South African Pome Fruit Industry

Packaging Material Guidelines 2024

Important Points to Remember

• Only source cartons and packaging material from reliable suppliers/manufacturers. Ensure you receive what you specified and ordered.
• Cartons must have adequate horizontal and vertical ventilation capabilities.
• Cartons must have sufficient compression strength to withstand pressure on bottom layers of hi-cube loads in high humidity (90%) conditions.
• Do not exceed the total pallet height of 2.4 m for containerised consignments (keep below the ‘Red Load Line’).
• Wooden pallet bases of good quality and sound palletisation methods are essential for cargo to withstand the numerous handlings in the logistics chain.
• Wooden pallets are not to be treated with SOPP fungicide as this chemical can lead to contamination of fruit and exceeding allowed residue levels for the EU. Packers must ensure MRL levels are acceptable.
• Correct width of slats and spaces between slats are vital to ensure carton ends rest on slats and not in gaps.
• Pallet corner blocks must be clearly marked with the ISPM15 mark to indicate correct treatment.
• Use temperature management tools (thermocouples & temperature recorders) to manage the cold chain.
• Rules/laws regarding the use of plastics are changing rapidly and have serious implications for the industry. Stay informed about the latest developments, including supermarket specifications.
• Although care is taken to keep guidelines updated, users must ensure they are aware of the latest changes in standards. Hortgro is not accountable for consequences from use of these guidelines.

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 Sponge/Jiffy Pads/Bubble Pack
   2.7 Paper Purple 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

Annexures:

• 1: Illustration of Ventilation
• 2: Food Safety
• 3: White Block Pallet Specification
• 4: Pallet Purchase Strategy

1. Cartons

1.1 General

Cartons are designed and manufactured for:

• Unitisation
• Protection
• Conditioning
• Promotion

When ordering cartons, ensure they comply with specifications and handle/present fruit in the best possible manner.
Cartons are mainly constructed from kraft corrugated paper board (liner sheets, corrugated sheet/fluting, adhesive). The combination and properties of these components determine carton strength.

Reusable plastic crates (e.g., Chep) can be used instead of cartons, but costs and receiver demands are deciding factors. Check for cleanliness as they can be a source of contamination.

1.2 Ventilation

Sufficient ventilation is crucial for effective pre-cooling and maintaining the cold chain.

• Airflow consists of horizontal (for forced air cooling tunnels) and vertical (for reefer containers/vessels) components.
• Air holes at the bottom of the carton are important for vertical cooling. At least 5% of each surface area should be open for airflow.
• Edge vent cartons (P21, P22) are recommended for shorter pre-cooling times and energy savings.
• Inner packing material may block ventilation holes, especially plastic bags (e.g., for Golden Delicious). Consider this when deciding on pre-cooling practices or temperature regimes.

1.3 Target Market

Carton type and design depend on target markets.

• UK market: Focused on generic black and green cartons (e.g., Tesco requires green, Sainsbury/M&S/ASDA require black).
• Some receivers and supermarkets insist on specific coloured cartons and special marking instructions, especially for registered varieties like Pink Lady® and Sundowner®.

1.4 Marking Requirements

The BUSINESS PANEL of any carton (including printed carton labels) should comply with EU or other target market regulations. Present your design to DAFF/PPECB and exporter before ordering cartons.
Required information typically includes:

• Class (I or II)
• Fruit Type
• Carton Depth (Recommended)
• Country of Origin: “Produce of South Africa”
• Complete Address of Exporter or Producer
• Name of Variety
• Number of Fruits
• Content of Carton (e.g., “14 x thrift bags”)
• PUC or PHC Code (Registered Producer or Pack House Code with DAFF)
• Food Safety Accreditation Number (e.g., Global Gap, Nature’s Choice)
• Pack Code (4-digit code for pack date; 2 additional digits for orchard numbers if required)

If all details are on the label, the carton itself only needs to be a carrier and does not require legal information. Include the international recycle logo and code in the carton design.

1.5 Carton Specification

• Source cartons only from reputable/accredited manufacturers.
• Insist that a 1 in 1000 sample of each lot is held by the manufacturer until season end for claims.
• Paper combination is crucial for carton strength. Ensure manufacturers guarantee minimum standards.
• Receive and store test samples of each batch for verification/testing.
• Telescopic cartons: Fruit should carry some of the weight of stacked cartons. Use correct trays to avoid blocking ventilation holes.
• Open Display cartons: Machine-erected cartons are sturdier than hand-folded if correct glue and supervision are used.
• Do not use below-standard packaging material.
• Paper combination and fluting (BE or BC) determine strength and price.
• Minimum BCT crush strength: Gross pack type × layers per stack × safety factor (5.6).

Example:
MK4 = 18.75 × 7 × 5.6 = 735 Nm² or 73.5 kg

1.6 Carton Size and Counts

Apples

Pears

Note: Some supermarkets require specific coloured cartons and special marking instructions.

1.7 Weights of Packs

• Confusion exists regarding NETT and GROSS weights. Underweight packaging may be a legal violation in the EU.
• Receivers usually specify weights. In the absence of this, follow these guidelines:

Minimum weight is compulsory on arrival in the market.

• Allow for moisture loss: add 200g per 12.5kg pack without plastic bags, 100g for fruit packed in bags.

2. Internal Packaging

• Trays: Pulp or black laminated polystyrene trays as specified by the customer. Consider paper trays as alternatives to single-use plastic.
• Apples and pears are packed according to specific counts per carton and tray/layer configurations.
• Fruit labeling: PLU codes must be used as per market requirements. Only registered PLU codes may be used.
• Carton pressure absorbing sheets: Use polystyrene pad, bubble pack, aerothene pad/net, corrugated craft sheet, or foam sheet as appropriate.
• Plastic bags: Use specified colour and micron thickness per variety and market requirements.

3. Palletisation

• Use only ISPM15-treated pallets for export, clearly marked on two sides.
• Pallet dimensions: Standard wooden block pallet is 1200 x 1000 x 155mm.
• Chep pallets may be required by some supermarkets.
• Pallet purchasing, quality control, and storage are critical for supply and quality.
• Use securing strips/sheets for display cartons to prevent pallet failure.
• Use standard metal buckles for strapping; do not over-tension.
• Use poli-coated angle pieces for corners; length must match pallet height.
• Pallet caps protect the top of pallets and help secure cartons.

4. Thermocouples

• Use Type T thermocouples to monitor cold chain integrity.
• Place the heat-welded end in a fruit in the center of the pallet; the other end should protrude from the pallet and be clearly marked.

5. Temperature Recorders

• Use temperature recorders compatible with receiver software.
• Mark cartons and pallets containing recorders for easy retrieval.
• New generation recorders can transmit data via cellphone technology.

6. Paltrack Registration

• All commodities, varieties, packs, classes, brands, target markets, inventory codes, and PUC/farm codes must be registered with Paltrack for export.
• Registration is exporter-specific and should be completed before the season starts.

7. Closing

• This document is revised regularly. Suggestions for improvements are welcome.
• Users must ensure they are using the latest version and standards.

Annexures

• Annexure 1: Illustration of Ventilation
• Annexure 2: Food Safety
• Annexure 3: White Block Pallet Specification
• Annexure 4: Pallet Purchase Strategy