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Filler meets tough standards at Stonyfield

Stonyfield Farm is so confident about the potential sales of its Yo Squeeze organic yogurt for kids that it’s purchased a second vf/f/s machine. Each machine produces 200 tubes/min, with an unusual ‘butt seal.’

The vf/f/s machine discharges four filled and sealed packs at a time (above). The equipment heat-seals a strip of unprinted film
The vf/f/s machine discharges four filled and sealed packs at a time (above). The equipment heat-seals a strip of unprinted film

Perhaps the most recognizable characteristic of Stonyfield Farm’s Yo Squeeze™ yogurt tube is what can’t be seen: a fin seal or a lap seal on the bottom of the package. Instead, Yo Squeeze tubes rely on a separate strip of unprinted film that’s heat-sealed inside the pack where the two edges of the outer printed film “butt” together.

The seal is much like taking a piece of notebook paper and joining the two long sides together to form a tube shape, then taping the two sides together on the inside.

This unusual “butt seal” is created on an SVL 16/24 vertical form/fill/seal machine from Hassia (Morganville, NJ). Londonderry, NH-based Stonyfield Farm is the first U.S. user of this SVL (stick/vertical/liquid) machine in a yogurt application. The equipment is used exclusively for Yo Squeeze, an all-natural children’s yogurt introduced last July (see Packaging World, July ’00, p. 2, or packworld.com/go/yosqueeze).

The inside film strip and the outer film are supplied by Curwood (Oshkosh, WI). The 4½-mil strip structure includes a 2-mil coextrusion of linear low-density polyethylene/48-ga oriented polyester/2-mil LLDPE coextrusion. The material is heat-sealed to the 3-mil outer printed film that includes a 1¾-mil layer of coextruded LLDPE and white (for additional opacity) ethylene vinyl alcohol/10# white PE extrudate/48-ga polyester that’s reverse-printed flexographically in eight colors.

The printed film’s oxygen barrier is 5 cc/100”2 per 24 hrs at 73°F and 80% relative humidity. Moisture vapor transmission ratio is 0.5 g H2O/100”2/24 hrs at 100°F and 90% RH. For the inner film strip, the O2 barrier is 9 cc/100”2/24 hrs at 73°F and 50% RH. MVTR is ½ g H2O/100”2/24 hrs at 100°F and 90% RH. Stonyfield Farm selected the oxygen and water vapor barrier properties of the film based on Curwood’s recommendations for the product, according to John Daigle, Stonyfield Farm’s vice president of operations.

Differentiation

“The butt-seal technology makes a firmer tube and a nicer-looking package,” believes Daigle. “We also like not having a fin seal, because it’s easier on the mouth for children, because there’s no fin seal that sticks out. It’s even more noticeable if you put the tube in the freezer and eat the product frozen, where the fin seal would be harder.” Yo Squeeze is targeted toward kids aged 6 to 12.

Sold in the refrigerated dairy case, with a pull date 50 days from date of manufacture, Yo Squeeze can be consumed refrigerated or frozen. Stonyfield Farm sells eight stick packs in a colorful folding carton (see sidebar p. 69). Three flavor combinations are sold, with suggested retail prices ranging from $2.39 to $2.69. The yogurt rolled out initially on the West Coast, moving eastward to Stonyfield’s largest customer base on the other coast. The gradual rollout was conducted so that as yogurt production capacity increased, it would match the product’s sales demand.

The “invisible” butt seal helps to differentiate the pack from General Mills’ Go-Gurt™ brand of yogurt, which Daigle says uses a fin seal. Minneapolis-based General Mills’ Yoplait Div. debuted Go-Gurt in ’98 (see PW, Oct. ’98, p. 200, or packworld.com/go/yoplait-gogurt).

A key advantage the seal provides is extra space for graphics. “The outside looks very nice and helps give us a pack with a strong graphics presentation,” adds Daigle.

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