Ship the Vegetables and Hold the Ice Using Cool New FilmShip the Vegetables and Hold the Ice Using Cool New Film

Adding broccoli to your diet is healthier for humans. As importantly, shipping broccoli and other vegetables using less wasteful packaging is healthier for the environment and supply chain efficiency.

That’s exactly what Israel-based StePacPPC is making possible by moving from ice-filled polystyrene foam and unrecyclable waxed carton boxes traditionally used for shipping fresh broccoli and other vegetables on long-haul shipments in the US and Japan to a packaging-reducing bag film that eliminates the ice. And it allows for the use of standard, recyclable corrugated boxes.

One major broccoli producer, the Otofuke Agricultural Cooperative in Japan (JA Otofuke), has already adapted StePacPPC’s Xtend MA/MH bulk bags for shipping broccoli on its overland journey from Hokkaido to Yokohama (MA/MH stands for modified atmosphere/modified humidity).

Traditionally, Japan relied on polystyrene foam boxes packed with ice for domestic vegetable transport. While effective at keeping produce cool, this approach comes with significant environmental drawbacks.

For example, some countries banning PS foams have banned polystyrene entirely. Japan is placing growing regulatory emphasis on reducing the use of non-recyclable materials including certain types of polystyrene foam.

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Breaking the US ice habit.

In the US, the go-to waterproof waxed carton boxes commonly used for iced broccoli shipments are increasingly seen as problematic. Their wax coating renders them unsuitable for paper recycling, relegating them to general waste. States like California have enacted local bans on non-recyclable containers.

Beyond waste concerns, the water from melting ice poses food safety and quality concerns. Studies show that iced broccoli often carries more microbial contamination and loses more vitamin C compared to broccoli shipped in Xtend MA/MH packaging. Melting ice also poses logistical challenges, from messy conditions to slipping hazards.

"In our efforts to move away from polystyrene foam with ice and its inherent contamination risks, we considered various alternatives for maintaining freshness without using ice," explains Akio Yamagishi, manager of the fruit and vegetable sales, JA Otofuke. "We tested various modified atmosphere packaging films, including the Xtend films from StePacPPC. After inspecting the condition of the broccoli upon arrival, Xtend outperformed the rest in both appearance and quality."

Xtend packaging films slow respiration, reduces ethylene (which causes yellowing), removes excess moisture, delays aging, and slows microorganism growth. Its design even minimizes the risk of foodborne illnesses caused by pathogens like E. coli.

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More broccoli (and bok choy) and less waste.

Switching to Xtend packaging has brought measurable benefits. According to Yamagishi, benefits are that it…

“With ice, each box holds only 6kg of broccoli; without it, we can pack around 10kg,” Yamagishi says. “[This] led to a net reduction in costs of more than 30%."

The US is also seeing broader adoption of Xtend packaging for fresh broccoli shipments to foodservice markets.

According to Gary Ward, CTO of StePacPPC, Xtend reduces the carbon footprint of cross-country shipments by approximately 40% while extending shelf life, minimizing waste, and improving food safety.

"Our Xtend bulk packaging also successfully preserves other produce traditionally shipped on ice, such as bok choy and green onions."