The e-grocery sector is growing
The growing popularity of online grocery shopping and the rapid expansion of e-commerce within the food industry are presenting new challenges for producers and distributors worldwide. As e-commerce continues to gain momentum, particularly in food retail, ensuring the safe delivery of perishable products is becoming increasingly important. Global trends indicate that online grocery sales are expected to see significant growth, with forecasts suggesting a rise in the global share of e-grocery sales from 1.4% in 2022 to 2.7% by 2027.
In response to this, leading platforms and grocery retailers are experiencing consistent year-over-year increases in orders, as well as growing average order values. With this surge in demand, packaging strategies must evolve to guarantee that food products reach consumers fresh, safe, and intact. In this article, we will explore optimal food packaging solutions for transportation, tailored to the specific needs of the food industry, cost-reduction strategies, and practical tips for selecting the most effective packaging materials.
Key aspects of food product packaging
1. Challenges in food packaging
Food packaging requires consideration of a number of factors that impact both the product’s shelf life and logistical efficiency. Some of these factors include:
- Limited space in warehouses and transportation vehicles
The use of coreless stretch film reduces waste volume and allows for better space management.
Reducing the number of packaging layers, e.g., replacing two layers with one stronger layer, results in the need to store fewer packaging materials
- The risk of mold growth on fresh products such as fruits and vegetables
An alternative to traditional plastic packaging is the palletizing net, which provides ventilation and protection against crushing. Additionally, products wrapped in it can be easily frozen.
- Loss of quality due to moisture condensation in refrigerated packaging
A good solution is the use of moisture-absorbing inserts, which regulate the moisture level in the package. The palletizing net also works well here, as it allows for air circulation.
- Difficulties in recycling multi-material packaging
A solution could be the use of mono-material packaging, such as high-strength PE film, which is fully recyclable, or bubble wrap or polyethylene foam (those produced by Mac-Graf are 100% recyclable).
- Protection of bulk products from accidental package tearing during opening
It is advisable to use additional cardboard inserts on top of the package to avoid damage caused by sharp tools.
2. Selection of appropriate packaging materials
Each type of food product requires a different approach to packaging:
Bulk products (flour, sugar, spices)
Require packaging that protects against moisture and spillage. Stretch film and embossed bags can provide additional sealing.
An extra precaution when transporting products on a pallet is to protect the bottom of the products by placing a thicker sheet of polyethylene foam (instead of cardboard) on the pallet – it will effectively protect the products from moisture.
Liquid products (oils, juices, soups)
PE film packaging and PE foam for shock absorption work best. Bubble wrap is also great for cushioning. If you’re shipping products of similar sizes, you can opt for bubble wrap pouches with adhesive strips – this way, you simply place the product inside without needing tape, scissors, or cutting the packaging to a specific size.
Fresh products (vegetables, fruits, dairy)
Require the right microclimate, making palletizing nets that allow air circulation an excellent solution.
Products requiring protection from mechanical damage
It is advisable to use foam laminates, which are very durable, as well as large-bubble bubble wrap (Fill&Wrap) to fill empty spaces and cushion shocks.
3. Optimization of the packaging process
To optimize the packaging process and reduce its costs, it is worth implementing a few strategies that are simple yet effective:
- Minimization of the number of packaging layers
Using laminated inserts or PE foam laminates helps reduce the consumption of additional materials, as they are durable on their own and provide high-level protection.
- Packaging automation
Using stretch film wrappers can speed up the pallet securing process, reducing time and labor costs. In wrappers, you can easily use coreless stretch film – this not only accelerates the packaging process with automatic or semi-automatic wrapping, but also eliminates the issue of core disposal.
- Standardization of packaging sizes
The use of corrugated cardboard as inserts and adjusting carton sizes to product dimensions optimizes warehouse space and reduces transportation costs.
- Changing the form of purchased materials
The most common form of materials such as bubble wrap or polyethylene foam is in rolls. However, simply changing the form of these materials can significantly speed up the packaging process! By opting for pre-made formats, you gain better control over the amount of material used for packaging and reduce the number of operations performed by warehouse staff.
Polyethylene foam sheets
Custom-made, delivered in packs. They facilitate material retrieval and standardize its usage.
Polyethylene foam bags / bubble wrap bags
They significantly simplify the packaging of products with similar dimensions. Bags with adhesive strips eliminate the need for adhesive tape! They are excellent for securing bulk products!
Bubble wrap sleeves
They increase the size of a single sheet – useful when packaging very large products for which the maximum range of a standard roll is too small.
PE foam / bubble wrap on a perforated roll
Perforation makes it easier to tear off equal pieces of material without using scissors. It also standardizes the amount of film/foam being used.
4. Safety and hygiene
In the food industry, it is crucial to ensure the appropriate level of hygiene and compliance with sanitary standards:
Stretch film and bubble wraps – protect against moisture, dust, and contaminants.
Packing and strapping tapes – ensure secure closure of packages, eliminating the risk of contamination.
Skropak and eco-friendly fillers (wood wool, Boxfill paper) – are food-safe, biodegradable, and environmentally friendly.
Eco-friendly approach to packaging
The growing environmental awareness is leading food companies to increasingly choose packaging materials that are recyclable. At Mac-Graf, we offer:
- Polyethylene foam and bubble wrap that are 100% recyclable.
- Coreless stretch films – eliminate cardboard waste.
- Corrugated cardboard and cartons – 100% biodegradable.
- Eco-friendly fillers (Skropak, Boxfill paper) – reduce plastic waste in packages.
Summary
Optimizing the packaging process in the food industry is not only a matter of safety but also of efficiency and cost. By using appropriate materials, automation, and eco-friendly solutions, the logistics of food distribution can be significantly improved, while ensuring high quality and durability.
Our clients include:
- Food product manufacturers
- E-commerce owners
- Farmers
