Revolutionary lid for triple tray

FINDING the right packaging for pre-prepared meals can be a test of ingenuity, especially when the meal to enclose is composed of different raw ingredients, from meat to vegetables. When a leading global food provider required this, it enlisted the help of KM Packaging Services Ltd to develop a packaging solution for a new pre-prepared meal concept, which comprises raw meat and vegetables in a three compartment APET tray.
 
With over four varieties in the new range, the compartments of the trays have a protein, vegetable and a carbohydrate, which all require different packaging atmospheres. Going with today’s busy and health-conscious consumer lifestyles, this new approach to pre-prepared meals is a direct ‘cook in pan’ option using fresh ingredients.

Customised perforation formats
The challenge was to develop a lidding solution to support all sections of the dish. The protein element required an oxygen barrier and the compartment gas flushing to help extend product self-life. The sections of the tray containing vegetables and carbohydrate needed the lidding film to have laser perforated holes customised for each compartment, thereby allowing the necessary levels of respiration for each product.

The radical, high clarity film lidding solution designed and engineered by KM Packaging is suitable for all three components, which has been developed from a unique blend of polymers able to withstand demanding processing conditions, whilst retaining optimum seal integrity.

With over two decades of experience in developing bespoke lidding solutions, KM Packaging efficiently identified the correct perforation formats, precisely register the perforations and accurately ensure enough tolerance on the surrounding film area.

 Dedicated product trial runs were carried out at the food manufacturer’s site to ensure that the new packaging’s carefully structured lidding film reels would work in sync with the sealing equipment and the selected APET tray.

Renowned for providing high quality, reliable lidding film, this complex lidding film composition from the leading flexible packaging specialists, delivers incomparable product safety through superior seals.

Anti-fog, clarity features
To be displayed on retailer shelves with just a watch strap sleeve, another vital feature of the lidding film was keeping the film clear through its superior anti-fog characteristics. Highly visible to consumers, the film represents the quality of the product and therefore had to show strength and superior clarity for maximum shelf appeal.

KM Packaging offers an extensive range of flexible packaging solutions, including those for chilled and convenience foods, as well as flexible packaging materials for the confectionery sector including aluminium foil wraps, cold-seal, laminates, twist wraps, pouches and bags.

It made its first mark with the development of a revolutionary film technology for sealing foil trays and has since continued to invest in emerging new lidding and flexible packaging solutions.

Commenting on this highly intricate project, the company’s UK and Ireland’s business manager, Alan Lockhart, said: “Although there were many different food types to consider for each meal, we were able to demonstrate our industry knowledge and quickly advise on the technical characteristics of the film including the perforation specifications for each. Knowing the behaviour and varying respiratory rates of different fresh produce items proved invaluable to being able to complete the project on time.

“The lidding film material chosen for the range combines sophisticated high barrier sealingAir Zoom Pegasus EM