Stone Fruit Packaging Material Guidelines

These guidelines have been compiled with input from various reliable sources. Efforts are made to update the guides regularly. Since deregulation of the deciduous fruit industry in 1998, exporters have more freedom in packaging dimensions and components, leading to many options. However, some basic characteristics are non-negotiable:

• Cartons must have stacking strength to support the weight of stacked cartons.
• Cartons must have sufficient horizontal and vertical ventilation for effective cooling.
• Carton and pallet base dimensions must ensure container loads remain within length, width, and height limits, regardless of the number of pallets.

Important Points to Remember

• Source cartons and packaging material only from reliable/accredited suppliers.
• Ensure cartons have adequate horizontal and vertical ventilation.
• Cartons must have sufficient compression strength to withstand pressure on bottom layers in high humidity (90%) conditions.
• Do not exceed a total pallet height of 2.4m for containerised consignments (keep below the top of the ‘Red Load Line’).
• Use good quality wooden pallet bases and sound palletisation methods to withstand multiple forklift handlings.
• Do not use SOPP fungicide for wooden pallet bases (risk of fruit/carton contamination above allowed MRLs).
• Ensure correct width and spacing of pallet slats so carton ends rest on slats, not gaps.
• Pallet corner blocks must be clearly marked with the ISPM15 mark.
• Use temperature management tools (thermocouples & recorders) to manage the cold chain.
• Ensure all plastic trays are correctly punched for moisture drainage.
• Take note of food safety issues (see Annexure 2).
• Monitor for supermarket/country bans on specific plastics.
• The purchaser is responsible for specifying and checking packaging material standards.

Index

1. Cartons
   1.1 General
   1.2 Ventilation
   1.3 Target Market
   1.4 Marking Requirements
   1.5 Carton Specification
   1.6 Pallet Heights
   1.7 Weights of Packs
   1.8 Sizing
2. Internal Packaging
   2.1 Punnets
   2.2 Trays
   2.3 Shrivel Sheets
   2.4 Plastic Bags
   2.5 Riffled Paper
   2.6 Foam/Jiffy Pads/Bubble Pack
   2.7 Paper Inter-Leaves
3. Palletisation
   3.1 Wooden Pallet Base
   3.2 Pallet Purchasing and Storage Strategy
   3.3 Pallet Sheets (“Deck Boards”)
   3.4 PVC Side Pieces
   3.5 Securing Strips/Sheets
   3.6 Buckles
   3.7 Corner Pieces
   3.8 Top Frames
   3.9 Pallet Caps
   3.10 Wooden Top Frames
4. Thermocouples
5. Temperature Recorders
6. Paltrack Registration
7. Closing
8. Annexures (Ventilation, Food Safety, Pallet Specification, Pallet Purchase Strategy)

1. Cartons

1.1 General

Cartons are designed for:

• Unitisation
• Protection
• Conditioning
• Promotion
• Functionality
• Circular environment

Cartons are mainly made from kraft or white corrugated paper board (liner sheets, fluting, adhesive). Plastic lugs can be used instead of cartons but must meet the same design requirements.

1.2 Ventilation

• Sufficient ventilation is crucial for pre-cooling and maintaining the cold chain.
• Airflow must be both horizontal (for forced air tunnels) and vertical (for reefer containers/vessels).
• At least 5% of each carton surface should be open for airflow.
• “Super Vent” carton designs are available and recommended.
• Inner packing material can block ventilation holes—consider this in cooling practices.

1.3 Target Market

• Carton type/design depends on the target market.
• UK market prefers generic cartons and sometimes bulk packs for repacking.
• Cartons used for export may be disposed of after arrival.

1.4 Marking Requirements

All export cartons must comply with DACRAD and target market regulations. The business/information panel must include:

• Class (e.g., “Class 1”, “Category II”)
• Fruit type
• Carton depth
• Country of origin (“Produce of South Africa”)
• Producer/exporter/owner name and address
• Variety name (as per DACRAD)
• Min/max diameter in mm with code
• Content (e.g., “14 x punnets”)
• PUC or PHC code
• Date code
• Orchard name/number
• Food safety accreditation number

Not allowed: “Super quality”, “Select”, “Excellent”, “Best of South Africa”, “Premium”, etc.

1.5 Carton Specification

• Only use reputable/accredited manufacturers.
• Keep a 1-in-1000 sample of each lot for claims.
• Insist on test samples for verification.
• Minimum flat crush after printing: 329kPa (SABS 431-1985).
• Machine-erected cartons are generally sturdier than hand-folded.
• Fluting (BE or BC) affects strength and price.
• Minimum recommended crush strength is calculated as:
  Number of cartons per pallet column × gross mass per carton × 5.6 (safety factor)

Example Table

1.6 Pallet Heights

• Pallet height is critical for handling and shipping.
• Max pallet height: 2.14m (conventional), 2.40m (hi-cube containers).
• Standard wooden pallet base: ~155mm; CHEP pallets: ~176mm.
• Ensure clearance for forklift operation.
• Trials are ongoing for smaller pallets to fit 21 per container.

1.7 Weights of Packs

• Know the difference between nett and gross weights.
• Account for moisture loss from packing to sale.
• Example norms:

• For punnets, add 10% extra nett weight at packing to allow for moisture loss.

1.8 Sizing – EU Size Groups

Refer to export standards for allowable sizes per cultivar.

2. Internal Packaging

2.1 Punnets

• Made from Polypropylene (PP, milky) or Polyethylene-terephthalate (PET, clear).
• Use R-PET (recycled PET) where possible.
• Main sizes: 500g and 750g.
• Main formats: 10 or 13 prepacks per carton.
• Ensure punnets fit cartons and allow optimal airflow.
• Lids must fit firmly; clamshells are an alternative.
• Pulp/corrugated punnets are being tested as alternatives to plastic.

2.2 Trays

• Order trays well in advance (imported trays may be delayed).
• Ensure holes in tray cups are open.
• Pulp trays are standard for 400x300mm packs.
• Keep records of lot numbers for recall purposes.

2.3 Shrivel Sheets

• Used to reduce moisture loss and improve fruit quality during cooling/logistics.
• Two types: paper and high-density (6mm perforations).
• Ensure correct size and perforation.
• Not effective for airfreight or abused fruit.
• Place a riffled sheet on top of shrivel sheets for the top pallet layer.

2.4 Plastic Bags

• 500g plastic bags for plums are common.
• MAP and “Long Life” bags are new technologies for sea export.
• Ensure bags are suitable for the cold chain and have correct ventilation.

2.5 Riffled Paper

• White riffled/corrugated sheets (58g) are standard; kraft (brown, 60g) is a cost-effective alternative.
• Sizes: 400x300mm and 600x400mm.

2.6 Sponge/Bubble Pack

• Used mainly for 400x300mm packs.
• Sponge: 3mm thick, 20m³/m² density.
• Bubble pack is cost-effective and available in both standard sizes.
• Migration certificate required from supplier.

2.7 Paper Inter-Leaves

• Used in 5kg plum loose packs.
• Sponge sheets may be used instead, especially for apricots.

3. Palletisation

3.1 Wooden Pallet Base

• CHEP pallets are sturdy but require strict admin and may reduce container capacity.
• Standard white block pallet (1200x1000x155mm) is recommended.
• Pallets must be square and kiln-dried.
• Must be treated to ISPM15 standard and marked accordingly.
• Ensure strength for racking systems.

21 Pallets in a Container

• Industry is trialing smaller pallets to fit 21 per container.
• Adjust carton and internal packaging sizes accordingly.
• Ensure pallet slats support cartons and do not block ventilation.

3.2 Pallet Purchasing Strategy and Storage

• Plan pallet needs in advance.
• Select reliable suppliers.
• Test pallets on delivery.
• Store pallets in a safe, ventilated area.
• Use FIFO (first-in, first-out) for pallet usage.

3.3 Pallet Sheets (“Deck Boards”)

• Not recommended as they restrict vertical airflow and cannot compensate for poor cartons or palletising.

3.4 Sidepieces (PVC and Paper)

• Used to stabilise pallet loads.
• Attach with 20mm nails before palletising.

3.5 Securing Strips/Sheets

• Essential for pallet stability.
• Use at least five sets per pallet.
• Ensure strips/sheets have adequate holes for airflow.

3.6 Buckles

• Use standard metal buckles for securing pallet straps.

3.7 Corner Pieces

• Barrier-coated angle pieces are standard.
• Length must match pallet height.
• Consider food safety and market requirements.

3.8 Top Frames

• Used to prevent straps from cutting into cartons/fruit.
• Barrier-coated, four parts per set.

3.9 Pallet Cap

• Protects top of pallet from damage and contamination.
• Must be strapped down and not restrict airflow.

3.10 Wooden Top Frames

• Used for apricots and sensitive plums on long/dirt road transport.
• Must comply with ISPM15 and be marked.
• Not allowed for UK markets.

4. Thermocouples

• Essential for cold chain integrity.
• Place heat-welded end in fruit in the centre of the pallet.
• Mark pallets and cartons with thermocouple stickers.

5. Temperature Recorders

• Ensure overseas receivers can read the recorders.
• Mark cartons and pallets for easy retrieval.

6. Traceability Registration

• All commodities, varieties, packs, classes, brands, markets, and codes must be registered with DALRAD.
• Unregistered consignments may be delayed or incur extra costs.

7. Closing

• This document is revised regularly. Suggestions for improvement are welcome.
• The Stone Fruit Packaging Work Group is not responsible for the use or consequences of this information.

Annexures

• Annexure 1: Illustration of carton ventilation holes
• Annexure 2: Food safety compliance for packaging material
• Annexure 3: White block pallet specification (1200x1000mm)
• Annexure 4: Pallet purchase strategy

The content of this document should be considered as a guideline. Application may differ for every unique situation. The Stone Fruit Packaging Work Group cannot be held responsible for the use and application of the information or any actions and consequences arising from its use. Any application of information from this document is at the user’s own risk.