Supplied by Fres-co System USA (Telford, PA), the 7.5-mil polyester/foil/biaxially oriented nylon/linear low-density polyethylene bag replaced a bag-in-box package. The new package eliminates three steps on the packaging line-box erecting, bag placement and bag labeling-and represents an 80% source reduction by weight, according to Ciba senior packaging engineer Walter Meisner. The bag is interesting in that it contains a one-way degassing valve similar to what Fres-co uses for its premade coffee bags. Since the product consists of 99% corn and oil, Ciba fills the contents under a nitrogen modified atmosphere to extend product shelf life. The one-way valve allows the excess headspace in the bag to bleed out as bags are palletized, creating dense and brick-like packs. Otherwise, says Meisner, the trapped air would create an unstable bag that doesn't stack very well. Meisner says the bag withstands static load, drop impacts and vibration stresses during distribution, thanks to "the weight and gauge of the material, and the strength of the sealant layer." Strong visual impact is provided by four-color reverse-printed gravure graphics on one side, with room enough for complete product directions on the other. A reinforced, die-cut carry handle completes the package, which won an AmeriStar award at Pack Expo last November.
