AVI Global Plast and Smart Packaging Industries collaborate on new packaging design

“Instead of functioning purely as individual packs, the trays form part of a geometric structure”

Blueberry harvests are subject to one of the most demanding supply chains in fresh produce, says Sukhdeep Sethi, managing director of packaging manufacturer AVI Global Plast: “After harvesting, berries must be kept cool, packaged, and shipped using temperature-controlled logistics for optimal distribution. Packaging therefore needs to protect delicate fruit while also using transport space as efficiently as possible. Yet once conventional, clamshell rPET-punnets are filled and stacked into cartons, significant gaps remain between packs. Industry estimates suggest that in many palletized shipments close to half of the available transport space can consist of empty air rather than fruit.”

“This inefficiency largely stems from the design of traditional containers,” Sethi continues. “Most punnets are tapered, so that empty packs can nest together when transported from packaging factories to packhouses. Once fruit is packed inside them, the same geometry leaves voids between containers when cartons are stacked on pallets. For exporters moving blueberries across long distances, these gaps reduce pallet efficiency and increase the total volume that must be transported and stored in refrigerated logistics systems.”

To solve this problem, AVI now introduces a new space-saving packaging system in India, Sethi explains: “The Q-Bic packaging concept, developed by Smart Packaging Industries, addresses the issue by rethinking how containers combine once they are filled and prepared for shipment. Instead of functioning purely as individual packs, the trays form part of a geometric structure, in which multiple units combine into compact cube formations. These cube units can then be stacked tightly inside cartons, reducing the empty space normally seen between conventional punnets.”

The impact becomes clearer when pallet density is considered, Sethi states. “Trials in commercial blueberry packing programs indicate that cube-based palletization can allow for approximately double the number of packs per pallet compared with conventional clamshell formats. In practical export logistics, this means that a large share of the ‘shipping of air’ typically present in conventional punnet pallets can be eliminated, often reducing pallet movements and refrigerated logistics volume by around 50%.”

Sethi adds that in addition to logistics efficiency, the cube-based structure also enables reductions in packaging materials across the supply chain: “The improved structural geometry allows optimization of the consumer pack (C-pack) in rPET, while the tighter pallet configuration reduces the amount of corrugated cardboard required for secondary packaging and distribution cases, with reductions of up to 59% in corrugated board usage observed in 125g blueberry formats.”

“The rPET clamshell punnets incorporate ventilation channels that allow airflow through palletized packs, supporting cooling performance during storage and shipment,” Sethi goes on. “Structural stability is another factor influencing fruit protection. Standard plastic punnets often take stacking stress on their top lid or rim. As a result, they can be damaged by compression due to uneven loads during transport. Combining rPET clamshell punnets together in cube formations distributes loads across a larger structural framework. The cube geometry transfers forces across three axes and six directions within the structure, rather than concentrating compression on the lid or rim of individual packs. This helps stabilize pallet stacks while decreasing the likelihood of damaged berries.”

According to Sethi, higher packing densities also affect how products move through the distribution chain. “Each pallet holds more product than before; therefore, fewer pallets travel through packing plants, cold storage facilities, and distribution centers. This reduces the number of loading and unloading processes necessary in the supply chain. In large blueberry export programs, improvements in pallet utilization have been associated with logistics and storage reductions of around 50%, reflecting the more efficient movement of fruit through refrigerated distribution systems.”

Transport efficiency is closely linked to the environmental footprint of fresh produce distribution, Sethi emphasizes. “Refrigerated transport and cold storage account for a substantial share of emissions in global produce supply chains. By combining higher pallet density with lower material consumption in both rPET consumer packs and corrugated distribution cases, the overall packaging and logistics system becomes significantly more resource efficient. Industry assessments suggest that improvements in packing efficiency and material reduction at this scale can contribute to emission reductions exceeding 40% in packaging and transport operations.”

For more information:
Sukhdeep Sethi
AVI Global Plast
sethi@avigloplast.com
https://avigloplast.com Publication date: Wed 11 Mar 2026

Edible coating and labelling reduce plastic and extend shelf life

How can the shelf life of fruit and vegetables be extended while reducing plastic consumption? AgroSustain, an agritech company developing solutions for pre- and postharvest, and Multivac, a manufacturer of labelling systems, present a joint approach combining edible coatings with packaging technologies.

AgroSustain, based in Switzerland, has developed Afondo™, an edible coating designed to preserve the quality of fresh produce after harvest. Afondo is applied directly after harvest on existing packaging lines using standard spraying and buffing technologies. It adheres to the fruit’s natural wax layer and forms a thin, breathable barrier on the surface. This layer slows respiration and moisture loss while allowing natural processes such as ripening to continue.

Afondo is positioned as a replacement for conventional waxes and coatings and can extend shelf life in cold storage by up to three weeks and at retail by three to five days, depending on the crop. It is designed to preserve natural ripening without altering taste, appearance, or texture.

Multivac presents two packaging systems in which trays are closed and labelled simultaneously: Topclose™ and Topwrap™.

Topclose combines cardboard trays with a cellulose-based self-adhesive label that closes the tray along the rim, protecting the contents from removal or falling out. This system results in plastic-free packaging and is processed on the L 330 conveyor belt labeller with a capacity of up to 250 packs per minute. It is used for products such as blueberries, raspberries, and gooseberries.

Topwrap uses a label that wraps over the top and along two sides of the tray, enabling rimless trays to be closed. Cardboard or corrugated trays combined with a paper or cellulose label create plastic-free packaging. This process runs on the L 310 conveyor belt labeller with a capacity of up to 150 packs per minute and is suitable for products such as tomatoes, apples, potatoes, mushrooms, and strawberries.

The collaboration combines edible coating technology with packaging systems as a response to food waste and plastic reduction in fresh produce supply chains.

For more information:
Aileen Fleer
Multivac
Tel: +49 (0) 5224 931 1037
Email: aileen.fleer@multivac.de
www.multivac.com Publication date: Mon 2 Mar 2026