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food Marketing & Technology 4/2021

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Packaging Reclosable,

Packaging Reclosable, Completely Recyclable MAP Solution for Sliced Meat – Swiss Manufacturer Bigler is Causing a Stir at Retail with FlatMap ® After finalizing a successful project across European borders, Swiss meat manufacturer Bigler (www. bigler.ch) now relies on the brand-new, paper-based FlatMap ® solution for its sliced meat. Packaging equipment manufacturer SEALPAC, together with packaging materials suppliers Buergofol and Van Genechten Packaging, found the right partner in Bigler to develop this new packaging concept, which has now been launched at Swiss retail. More resource-saving, more eye-catching and more user-friendly is what summarizes the result. True pioneer in Switzerland The Swiss family company Bigler AG, with 700 employees and a total of six plants at three different locations, has its headquarters in Büren an der Aare and has been around for 75 years already. Under its motto “Ä Portion Tradition,“ Bigler supplies retailers and butchers in Switzerland under private label, as well as under its own Bigler brand. Always open for new ideas, the company became a pioneer in 2017 by launching skin packaging based on cardboard carriers, also known as FlatSkin ® . As such, Bigler paved the way for paper-based skin solutions on the Swiss market, which have since become the new standard. By introducing FlatMap ® within its business unit Charcuterie, the company is now launching another true innovation. This reclosable, largely fiber-based, completely flat, and recyclable packaging system for sliced meat consists of an FSC-certified cardboard carrier that can be printed on both sides. The carrier has been coated with a thin plastic layer, on which the sliced meat can be served appetizingly. The product is sealed with a highly transparent top film, which can be removed from the cardboard carrier before consumption. Afterwards, the film is easily placed over the product again, where the edges are pressed against the carrier to provide excellent reclosability. The tight-fitting top film allows for less oxygen to enter the inside of the pack compared to common MAP solutions. This prevents discolouration of the product whilst keeping it fresh and appetizing throughout the remaining storage time. After use, it Gérard Bigler, Head of the business unit Charcuterie at Bigler AG, presents FlatMap ® is possible to completely separate the plastic and cardboard components, therefore allowing full recyclability of these materials. A joint development SEALPAC initially came up with the idea of FlatMap ® . Under its motto Forming Innovations, also related to its “GO sustainable!” initiative, the family company and leader in tray-sealing and thermorming technology decided to develop the idea into a contemporary packaging solution. Several years ago, SEALPAC already entered the market with FlatSkin ® , an innovative, paperbased skin packaging solution. From project discussions with customers, it became clear that similar solutions were also being sought for products packaged under MAP. Together with its proven partner Van Genechten Packaging, the basic idea for FlatMap was born ® . Buergofol joined as a suitable film partner. The project was presented to Bigler AG in Switzerland, which had already used a number of SEALPAC innovations before. Markus Bigler, CEO at Bigler AG, explains: “The idea of FlatMap ® came at the exact right time. It became our joint goal to combine characteristics such as product protection, high barrier, recyclability, low packaging weight and reclosability in one of the most sustainable packaging solutions on the market.” Reliability in all steps of the process In achieving that goal, the project partners had to overcome several challenges. When using a cardboard 38 food Marketing & Technology • August 2021

Packaging Markus Bigler, Chief Executive Officer at Bigler AG Vittorio Ranaldo, Head of Marketing and Communications at Bigler AG carrier with FSC certification, the challenge is to maintain the shape of the carrier holding the chilled products, as this material is particularly sensitive to moisture. Cardboard specialist Van Genechten Packaging was able to demonstrate its know-how, also obtained from the previous FlatSkin ® project. For example, the material used for FlatMap ® is characterized by stability and durability throughout the entire process chain. In order to rule out microbial risks, only virgin fibers are used. Since an absolutely flat carrier is required for the packaging process, as well as for the presentation at retail, Van Genechten Packaging developed guidelines for its customers on how to optimally handle the cardboard carrier. The carrier can be printed in highquality offset using low-migration printing inks and varnishes. This gives manufacturers like Bigler a lot of creative freedom for an attractive presentation, to highlight their product at retail. After printing, the cardboard carrier is coated with a thin plastic layer, which provides a reliable barrier against moisture, fat, and oxygen. Film partner Buergofol was faced with the challenging task of developing a liner that adheres well to the cardboard on SEALPAC A7 traysealer, reliably producing the FlatMap ® packaging at Bigler AG the one hand, but can still be easily separated later for recycling purposes. The company chose a polyolefin-based and therefore recyclable material. For meat manufacturer Bigler, a reliable reclose function of the packaging was an absolute must. The development work of film specialist Buergofol resulted in a top film that shows a consumer-friendly opening behaviour, but at the same time provides excellent reclosability. In addition, it had to be ensured that the liner of the cardboard carrier does not come off with the top film when the packaging is opened, but only when it is pulled off with the recycling tab. Last but not least, Buergofol made sure that the thickness of both liner and top film was reduced to a minimum. At Bigler, the FlatMap ® packs for sliced meat are produced on a SEALPAC A7 traysealer in double lane execution. In general, the new packaging system can be reliably produced on all SEALPAC traysealers with FlatMap ® preparation, currently from the A6 up to the A10. This preparation implies the use of SEALPAC’s patented transport system to allow for optimal handling of the flat carriers on the traysealer, as well as the use of a suitable vacuum and gas system for consistent modified atmosphere packaging. Combined with high-quality servomotors, which provide excellent drive coordination, these traysealers, such as the SEALPAC food Marketing & Technology • August 2021 39

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