Paramount Packaging Systems: 65% film reduction in field-based lettuce wrapping

Paramount Packaging Systems supplied a specialist FUJI VX2 flow wrapping solution for field-based iceberg lettuce harvesting operations. The system was designed to address one of the most persistent inefficiencies in field packing: excessive film consumption from traditional wrapping methods.

The objective was straightforward: reduce film consumption, reduce operating cost and simplify operation for seasonal labour teams working in field conditions.

The challenge: Film waste and operational complexity in the field

Field-based produce wrapping presents challenges that differ significantly from fixed-site packing operations. Equipment must be compact enough to mount on a field rig, simple enough for seasonal operators to run reliably and robust enough to perform consistently in outdoor conditions.

Traditional wrapping methods used on iceberg lettuce operations were consuming far more film than necessary. The cost of carrying, storing and consuming that volume of film, across an entire harvesting season, was a significant and addressable inefficiency.

The solution: FUJI VX2 configured for field operation

The FUJI VX2 was specified and configured for this application, with a focus on film efficiency, ease of use and compact footprint.

Key results included:

• Up to 65% reduction in film volume compared to traditional wrapping methods
• Ability to run lower gauge film consistently
• Reduced packaging spend per unit
• Lower transport and storage requirements for film reels
• Reduced environmental impact

The compact machine design allowed the wrapper to be housed on a smaller field rig, improving mobility and reducing the overall equipment footprint during harvesting.

Built for seasonal labour teams

Ease of use was a primary requirement. Field operations rely on seasonal staff and any packaging system needs to be simple to operate, fast to set up and easy to maintain without specialist engineering support on site.

The FUJI VX2 was selected in part because it offered:

• Straightforward operator controls
• Fast changeovers between formats
• Easy cleaning and maintenance in field conditions
• Reliable performance across the full harvesting season
• Low total cost of ownership

Where packaging complexity creates dependency on skilled operators, the FUJI VX2's design directly reduces that risk.

Proven deployment: UK and Spain

The system has been successfully deployed across two countries:

• 1 machine operating in the UK
• 2 machines operating in Spain

The continued rollout across both markets was driven by the consistently low operating cost, ease of deployment and the film savings achieved in live production environments.

What this means for you

A 65% reduction in film volume changes the economics of field packing immediately. Lower film consumption reduces per-unit cost, reduces logistics overhead for film supply during the season and supports the sustainability commitments that major retailers increasingly require from fresh produce suppliers.

For fresh produce operations evaluating field-based wrapping solutions, Paramount Packaging Systems can advise on machine specification, film compatibility and total cost of ownership. Get in touch to find out more.

This article was originally published by Paramount Packaging Systems.