Robust cardboard packaging developed specifically for the door-to-door delivery of chilled and frozen foodstuffs.
Off the back of unseasonably high spring temperatures, chilled and frozen food manufacturers are being encouraged to prepare for summer heat by working with specialist partners to deliver thermally insulated packaging solutions, particularly when it comes to foodstuffs that are sent to consumers by courier.
The combination of rising temperatures and ineffective packaging could significantly impact on spoilage of foodstuffs. Temperatures exceeding 25°C are now becoming increasingly common throughout the nation, placing pressure on packaging manufacturers to design and manufacture suitable shipping and courier packs to reduce the risk of overheating and subsequent failing of chilled and frozen goods.
Dorset-based Ablebox have been working with raw pet food manufacturers and fresh grocery fulfilment companies to develop a thermal packaging solution made entirely of corrugated cardboard.
The packaging solution, which is made on site at Ablebox’s state-of-the-art facility near Sherborne, helps ensure that frozen and chilled products get through the supply chain and to the consumer without thawing out or spoiling. And because it is made of corrugated cardboard, the packaging can be effortlessly recycled in the household recycling system.
“Current solutions such as polystyrene are not sustainable, as they can’t be recycled kerb-side and are often difficult to handle and dispose of,” explains Chris Maskrey, Sales Manager. “The latest EPR regulations also mean there is more impetus for brand owners to get out of less sustainable, plastic solutions in order to avoid paying more tax. A move to corrugated cardboard is the obvious choice.”
A proven solution
For one pet food manufacturer, Ablebox designed a corrugated case with a series of cardboard fitments that build up layers of corrugated board to provide thermal insulation. During the design phase, the size was optimised for the customer’s product which also allowed for mixed pallets, giving flexibility and optimal logistics efficiency.
“During the process, we tested prototypes against the current poly box solution in our laboratory, using an environmental chamber to mimic the summer supply chain profile,” continues Chris. “Our Technical Manager, Bebil Poovakottu, headed the project. Probes were placed within the frozen food to monitor the internal and surface temperatures and log when certain thresholds were breached. The results really did speak for themselves!”
The full test reports were shared with the customer and Ablebox’s corrugated solution was highly successful, achieving the 48 hour threshold required for the courier network. Thanks to these results, the solution was put into production, and the solution is now live in the field.
Testing performed at 25 deg C saw performance maintained for 46 hours.
“We have developed a phase two solution that is quicker and easier to make up and automate in the packing facility,” adds Chris. “It will be easier for consumers to dispose of in kerbside recycling as well, making it a game-changer for chilled and frozen food shipments direct to consumers.”
The second phase, telescopic design that has now been developed performs slightly better thermally. In addition it is more robust and less prone to damage and potential thermal losses in the supply chain. Further enhancements have been developed and successfully tested to cope with summer temperature spikes that are now the norm.
Benefits to customer from using the Ablebox thermal corrugated solution:
Significant cost saving on packaging;
Significant EPR tax saving;
Takes up less space in the packing facility;
More sustainable;
More potential for marketing i.e. printing on the internal elements;
Stronger and less prone to subsequent thermal losses;
End customers prefer a more eco-friendly and easy to dispose of solution.
“From a service perspective, we offer a Stock & Serve solution and a flexible delivery schedule, as well as helping to manage customers’ replenishment requirements for them,” concludes Chris. “We can ensure Just-in-Time deliveries each week, meaning you never miss a delivery to your end customer. And the best part? Once used, the consumer simply folds down the shipping box and pops it into the blue-top bin - easy.”