packaging

The Sealed Air Cryovac® Darfresh® on Tray Meat
Packaging Economic and Sustainability Impact
report describes and quantifies how this new meat
packaging technology reduces costs and enhances
sustainability. While it focuses on the processor, it
also considers the benefits this packaging system
has for retailers and consumers and how that
might further benefit the processor.
The direct advantages for processors include
significantly faster processing speeds, which
means increased productivity and reduced utility
and capital investment costs, as well as more
efficient use of materials and space, such as
zero film scrap, recyclable trays and lower
distribution costs. A key advantage to retailers
is how the new approach significantly extends
the shelf life of meat and poultry; a sharp cut in
food wastage saves retailers money and creates a
marketing opportunity.
While the greater convenience (easy opening
packaging and extended product life) of Darfresh
on Tray products will likely appeal to consumers,
its sustainability and food safety benefits will
positively impact purchasing decisions as well.
After all, increased shelf life reduces waste and
contributes to the overall goals of greater food
security and environmental benefits.
2 SEALED AIR FOOD CARE
Introduction
Darfresh® on Tray is a new case-ready packaging
Despite these significant benefits, many consumers system for red meat and poultry that delivers better
do not yet understand the role packaging plays in
extending shelf life of food products. As a result, operational efficiency and sustainability for processors
consumer education may be helpful in better
informing consumers about the benefits of new
while expanding merchandising opportunities and
packaging technologies. waste reduction capabilities for retailers. The system
Ultimately, as consumers understand the packages meat faster than current skin pack systems,
benefits of Darfresh on Tray, they will demand
the product from their retailers; and as retailers reduces food waste through the benefits of vacuum
better understand the benefits and see increased
consumer interest, they will desire their processors packaging and use of materials and energy, and allows
to make it available. This is on top of the already
significant economic benefits this new technology the product to be more efficiently and effectively
has for processors – we estimate, in fact, that most
processors will recoup their investment in the
transported, stored, displayed and marketed.
system in 12 to 18 months.
Thanks for your interest in Darfresh on Tray. DARFRESH ON TRAY:
If you have questions as you read this report or
would like to know how Darfresh on Tray could
benefit your company, please don’t hesitate to
• More than doubles the shelf-life of fresh red meat and poultry when compared to
contact us.
the standard Modified Atmosphere Packaging (MAP) process
• Virtually eliminates scrap material with optimal film utilization, lowering total
Sincerely, packaging cost (facilitates 25-50% reduction in overall pack volume compared to
alternative solutions)
• Supports sustainability with zero scrap, a recyclable tray and reduced distribution
costs (equaling carbon footprint savings of 20% across the entire system)
Karl Deily
President, Food Care
This resourceful solution is an important innovation for the food packaging
industry in general and the meat packaging industry in particular.
CRYOVAC® DARFRESH® ON TRAY 3
An Overview of Darfresh® on Tray
In response to growing demand for more sustainable,
case-ready packaging for fresh red meat and poultry,
Sealed Air recently expanded its line of Cryovac® Darfresh
vacuum-packaging technologies as part of a strategic
alliance using Harpak-ULMA’s Mondini Trave® tray-sealing
technology.
The new Darfresh on Tray packaging system eliminates
film scrap, increases throughput, and provides a tighter,
more even, vacuum than competing systems.
The result is a pack that:
• Reduces risk of cross contamination
• Processes at speeds 35% faster
• Has zero film scrap and up to 40% less material waste
• Can more than double the shelf life of a protein
compared to typical mother bag packaging
• Prevents juices from leaking through the seal
• Provides consumer convenience through an easy
opening easy-peel corner
• Increases point-of-sale competitiveness by allowing
many tray colors, including clear, for increased
visibility and attractiveness
• Guards against freezer burn during frozen storage
• Allows for better retail merchandising via a
vertical display
4 SEALED AIR FOOD CARE
The new system uses specially formulated top film and
bottom tray to create a vacuum skin consumer pack that
fits the product like a second skin. The top film seals firmly Advantages
to Processors
but gently around every contour of the product without
distorting its shape. The top web and tray are then heat-
sealed together right up to the product’s edges to produce
a securely and hygienically sealed pack.
Unlike most packaging systems that cut the excess film Darfresh® on Tray can make the meat packaging process both
from around the flange, each Darfresh on Tray package is faster and more efficient, saving time, money and materials.
sealed using only the necessary amount of film, eliminating
film waste and improving efficiency. Darfresh on Tray’s faster processing speeds increases productivity, reduces utility costs and lowers capital investment
requirements, while its zero scrap and recyclable trays enables processors to become more efficient and achieve
As the Mondini Trave system pulls film into the machine,
sustainability goals.
a patented system cuts the film to fit the exact size of the
tray. Once the lidding is cut free from the roll, a vacuum
shuttle system transfers it to the vacuum chamber and FASTER PROCESSING
tray-sealing head. The top film is heat-sealed to the tray
to form a completely flat seal right up to the edges of
the product. This process results in a compact package
produced with up to 35 percent less material than what
THE DARFRESH® ON TRAY MACHINE:
other available tray-skin offerings require.
• Runs at 8.5 cycles per minute
Darfresh® on Tray • Generates an estimated 80 to 85 trays per minute
• Works roughly 35% faster than other skin pack and rollstock technologies
first launched in Europe in 2013
and then in the U.S. in 2015.
Faster packaging reduces the costs for processors by increasing productivity as measured in pounds per man-hour, and
reduces capital investment costs and costs related to utilities, such as water and electricity.
The speed of the Darfresh on Tray process increases productivity, enabling employees to produce a significantly
higher throughput in terms of pounds of meat packaged per hour. Given the 35 percent faster speed of Darfresh on Tray,
employees who were originally processing 100 pounds per hour will increase that output to 135 pounds per hour, directly
improving their key performance indicators (KPIs). Given that these employees typically earn up to $25 per hour, the
savings from this increased productivity are significant as well. Some processors will find they can accomplish in one shift
The revolutionary
with Darfresh on Tray what it would take two shifts to do using standard technology.
packaging solution
recently won
the Flexible
Faster processing also leads to a reduction in utility costs since processors will reduce the amount of water and
electricity used to package the meat on a per-pound basis. Essentially, the utilities savings should be 35 percent, reflecting
Packaging Association’s the 35 percent less time it takes to do the job.
Highest Achievement Finally, the 35 percent faster speed reduces capital investment requirements because three Darfresh on Tray machines
can do the work of four standard machines. As a result, processors potentially will not need to buy as many machines,
Award in Retail. 1
thereby lowering their capital investment costs.
CRYOVAC® DARFRESH® ON TRAY 5
EFFICIENT USE OF MATERIALS AND SPACE DARFRESH® ON TRAY
REDUCES FILM USAGE BY
Advantages to Retailers
Another set of advantages to processors utilizing the Darfresh on Tray 30-40% Retailers across the U.S. consider escalating food waste as a key issue affecting their store’s operations and profitability,
system is more efficient use of materials and space. Darfresh on Tray according to a 2015 survey conducted by Progressive Grocer on behalf of Sealed Air.2 The survey found that 69 percent
TRADITIONAL NEW
eliminates film scrap, offers recyclable trays and reduces shipping costs MACHINES SYSTEM of retailers view food waste reduction as the operational area they would like to improve most, topping labor costs
by enabling significantly more product to be loaded into transportation (68 percent) and preventing theft (68 percent).
containers.
REDUCES SHRINK
Zero film scrap means that Darfresh on Tray reduces film usage by 30-40
percent or more. This saves money spent on materials – for instance, on a
DARFRESH® ON TRAY REDUCES SHRINK BY EXTENDING
No. 3 footprint tray, every 200 trays processors will save 2.5 cents in film Non-vacuum packaged meat has only two days to get to the retailer and USEFUL LIFE IN RETAIL CASE
costs. Given that a processor may package 16-20 million trays a year, the has a shelf life of two to four days in the refrigerated display case. For a 15 15 15

savings add up to thousands of dollars a year. In addition, this will save the typical mother bag packaged meat product, processors have eight days in 14 14 14

energy and materials that go into making and transporting the scrapped film. NO FILM a dark refrigerated storage during distribution and two to four days in the 13 13 13

SCRAP refrigerated display case. Darfresh® on Tray, on the other hand, can be
12 12 12

Also, machines need to be occasionally stopped to remove film scrap; by 30-40% 11 11 11

eliminating scrap, this reason to stop the machine is also eliminated. FILM SCRAP stored up to 15 days in dark, refrigerated storage, and has from five to 10 10 10
15
eight days of life in the retail case (see bar graph).

# of DAYS
9 9 9

8 8 8

7 7 7

Made of polypropylene with a barrier sealant, Darfresh on Tray trays are recyclable. Specifically the trays are Most retailers experience 2 percent to 4 percent shrink, and are forced 6 6 6

classified for recycling stream 5; 60 percent of American households have access to recycling programs that take to mark down the price or throw the meat product out. Cryovac Darfresh 5 5
8
5

4 4 4

this type of material. Standard styrene foam trays are not recyclable, nor is the soaker pad, oxygen scavenger, on Tray can help with the issues retailers face surrounding shrink by 3 3 3
5-8
and mother bag film that is often part of the packaging. effectively impacting the largest causes of it. This reduction in shrink 2 2 2

2 2-4 2-4
saves money for the retailer. In fact, the Progressive Grocer survey 1 1 1

showed that retailers believe store profits would rise by 10 percent if NON-VACUUM TYPICAL DARFRESH
The Darfresh on Tray system enables processors to significantly reduce the packaging volume of the meat products, leading PACKAGING MOTHER BAG ON TRAY
shrink were eliminated.3
to reduced distribution costs and other advantages. The “mother bag” system used in standard MAP process alternatives is Dark Refrigerated Storage Refrigerated Display Case

significantly more bulky than the Darfresh on Tray system, largely due to the air inside the mother bag. Darfresh on Tray can With many types of beef priced at nearly $6 per pound or more, cutting
typically fit 25 percent to 50 percent more product inside of a distribution box than can standard mother bag packaging systems. shrinkage could add significantly to the retailer’s revenues and earnings.4 If a retailer experienced 1 percent less shrink and
As a result, a processor who might only be able to load 18,000 pounds of packaged meat in mother bag format onto a typical sells $20,000 in meat per week, that’s an estimated $200 per week in lost meat profit. For retail chains with 1000 stores,
truck can load up to 32,000 pounds of Darfresh on Tray meat onto the same truck. that adds up to $200,000 per week or $10 million annually.

Since each truckload costs about $1,000-$1,200, this is significant savings. Put another way, processors may be able to ship REDUCES FOOD WASTE
the same amount of packaged meat in 700 truckloads using Darfresh on Tray as it would take 1,000 truckloads using standard
mother bag packing system.
An estimated 2.7 billion pounds of meat, poultry and fish valued at $8.8 billion, or about 5 percent of all such inventory, are
thrown out by retailers each year, according to the U.S. Department of Agriculture.5 As we will see in the next section, this
has become an increasing environmental concern to both to consumers and policymakers.
TRUCKS NEEDED TO TRANSPORT 32,000 LBS OF MEAT
To reduce waste, more than half (56 percent) of retailers cited improved packaging as an important factor. Likewise, more than half
TYPICAL MOTHER BAG SYSTEM DARFRESH ON TRAY ®
of surveyed retailers (55 percent) consider shelf life extremely or very important when evaluating new products to potentially carry.
18,000 LBS PER TRUCK 32,000 LBS PER TRUCK
Meat not only is one of the most costly items retailers sell, but it must be thrown out when its shelf life expires. This is in
contrast to canned food or dry goods, which often can be donated to food banks once their shelf life expires.

SPACE-EFFICIENT PACKAGING

Since Darfresh on Tray is less bulky than meat packaged in a mother bag process, more product can be displayed in the
refrigerator case. This, in turn, increases sales since more of the product is likely to be sold if it is displayed in the retail case
$ A typical processor could save as much as $200,000 a year just on lower trucking costs alone rather than kept in dark, refrigerated storage. As a result, the cubing efficiencies of Darfresh on Tray meat packaging lead to
increased sales and decreased shrinkage.
6 SEALED AIR FOOD CARE CRYOVAC® DARFRESH® ON TRAY 7
Advantages to Consumers
VACUUM-
Although consumers worry about the environment, wasted resources, pollution and food waste, PACKAGED
among other ecological issues, they generally are not willing to sacrifice price or convenience to BEEF BRIGHTENS
address these concerns. In addition, while they worry about food waste, they are skeptical WHEN EXPOSED
or unknowledgeable about the ability of advancements in packaging to extend the life of food TO AIR
products and cut waste. Finally, while there are some clear advantages to Darfresh ® Education can help overcome this disconnect. Based on the information they were presented with
on Tray, such as being freezer-reader, easy-to-open, and, if clear trays are used,
transparency, some consumers may hesitate to accept claims of extended shelf LEAK-PROOF
life or to buy beef that has a different red color than they are used to seeing. EASY TO OPEN
Effective consumer education is needed to address doubts consumers have FREEZER-READY
about the safety or sustainability of Darfresh on Tray beef. This means short
phrases that help consumers quickly understand the benefits of new packaging.
CONSUMERS WANT SAFETY AND SUSTAINABILITY
IN A 2014 HARRIS POLL
CONSUMER FOOD WASTE
U.S. consumers are concerned about a variety of environmental issues, including STUDY COMMISSIONED BY VACUUM-
food waste and food safety. In fact, concern over food waste and food safety SEALED AIR... PACKAGED
exceeds concern over climate change, air pollution and water shortages, according BEEF BRIGHTENS
to a 2014 Harris Poll consumer food waste study. This concern is well placed. WHEN EXPOSED
• 63% of those surveyed were
Food waste not only wastes money, but it damages the environment by producing worried about the amount of
TO AIR
methane, the harmful greenhouse gas. Also wasted are the freshwater and fertilizer
food wasted in the USA6
used to produce the food and the energy used to produce, store and transport it.8
• 3 out of 4 agree that food
waste in the USA has a long
Increased shelf life of food products provides access to healthy food and term impact on the environment
reduces waste, which in turn contributes to increased food security and
environmental benefits. We have already seen the direct benefits to retailers of • An estimated 12.7 billion pounds
of meat, poultry and fish valued
extended product life, but retailers can also benefit from the positive effect food
waste reduction can have on consumer perceptions. at $39.7 billion, or about 22% of
their supply, is thrown out by
Consumers favorably view retailers that promote efforts to reduce waste and consumers each year,
operate more sustainably, according to the 2014 Harris Poll consumer food according to the U.S.
Department of Agriculture7
waste study.9 By taking proactive initiatives to address food waste, retailers can (This is in addition to the amount
improve brand loyalty and reputation with customers while also experiencing the
thrown out by retailers)
corresponding benefit of increased sales potential.
• 8 in 10 consumers agree that
they would think more highly
CONSUMER DISCONNECT ON PACKAGING of stores or food brands
that help them reduce food
waste
But there are some hurdles that retailers face in promoting the environmental
benefits of their products. Many consumers are unwilling to pay more for products
• 57% would think more favorably
of a store if it used packaging
that are better for the environment – for consumers, cost and convenience still that kept food fresher longer10
trump ecofriendly intentions.
• 43% of consumersconsider
This is because many consumers do not yet understand the role of packaging in food products that have
extending shelf life – they believe that less packaging is better for the environment. packaging designed to keep
While consumers do not put “over-packaging of food products” near the top of food fresher longer to be
their environmental priorities, a significant proportion – 41 percent – are concerned environmentally friendly
about it.11
8 SEALED AIR FOOD CARE
More than half of adults do not think of environmentally-friendly packaging designed
to keep food fresher for longer even though it has been shown to reduce food waste. There is a
clear disconnect for adults between intelligent package design and its benefits for the environment.
in the 2014 Harris Poll consumer food waste survey, most consumers said there were likely to make
different choices with regard to packaging now that they understood its ability to help food stay
fresh longer.12 Packaging industry and retailer-driven education efforts could focus on how environmentally-
friendly packaging affects product pricing and its ability to extend the shelf life of fresh food.
DIRECT CONSUMER ADVANTAGES
Many consumers say they often remove packaging on purchased food in order to subdivide it into better portion sizes
for later use. By re-packaging their own food, however, they are not only wasting packaging material (using both the
packaging the food came in and the packaging they are substituting) but also reducing the freshness of the food.
Darfresh on Tray trays come in a variety of sizes, including those that can accommodate individual packed portions.
Individually packed portions are attractive to consumers – they are perceived as convenient
6 in 10 and likely to help reduce food waste and would save consumers time and effort.
consumers
wish more food There are a number of other advantages Darfresh on Tray offers consumers: for instance,
came in it is leak-proof, easy to open and freezer-ready. In addition, the trays can come in any
pre-packaged color, including clear. Meat packaged in clear trays and clear film is popular with many
individually consumers because it offers transparency. By showing they have nothing to hide,
packed portions clear packaging bolsters the seller’s brand integrity and brand trust.
* According to a 2014 Harris Poll
consumer food waste survey
MANAGING CHANGE AND CONSUMER PERCEPTION
With any advancement, especially in food packaging technology, comes inevitable consumer IN A SEALED AIR
& BEEF CHECKOFF
skepticism and resistance. With regards to Darfresh on Tray, some consumers assume that
extended shelf life means chemical additives, while others may wonder if the meat is really SURVEY:
safe for such an extended period of time. In addition, other consumers may not be used to
Consumers
seeing the deep natural red color of the meat packaged in Darfresh on Tray, and therefore
may be resistant to buying it. educated about
vacuum packaging
All of these issues are a matter of perception – or, in fact, misperception. Darfresh on Tray
processors do not have to apply any special additives to keep the meat fresh for a longer are 78% more
period of time. In addition, Darfresh on Tray credentials regarding safety are vetted by the likely to buy meat
U.S. Department of Agriculture.
that is vacuum-
Concerns that the deep red color of the beef in a Darfresh on Tray package will deter packed and most
consumers from buying the product are mostly unfounded. A consumer survey shows that
just one in six (16 percent) of consumers see the deep red color of the beef as a potential are willing to pay
deterrent to purchase. Once consumers understand that beef brightens when re-exposed more for it.
to air they are more like to buy it vacuum-packaged.
CRYOVAC® DARFRESH® ON TRAY 9
Conclusion SOURCES

By offering a combination of freshness and retail presentation, Darfresh® on Tray enables processors and retailers to 2015 Flexible Packaging Association’s Highest Achievement Award Winner—Retail; Italian Institute of Packaging’s 2014 Packaging Oscar as best overall; and a
1.

offer customers high quality meat and poultry, while also delivering increased productivity and manufacturing efficiency
for improved sustainability.
Enhanced efficiencies and reduced wastage means that Darfresh on Tray costs about 20 cents less per package than
alternatives, such as MAP mother bag overwrap, according to Sealed Air’s analysis of the total cost of ownership of
the system. These savings mean the typical processor who buys a $400,000 Darfresh on Tray system will recoup
their investment costs within 12 to 18 months. This, of course, does not reflect the added potential savings and
marketing advantages that Darfresh on Tray provides retailers in terms of extended product life, sustainability,
transparency and convenience.
As processors and retailers face added pressure to reduce costs, waste and environmental impact, this state-
of-the-art packaging delivers value in a crowded meat case.
PackTheFuture award at Interpack 2014 for innovative packaging, functionality and ergonomics and environmental benefits.
2.
Taking Stock: Retail Shrink Solutions. Sealed Air Cryovac. April 2015. The survey was conducted in 2014 among more than 100 U.S. retail decision-makers, ranging
from headquarters-level executives to store and department managers.
3.
Taking Stock: Retail Shrink Solutions. Sealed Air Cryovac. April 2015. The survey was conducted in 2014 among more than 100 U.S. retail decision-makers, ranging
from headquarters-level executives to store and department managers.
4.
The Cattle Site. CME: Beef Retail Prices Fell Sharply on the Year. Feb. 24, 2016. http://www.thecattlesite.com/news/49343/cme-beef-retail-prices-fell-sharply-on-
the-year/
5.
Buzby JC, Wells HF, Hyman J. The Estimated Amount, Value, and Calories of Postharvest Food Losses at the Retail and Consumer Levels in the United States. U.S.
Department of Agriculture Economic Research Service. Economic Information Bulletin No. 121, February 2014. http://www.ers.usda.gov/media/1282296/eib121.pdf
6.
Nielsen. Consumers and Food Waste. Harris Poll survey on behalf of Sealed Air of 1,005 adults who do at least 25 percent of their households shopping between
April 18 and April 25, 2014.

To further enhance this value, some consumer education may be necessary. When so many think that packaging is
worse for the environment than food waste, consumers need to be shown that intelligently designed packaging (with
portion control) serves dual purposes: it can be environmentally friendly and do a better job of keeping food fresher
for longer, thus reducing food waste. If consumers had this knowledge and supporting facts at the point of purchase
(signage around food products, or predominantly visible on the packaging itself) this could help them make more
educated decisions at the grocery store that could lead to food waste reduction in the U.S. If stores offered more food
7.
Buzby JC, Wells HF, Hyman J. The Estimated Amount, Value, and Calories of Postharvest Food Losses at the Retail and Consumer Levels in the United States. U.S.
Department of Agriculture Economic Research Service. Economic Information Bulletin No. 121, February 2014. http://www.ers.usda.gov/media/1282296/eib121.pdf
8.
Hall KD, Guo J, Dore M, Chow CC, National Institute of Diabetes and Digestive and Kidney Diseases. The Progressive Increase of Food Waste in America and its
Environmental Impact. PLoS ONE (2009) 4; 11: e7940. http://journals.plos.org/plosone/article?id=10.1371/journal.pone.0007940
9.
Nielsen. Consumers and Food Waste. Harris Poll survey on behalf of Sealed Air of 1,005 adults who do at least 25 percent of their households shopping between
April 18 and April 25, 2014.

products in these types of intelligently designed packaging, consumers would buy the products for both convenience and 10.
Nielsen. Consumers and Food Waste. Harris Poll survey on behalf of Sealed Air of 1,005 adults who do at least 25 percent of their households shopping between
food waste reduction reasons. April 18 and April 25, 2014.

11.
Nielsen. Consumers and Food Waste. Harris Poll survey on behalf of Sealed Air of 1,005 adults who do at least 25 percent of their households shopping between
Ultimately, as consumers understand the benefits of Darfresh on Tray, they will demand the product from their retailers. April 18 and April 25, 2014.
Likewise, as retailers see increased consumer interest and better understand the benefits themselves, they will put a
12.
 ielsen. Consumers and Food Waste. Harris Poll survey on behalf of Sealed Air of 1,005 adults who do at least 25 percent of their households shopping between
N
higher value on Darfresh on Tray. April 18 and April 25, 2014.

In summary, the economic and sustainability benefits of Darfresh on Tray make it 13.
Are Consumers Ready to Buy Beef in a Different Package; Consumer Research Results. Sealed Air/Cryovac and Beef Checkoff. http://www.businesswire.com/news/
home/20130603006098/en/Consumers-Ready-Buy-Beef-Package
a “win-win” for processors, retailers, consumers and the environment.

To see a video or animation of this patented process visit www.sealedair.com/darfresh-on-tray

10 SEALED AIR FOOD CARE CRYOVAC® DARFRESH® ON TRAY 11

At Sealed Air Food Care, we help
sustain healthy communities by
ensuring the safety and quality of
what people eat and drink by creating
sustainable innovative solutions.

These solutions provide measurable

results to our business partners
through increased shelf life, food
safety, operational efficiency and
help in building their brands.

To learn more, visit: www.sealedair.com/foodcare

For more information, contact us at foodcare.na@sealedair.com.
® Reg. U.S. Pat. & Tm. Off. © Sealed Air Corporation (US) 2016. All rights reserved.