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Vend packs turn to new materials for new markets

Designed initially for vending sales, a new material blend permits skin-packed frozen Mini Meals for microwave heating to expand into diverse outlets.

Five Mini Meals are manually loaded into a chipboard ?boot? and overwrapped in film for multipack sales
Five Mini Meals are manually loaded into a chipboard ?boot? and overwrapped in film for multipack sales

An unusual blend of high-impact polystyrene and polyphenylene oxide is now being used to produce trays that allow Rook's Recipes to market frozen, ready-to-heat microwavable meals from vending machines. This success led to expanded marketing to both club and retail stores.

The St. Charles, IL, company uses an unusual skin packaging system to seal the precooked foods in their trays. Packaging is farmed out to Kitchen Fresh Foods (Green Bay, WI). Rooks purchased the Trigon Intact(TM) packaging machine, made by Trigon Engineering in New Zealand, from Trigon representative Koch Equipment Group (Kansas City, MO).

Rook's purchased the machine about a year ago, which Kitchen Fresh uses solely for Mini Meals(TM) packaging. The black-colored trays are supplied by Plastic Ingenuity (Cross Plains, WI). PI thermoforms them from 25-mil sheet it extrudes from a blend of high-impact polystyrene resin from Dow Chemical USA (Midland, MI), and NORYL® PPO resin from GE Plastics (Pittsfield, MA). The Noryl PPO resin provides the heat-resistance necessary for microwaving.

PI custom-built the tooling for the trays. Rook's owns the tray mold. The 7" x 4" rectangular trays have rounded corners, with an approximately 3/8" flange area for sealing. Notches in four areas along the flange (two on each long side) help hold in place a paper label that wraps around the tray's width dimension. The product is clearly visible near both tray ends that are not covered by the label.

Harry Rooker, Rook's owner, attributes much of Mini Meals' initial success to its packaging. "These are see-through skin-packs that let the buyer see the restaurant-quality food inside," he says. "The film contours to the shape of every bean, or every noodle within the tray. The finished package has no unappealing ice crystallization like you find in many frozen meals that rely on printed cartons to sell the product."

For more than a year, Rooker worked closely with James Tingey, president of Northfield, IL-based Marketstart, to develop Mini Meals. Both companies continue to push for nationwide sales. To date, more than 20 Mini Meals varieties have been sold in limited test markets. But, says Rooker, "Four products are now in broader distribution in regional U.S. markets." Serving sizes range from 5 to 7.5 oz.

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