"What we see now is not a return to paper, but a new development path"

While packaging once followed functionality, Joost Somford with JASA Packaging says it now evolves alongside regulation, branding, and automation. "It's not just about wrapping a product anymore. It's about aligning with an entire set of expectations—commercial, technical, and regulatory."

Speaking at the Leafy Hydroponics Event in the Netherlands and welcoming all visitors to the company's HQ in Obdam, Joost explains that packaging in the past primarily served as containment. "You put lettuce in a crate, wrap it if needed, and ship it out. There was little focus on machine handling, shelf presentation, or moisture regulation." That changed as retail became more standardized, especially with the growth of supermarkets and pre-packed produce. Plastic emerged as the dominant material. "Plastic films allow for consistent sealing, visibility, and barrier control. It became the standard because it performs reliably on automated lines."

The current shift toward paper-based and mono-material packaging does not reflect a return to traditional methods. "What we see now is not a return to paper, but a new development path," Joost says. "Paper is being engineered to run on machines that are originally built for plastic. And plastics themselves are being reformulated to meet recyclability targets." © JASA Packaging Solutions B.V.He adds that these changes are not isolated—they affect sealing temperatures, machine calibration, dwell times, and product behavior. "When you switch from OPP to a coated paper or a mono-PE film, you're not just changing a roll. You're changing the operating conditions of the entire line."

Right: The NXXT packaging line, and below the NXXt packaging

Underestimating
According to Joost, many growers underestimate how much time and testing are needed to integrate new materials without impacting throughput. "You can't treat it as a plug-and-play situation. Materials, machines, and products interact." Policy also plays a role. "Retailers and countries are setting requirements that shape what growers can use. It's no longer just about performance, but also about compliance and perception."

He argues that packaging should be included early in the planning process, not considered as a final step. While this may sound self-evident coming from a packaging machine supplier, Joost outlines broader reasons. "Decisions made at the beginning of a greenhouse project—whether in system design, crop planning, or automation—have direct consequences for what is technically feasible at the end of the production chain."

Growers tend to focus on yield per square meter, water efficiency, or energy input. Joost says these metrics are essential but are often overlooked in post-harvest realities. "The speed at which you can harvest, weigh, fill, seal, label, and ship the product increasingly determines whether a system is operationally viable. It doesn't end at the gutter."

For leafy greens—especially baby leaf, multi-leaf mixes, and loose-leaf heads—the packaging challenges go beyond shape or volume. These crops need solutions that maintain freshness under fluctuating humidity, protect against mechanical damage in transport, and function across retail and foodservice formats. Joost says modified atmosphere packaging (MAP), vertical form-fill-seal (VFFS), and resealable top seal systems are now assessed not just for shelf life, but also machine compatibility and processing speed.

"Some farms integrate their harvesting line directly with the packaging line," Joost notes. "This means you're not only thinking about how a robot harvests, but how it delivers that crop into a format ready for packaging without manual steps. It changes the entire handling protocol."

Limited space and labor
Hydroponic production adds further constraints. Limited space and labor require tight synchronization between production and packaging. Fast crop turnover demands systems that support rapid batch switching, minimal downtime, and SKU changes. According to Joost, this has implications upstream—affecting cold storage entry points, buffer capacity, and palletizing strategies.

Material choice remains a technical consideration. "Not all films behave the same in real-world conditions," he says. "Condensation, static charge, and oxygen transfer rate all matter. You might have the right crop and machine, but if your film fogs up in the cold chain, it may fail retailer acceptance."

Early coordination between growers, system designers, and packaging specialists is necessary. "A packaging machine can't fix crop moisture, substrate residue, or inconsistent portions," Joost explains. "Those need to be managed earlier. Otherwise, they introduce variability into the final package."

He also highlights data requirements. Retailers increasingly demand item-level tracking, QR or data matrix codes, and system integration. "Your packaging setup now has to manage more than product and film. It has to manage data too," he says. "You need to print, verify, and sometimes transmit that information in real-time."

Modular systems are also in demand. Rather than custom lines for every crop, Joost observes that more growers opt for flexible setups that can switch between flow wrap, clamshell, and top seal. "You might grow one crop today, but face five customer specs next season. Retrofitting is possible—but expensive in time and resources."

Joost ends with a practical observation: packaging operates as part of the production logic. "If your packaging setup can't match your harvest speed or meet your customer's requirements, then the rest of the system slows down."

For more information:
Jasa Packaging Solutions
Butter 17, 1713 GM Obdam
The Netherlands
Tel: +31 (0) 725 612 700
Email: d.baths@jasa.nl
www.jasa.nl