H2020 CleanPack Project: UltraCLEAN thermoforming equipment for food packaging, a cost-effective alternative to cleanrooms
- Type Project
- Status Filled
- Execution 2017 -2019
- Assigned Budget 960.603,00 €
- Scope Europeo
- Main source of financing H2020
- Project website CleanPack
Summary and overview of the first year: During the first stage of the project, new CleanPack modules were designed. These comprised the four modules and the aseptic enclosure: (i) Thermoforming module; (ii) Filling module with essential oils for surface decontamination; (iii) Heat-sealing module; (iv) Cutting module. All technical designs were developed from the first year considering compatibility with the other modules, which was essential for the successful assembly of the entire CleanPack machine during the project. In addition to these technical designs, it is worth noting that the microbiologically controlled enclosure was also successfully validated during the first year according to ISO class 5 standard conditions (less than 100 particles ≥0.5 μm in size; airborne microbial count ≤1 CFU/ft³), to ensure ultra-clean conditions of the assembled machine. On-site validations initially began at the end of the first period. This consisted of verifying the machine's performance under real-life conditions and using different types of food products.
Information about CleanPack has been published on the TECSELOR website, in social media, and in specialized media. Various demonstrations have been held at food industry events and meetings with potential customers. In addition, a demonstration truck was developed with the manufactured prototype to facilitate transport of the machine to various project tasks, such as on-site validations or demonstration and marketing activities. Preliminary results from the first year were positive, with business contacts established with potential customers and distributors in the food packaging technology sector.
Summary and Overview of Year 2: During the second period of the project, and in accordance with the implementation of the Project Work Packages, industrial validation was completed, obtaining positive results in terms of microbiological control, as well as in the sensory and shelf-life conservation of food products [WP3]. Internal and external validations were also successfully developed, and pre-commercial activities were carried out, such as dissemination, international extension of industrial protection (patent), certifications and documentation for commercialization [WP4]. In this way, positive preliminary results were obtained, establishing pre-commercial agreements with potential customers and distributors interested in the acquisition and installation of CleanPack equipment. [WP5]
The CleanPack packaging machine aims to provide (on a small scale) aseptic/ultra-clean food packaging conditions and safety standards that until now could only be guaranteed in the cleanrooms of large food processors. In response to customer needs, TECSELOR is developing the CleanPack prototype, which enables ultra-clean/aseptic packaging conditions for food products, representing a cost-effective alternative to a cleanroom with the same level of food safety.
CleanPack goes beyond cleanrooms in terms of extending food shelf life. This goal could be achieved through a new packaging technique that combines several patented technologies: sterile thermoforming and packaging, surface decontamination filling of perishable fresh foods, and ultra-clean tray cutting. Integrating these techniques into a complete CleanPack machine will allow small and medium-sized packaging companies to maintain the same level of food safety as cleanrooms and extend the shelf life and freshness of their packaged foods even more than larger producers.
The industrial sector for preparing and packaging refrigerated solid foods, such as dairy products, meats, fish, ready meals, salads, and cut fruits and vegetables, demands higher levels of hygiene to package products with minimal microbial contamination or under commercially sterile conditions (aseptically). CleanPack extends food shelf life, preserving its freshness thanks to a clean label, as it does not require the addition of additional chemical preservatives. The implementation of this gentler technology also has the potential to reduce energy consumption and dependence on cold chain logistics, enabling decentralized production for a more sustainable and cost-effective distribution chain. Therefore, a large number of food SMEs could obtain better products with a longer shelf life thanks to CleanPack, thereby improving the sector's competitiveness.
Today, only large food processing companies can afford aseptic packaging.
CleanPack, the packaging machine, provides the food safety standards of a small-scale cleanroom. In response to our customers' needs, TECSELOR has developed the CleanPack prototype, which enables ultra-clean/aseptic packaging of food products, representing a cost-effective alternative to a cleanroom, with the same level of food safety.
CleanPack goes beyond cleanrooms in extending food shelf life. This goal has been achieved thanks to the promising results of the new CleanPack packaging technique, which combines three patented technologies: sterile thermoforming and packaging, surface decontamination filling of perishable fresh foods, and ultra-clean laser cutting of trays. Integrating these techniques into a complete CleanPack machine will allow SMEs to maintain the same level of food safety as cleanrooms and extend the shelf life and freshness of their packaged foods even more than larger producers.
The food industry, which specializes in the preparation and packaging of refrigerated solid foods, such as dairy products, meats, fish, prepared meals, salads, and cut fruits and vegetables, increasingly demands higher levels of hygiene that allow the product to be packaged with minimal microbial contamination or under commercially sterile conditions (aseptically).
CleanPack preserves the freshness characteristics of clean-label foods by eliminating the need for additional chemical preservatives, extending product shelf life by at least 150%. Implementing this gentler technology also has the potential to reduce energy consumption and reduce dependence on cold-chain logistics, enabling decentralized production, providing sustainability and reducing costs in the distribution chain. Therefore, many food SMEs could obtain better products with a longer shelf life thanks to CleanPack, which would improve the competitiveness of the sector.
CleanPack is a unique solution that will allow packaging SMEs to maintain the same level of food safety as cleanrooms and extend the shelf life and freshness of their packaged foods even more than larger producers. The CleanPack machine's four-module design can be adapted to different markets and customer needs, resulting in a more efficient and cost-effective process. Furthermore, the new decontamination technique using essential oils within the filling module helps extend product shelf life, estimated at a minimum of 150%, without additional chemical preservatives. CleanPack technology also has the potential to reduce energy and costs within the food distribution chain by decreasing reliance on cold chain logistics, enabling decentralized production and improving the competitiveness of the food sector.
The results of the CleanPack project: Following the successful implementation of the work packages during the second year, TECSELOR has been able to introduce a thermoforming machine for the on-site production of aseptic trays to the ready-to-eat (RTE) food packaging market. This machine reduces foodborne illness and food waste, and extends the shelf life of ready-to-eat (RTE) foods, primarily freshly cut fruits and vegetables, sliced foods (meat, fish, poultry), and other prepared dishes. Furthermore, these results have provided significant technological advantages over the competition.
- TECSELOR SL (TECSELOR)
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