' A.'”-‘Oaj TH! MEG-MMCS AM TECHNIQUES 0F PRODUCE PREPACKAGNG AT STORE LEVEL Thais fur tho Dogma cf M. A. MICE-IMAM STA}? UNWERSETY L. S. Nomechek, Jr. 1956 ‘I...Q-~ Q‘vo-‘foflnfio ~‘m'- -..w ‘k fl'HESlS This is to certify that the thesis entitled Techniques of Produce Prepackaging presented by L. S. Nemechek, Jr. has been accepted towards fulfillment of the requirements for Master of Arts degree inFood Distribution Kid dine; Major professor Date __M%)L5_._l9_5.6.— O~169 "The Food Distribution program at Michigan State University is under the sponsorship of the National Associa- tion of Food Chains. " The Mechanics and Techniques of Produce Prepackaging at Store Level by I... S. N_e_mechek, Jr. A Thesis Submitted to the College of Business and Public Service of Michigan State University of Agriculture and Applied Science in partial fulfillment of the requirements for the degree of MASTER OF ARTS Department of General Business Curriculum in Food Distribution 5915334; TECHNIQUES OF PRODUCE PREPACKAGING By L.S. Nemechek, Jr. AN ABSTRACT Submitted to the School of Graduate Studies of Michigan State University of Agriculture and Applied Science in partial fulfillment of the requirements for the degree of MASTER OF ARTS Department of General Business Curriculum in Food Distribution Approved {(3% r L. S. Nemechek, Jr . The writer has prepared this thesis to encourage operators of service and non-packaged produce departments to convert to self service prepackaged product operations. Presented in this study are the opera- tional requirements necessary for prepackaging produce. There are two advantages for prepackaging produce. First, pre- packaging reduces costs. Second, prepackaging increases sales. The most important factor in the produce cost structure is the waste factor. Prepackaging produce reduces waste by minimizing customer handling and deterioration due to dehydration. Sales are increased because customers are allowed to choose from a wider variety of produce, impulse sales are stimulated and the customer enjoys the advantage and convenience of reduced shopping time. Successful prepackaging operations have been established in pro- duce departments with sales ranging from $500 to $27, 000. Produce departments with sales of $500 or greater can successfully convert to pre- packaging. The cost of equipment and installation will vary with the size of the operation. The cost of the prepackaging materials and supplies is approximately two percent of sales and iépff— set by reduced labor costs. Proper merchandising of prepackaged produce is essential if suc- cessful conversion is to be achieved. Successful conversion also neces- sitates correct introduction of the prepackaging; both to the customer and to the employees. The customer should be introduced to prepackaging L. S. Nemechek, Jr . through concentrated advertising both at store level and in the regularly employed advertising media. Prepackaging should be introduced to the employees in special meetings and/or in training sessions. Proper supervision and training are perhaps two of the most impor- tant factors contributing to the success of a prepackaging produce operation. Training must include all personnel levels of a produce department. T rain- ing and the creation of a favorable attitude must be initiated at the admin- istrative level in order to obtain proper support and supervision from the key produce personnel. Department manager training should include principles of management and human relations as well as operational techniques. Employee training should include all the operational and mechanical techniques of produce prepackaging. The following four steps are recommended for training: 1. Tell them why 2. Show them how 3. Let them practice, under supervision 4. Put them on their own. In conclusion, the writer believes that produce sold in a modern super market should be prepackaged and self service. The highly competitive condition of the super market industry requires constant change and improvement. Prepackaging appears to be one method of improving the produce department. ACKNOWLEDGMENTS The author wishes to expremhis deepest appreciation and gratitude to his parents without whose help this year of graduate study could never have been attempted. Grateful appreciation is extended to the management of Busley Supermarket Company for their financial aid and encouragement during the past four years. The writer is endebted to Dr. E. A. Brand and the Food Distribution staff under whose guidance and council this project was undertaken. Sincere appreciation is extended to those members of management re— presenting: The National Association of Food Chains, Super Market Institute, Chain Store Age, Progressive Grocer, Super Market Merchandising, Albers Super Markets. Division of Colonial Stores, Inc., Be-Wise Food Store, Biloxi, Mississippi, The Kroger Company, Wrigley Os Stores, Inc., Piggly- Wiggly, Montgomery, Alabama, Super Valu Stores, Minneapolis, Minnesota and the United States Department of Agriculture. Special mention is accorded to Ezra Lapides Associates, Inc. , Mass Distribution Publications, Inc. , and the many equipment and material manu- facturers whose cooperation and advice greatly aided the writer. The writer wishes to give special recognition to his fellow students: Thomas Malewitz, Robert Rothhaup, William Stevenson, William Ball, C. J. Stone, Duncan Birdsell, and Charles Beer whose aid and encouragement stimulated completion of this project. Also, grateful acknowledgment is accorded the members of the Food Distribution Curriculum. No list of acknowledgments would be complete without tribute to Margaret Curry, department secretary, for her assistance during the year and with this thesis. ii TABLE OF CONTENTS CHAPTER PAGE I INTRODUCTION Why Prepackage ........................... 1 Advantages for the Consumer .................... 3 Advantages for the Operator .................... 5 H PREPACKAGING MATERIALS AND SUPPLIES Films ............................... l 1 Bags ................................ 1 5 Trays ............................... 16 Labels ............................... I 7 Tape ................................ 19 Tags ................................ 20 Storage ............................... 20 III PREPACKAGING EQUIPMENT Wash and Trim Unit ........................ 23 Packaging Table .......................... 24 Methods of Filling ......................... 25 Scales ............................... 26 Sealing Equipment ......................... 26 Perforations ............................ 27 Marking Equipment ........................ 28 Automatic Baggers ........................ 28 IV LAYOUT Workflow ............................. 29 Layouts .............................. 31 CHAPTER PAGE V MERCHANDISING Ordering .............................. 40 Receiving ............................. 43 Displaying ............................. 44 Pricing ............................... 47 Price Marking ........................... 49 VI SUPERVISION AND TRAINING Department Employees ....................... 53 Training Areas for Managers ................... 54 Training Areas for Employees .................. 54 Physical Facilities for Training .................. 56 VII SUMMARY AND CONCLUSIONS Why Prepackage .......... . ................ 5 9 Prepackaging Materials, Supplies, and Equipment ........ 60 Merchandising Prepackaged Produce ............... 60 Supervision and Training ..................... 60 APPENDIX 1 Store Level Vegetable Prepackaging Chart ............ 62 APPENDIX II Store Level Fruit Prepackaging Chart .............. 69 BIBLIOGRAPHY .............................. 75 LIST OF FIGURES FIGURE PA CE I Prepackaging Room Layout, Hudson and Thompson, Piggly-Wiggly ........................... 33 II Prepackaging Room Layout, Be-Wise Food Store ........... 35 Ill Prepackaging Room Layout, Albers Super Markets, Division of Colonial Stores, Inc. ................. 37 CHAPTER I INTRODUCING PREPACKAGED PRODUCE Why Prepackage A few years ago the supermarlet revolutionized the food business; currently the prepackaging of produce is revolutionizing the produce depart- ment. Why should the housewife be offered prepackaged produce? Perhaps this question can best be answered in terms of what has happened in meat markets throughout the country. Today it is difficult to find a modern super market which does not have 100 percent prepackaged meats. The success of prepackaged meats points out two things: I. The customer accepts prepackaged meats. 2. Super market operators have found that prepackaging is more profitable than the traditional service meat counters. Many surveys have shown that customers prefer service meats, however, they accept self service. 2 It should be kept in mind that the customer, where surveyed, had just come from a fast and economical self service counter and undoubtedly she unintentionally biasis her answer because she forgets the long lines she used to wait in at service counters l. Lapides, Ezra, Techniques in Produce Prepackaging, 1955, p. 8. 2. Riley, H. M., and R. C. Kramer, What Consumers are Saying About Prepackaged, Fresh and Frozen Meats, 1955, p. 5. during rush periods. Perhaps a survey should be conducted of shoppers who are waiting in line at service counters. It is quite possible that such a survey might show a different consumer preference. The purpose of this chapter is not to defend self service and pre- packaged meats, they need no defense. Prepackaged meats are here, they are more profitable, the consumer accepts, if not prefers, them. Produce operators have an advantage over their prepackaged meat predecessors. From the pioneers of meat prepackaging, the produce oper- ator can learnmuch concerning layout, merchandising, supervising and training, and in some cases the techniques of wrapping and sealing. Addi- tional help may be obtained from manufacturers of equipment and suppliers who have overcome, through thorough research, many of the difficulties of prepackaging perishables. Imagination, foresight, and planning are the keys to successful operation. Produce prepackaging is not new. Almost every produce department sells some items that are prepackaged. For example; packaged carrots, potatoes, and celery have been available to super market operators for over ten years. Admittedly, most of this prepackaging is done by the grower. What is important, however, is the fact that these items are sold and have been sold successfully for quite some time. Everyday operators are finding more and more items available in prepackaged form. There is a variance of opinion among operators as to where the actual prepackaging should take place - on the farm, at the central location, or in the store. The writer is of the opinion that the majority of items should be prepackaged at store level because of the highly perishable nature of the produce. Grower packed items, however, enable store operators to carry merchandise which would not be to their best advantage to package because of the quantity requirements. Prepackaged produce departments are more economical to operate than service type departments. Operators who have converted to 100 percent prepackaging report that conversion increases sales and permits a fuller utilization of labor.4 Super Market Institute reported that in 1955, 55 percent of its members operate self service produce departments. Sales gains of 13 5 percent were registered by these operators. Much of this gain must be attributed to self service and prepackaging. Advantages for the Consumer One of the biggest advantages of self service and prepackaged produce is that consumer shopping time is reduced. No matter how hard operators try, it is still a fact that "Mrs. Consumer" considers grocery shopping a chore. The less time she has to spend in shopping for her food means more 3. Lapides, Op. Cit., p.8. 4. Progressive Grocer, November 1955, p. 50 5. Super Market Institute, The Super Market Industry Speaks , 1955. time for household duties and leisure. With the advent of self service and prepackaging, she can literally breeze through the produce department with no waiting for clerks to weigh and mark each item. The customer is allowed to shop at her own pace with no clerk interference. Time savings continues at the check stand. It is much easier and quicker to handle and ring up prepackaged items because there are no prices to remember and no weighing of the produce items. The attractiveness of the package is a factor in consumer acceptance and preference. Prepackaging allows new color schemes; and color breaks can be obtained in the package as well as in the department as a whole. The materials used in the packaging operation tend to beautify and amplify the produce. Convenience of handling at home prompts the housewife to buy pre- packaged produce. She knows it has been thoroughly cleaned and trimmed before packaging and she can place it in the refrigerator just as she bought it. Sanitation and cleanliness also stimulate the housewife to purchase pre- packaged produce because the package prohibits physical contact with the item by other customers. Waste and breakage have been eliminated by packaging. The housewife no longer has to remove leaves or broken stems when she arrives home. The rigidity of the container and the tightness of the wrap guarantees a whole product. Successful operators point out that prepackaged produce can be sold at the same or lower price as bulk produce. If prepackaging allows the consumer to purchase her produce at the same price or lower, certainly it will be preferred. Advantages for Operators Waste costs are reduced by cutting down the amount of retrim. Re- trim raises expenses through produce shrinkage and extra labor costs. A Manchester, New Hampshire operator reports on his prepackaging operationp "With the same complement of employees and the same amount of sales area, produce volume has been increased so that it now totals 10.5 percent of total store sales and the de- partment's labor expense has been cut to a low of 6 percent of sales. Losses due to shrinkage, spoilage and markdowns have been cut in half from 3 to 1. 5 percent; while gross margins on sales average out to 28 percent over the period prepackaging was adopted. " Many operators have reported the same or similar results, indicating that operators large and small are profitably prepackaging produce. The expense of housekeeping is reduced by prepackaging. Operators have long experienced the "Saturday night blues" when they had to tear down displays and clean racks. Even in the dry bins, flakes of skin, peel and dirt have always increased the amount of work necessary to make the department "Kitchen Kleen". With prepackaging dirt, skins, and peels are practically eliminated, thus cutting down the amount of time required to police the department. Packaging also cuts down the danger of customers slipping on leaves, etc. , with possible damage suits resulting. Safety is economical. 6. Progressive Grocer, November 1955, p. 51. ’3 The actual packaging operation cuts labor costs. The assembly line, mass production that is so prevalent in heavy industries, can be, and is being applied in the prepackaging operation. The claim that prepackaging is too expensive because of the cost of materials used is exaggerated. Operators are already using a packaging operation. Kraft bags are extensively used in service operations, and they represent a considerable expense to these operators. In a prepackaged oper- ation the expense of the Kraft bags is replaced to a considerable extent by prepackaging materials. Therefore, the cost of the prepackaging materials is actually only the difference between the cost of the packaging material and the old style Kraft bag wrap. The problem of keeping perishable displays looking fresh and neat has been a major problem to produce department managers. Because of the variety of sizes, shapes, and forms of produce displays are difficult to build. However, prepackaging allows displays to be built that do not require the tedious, unit by unit, stacking formerly done in bulk departments. The use of multi-unit bags and trays permits displays to be built and restocked with a minimum amount of time and effort. Greater uniformity and neatness may also be achieved with the use of bags and trays. Spoilage and wilting due to exposure and handling contribute to the high expense ratio of bulk produce departments. Prepackaging decreases evaporation and customer handling of the items, thus increasing shelf life. The packaging films prevent the warmth and perspiration of customers hands from coming into contact with the produce. The film also reduces evaporation. Produce breathes, giving off moisture and absorbing oxygen. This moisture is not so readily lost due to the wrapping material surrounding the item. However, some breathing must take place so that there will be a certain amount of gas passage. Film manufacturers have allowed for this and have made available films of a porous nature. In the cases where certain produce requires additional ventilation, holes may be punched in the film to allow for the extra passage of air and gas. A more comprehensive discussion of films follows in Chapter II, entitled, "Produce Prepackaging Materials and Supplies". High standards of quality control and uniformity that were impossible to achieve with bulk produce can be maintained with prepackaged produce. By determining what size (length and/or weight) item should be used in a specific bag or wrapping, a department manager can trim to specific lengths and attain the desired uniformity. Also, since each item is individually washed and trimmed before wrapping, the desired quality can be maintained. Quality must be sold to the employee as well as to the consumer. The employee must be impressed with the fact that nothing but top grade and quality produce is to be packaged. Often an employee or department manager will hedge on his responsibility to insure only quality packaging. For example, a piece of fruit may be "slightly" over-ripe. The employee puts the soft side down rather than throw the item away. What happens? In a few hours the item is "really" ripe and makes the whole package unsaleable. Even if the package is sold, the customer becomes aggreviated when she discovers the deception. Thus another customer may be lost and prepackaged produce receives a blackeye. Therefore, to set and observe only the highest quality standards is a necessity for successful produce prepackaging. There is no substitute for quality, this is a necessary education point that must be made to employees. Closely allied with standardization and quality control is the appeal the package has of itself. Assuming the produce is of top quality, prepackag- ing emphasizes and highlights that top quality produce. When one looks down the"glass aislé'of a super market he is attracted by its sparkle and uniformity. The film and other materials used in prepackaging add sparkle and attractive- ness to the produce. With appropriate color breaks and package designs, produce covered with sparkling film can make the produce the jewel of the super market. In addition to the usual color breaks used in a produce department, Busley's Supermarket Company, Denver, Colorado, also uses color or variety breaks within individual packages. For example, apricots and plums, grapes of different varieties are packaged together. Busley's reports that not only are impulse sales increased but less popular merchandise often shows a sales increase. . Accurate inventory control has long been a problem in the produce department. However, with prepackaged produce a new and accurate method 7 has been made possible. As Mr. Lapides puts it: "in the last analysis, inventory control is one of the most important phase in any operation. It is directly responsible 7. Lapides, Op. Cit., p. 11. for having the right items in the case at all times as well as the proper quantities of the items. The rotation of the items can be controlled so that the oldest items will move out first. By counting the number of packages, the cost and selling prices of the total inventory can quickly be determined, thus turning the most difficult-to-inventory department into the easiest one. This in itself is important. With the advent of pre- packaged produce it is possible to have produce figures readily available at all times. " Prepackaging produce also helps to solve the problem of price marking produce. First, errors which may occur at the check stand resulting from smudged pencil marks can be eliminated with the use of new labeling equipment and machines. Automatic labeling machines are available which print with non—smear ink. Secondly, labeling also helps to minimize customer complaints. The most frequently mentioned criticism of prepackaged meats was that people did not know how lnng the meat had been packaged. 8 Correct labeling giving (1) the date of packaging, (2) weight, and (3)» price, would help to build consumer confidence in prepackaged produce as well as in prepackaged meats. Another advantage offered in prepackaged produce is speed of consumer shopping. Speed in shopping is as important to the operator as it is to the housewife. By freeing her of waiting and irritation, the housewife can spend more time looking over items in the produce department and in other depart- ments of the store. The effect of prepackaging produce on consumer speed of shopping and a resulting increase of sales is substantiated by a survey conducted by 8. Riley and Kramer, Op. Cit., p. 51. 10 E. I. Du Pont de Nemours and Company. Du Pont surveyed the shopping habits of 10,000 shoppers in service and prepackaged produce departments. The survey results revealed that:9 A. B. 5, 000 shoppers spend 220.1 hours in service produce departments. 5, 000 shoppers spent 167.4 hours in self service produce depart- ments. 5, 000 shoppers bought 11, 859 items in service produce depart- ments. 5, 000 shoppers bought 14,095 items in self service produce depart- ments. While shoppers spent 24 percent less time shopping in self service prepackaged departments, they bought 16 percent more merchandise. From these facts it is possible to conclude that (1) self service prepackaged produce departments sell faster and (2) self service prepackaged produce departments sell more . The advantages gained by the consumer are advantages gained by the operator . The consumer is boss. If the consumer wants and prefers pre- packaged produce this in itself is indicative of a need for investigation into prepackaged produce. 9. E. I. Du Pont de Nennurs and Company, Prepackaging:- An Approach to Produce Profits , 1951, p. 9. CHAPTER II PREPACKAGING MATERIALS AND SUPPLIES Films The materials most frequently used in prepackaging produce are: l. 2. 7. cellophane cellulose acetate polyethylene pliofilm mylar polysel sar an Mylar, polysel, and saran are relatively new types of film and are not too widely used at the present time in the packaging of fresh produce. What is important, however, is the fact that film manufacturers are striving to improve and create new materials for the packaging field. These materials have the essential characteristics necessary for the packaging process. They are flexible, transparent, printable and heat-sealable. However, no single film has all the necessary attributes for all packaging applications. Cellophane manufacturers make many types of cellophane to meet the requirements for prepackaging the various types of items. 12 Mr. Lapides explains these types of cellophane as follows: 10 "The cellophane companies have code letters and numbers attached to the types of cellophane used. The Du Pont Company and Olin Industries use the same code letters and numbers. MSAT- 80 is the Du Pont classification for the pro- per film to use on fresh meats. Most users of cellophane are familiar with the MSAT- 80 classification, yet not too many realize what it means. In the case of this particular film: M - means moisture proof S — means heat-sealable A - means anchor~coated T - means transparent. This film carries all of the above classifications because of the nature of fresh meats. The 80 is the code number for the fresh film. " The Du Pont classification for the entire film line is as follows: A - anchor-coated C - colored F - flame resistant H - particularly resistant to blacking L - less moisture proof than standard M - moisture proof P - plain R — rancidity retandant S - heat-sealable T - transparent Cellophane is manufactured in three gauges or thicknesses, 300, 450 and 600. The 300 is about . 0010 of an inch; the 450 is about .0014 of an inch; and the 600 is about .0017 of an inch. 10. Lapides, Op. Cit., pp. 30-31. m— 13 By using the code numbers (previously listed) and the gauge number it is possible to determine exactly what qualities a given type of cellophane has. For example, 600 MSAT is a moisture proof film, heat-sealable, anchor coated, transparent, and .0017 of an inch thick. The cost of cellophane per pound is the same in all gauges. However, the cost of the thicker film is more because the footage per pound is less. Most of the films used in packaging are sold by the pound. In most cases the manufacturers make known the number of square inches per pound. With this information, it is quite easy to figure the film costs per thousand square inches. This may be done by dividing the number of square inches per pound into the cost per pound thus arriving at the cost per thousand square inches. From this point, it is then possible to determine the cost per sheet of the various films. Cellophane is heat-scalable, transparent, flexible, and printable. It accepts the band of thermoplastic labels, is permeable to gases and has a fine appearance package-wise. Cellophane is used on tray-wrapped items as well as bags up to a two pomid quantity. Anything two pounds or over should be packaged in polyethylene or pliofilm which have better tear resis- tance. The types of film for produce prepackaging are LSAT and MSAT, or the Sylvania equivalents, D83 or MSBO provided perforations are present. 11 11. E. I. Du Pont de Nennurs and Company, Inc., Chart for Prepackaging Fruits and Vegetables at Store Level,. 14 Two other manufacturers of cellophane are the Sylvania Division of the American Viscose Corporation and Olin Industries. Both companies are reputable manufacturers of fine grades of film. The volume of cellophane sold in the country today is many times greater than all the other types of film combined. Another type of film used in prepackaging produce is cellulose acetate. The biggest advantage of cellulose acetate is‘ that it needs no perforations. Growers and packers who have machines that seal it by means of glue or paste use this film to a great extent. Among the other qualities of cellulose acetate are that it is printable, transparent and flexible. This film is manu- factured by the Celanese Corporation of America under the name of "Lumarith". Pliofilm is a heavy duty film used for packaging such items as potatoes, carrots, and citrus fruits. The pliofilm has fine transparency, stretch pro- perties, and is printable. Goodyear corporation manufacturers pliofilm. It may be obtained from a number of suppliers. Polyethylene is one of the latest films which has become commercially available. Although polyethylene is less transparent than other types of films, reports from manufacturers indicate that it will not be too long before fully transparent polyethylene will be made available. The advantages of this film are as follows: odorless, tasteless, unaffected by water, very strong and pliable, non-blacking and very printable. Heavier items are usually packaged in polyethylene. 15 Polyethene is manufactured in several gauges; but the one and one-half mil are the ones preferred for most packaging operations. One and one-half polyethylene can be used for bags to up 100 pounds. Although some packers are using two mil polyethylene for 10 pound packages of potatoes, most convertors have very satisfactorily used one and one-half mil film in the whole produce line. 12 A substantial savings may be obtained through the use of one and one-half material whenever possible. Bags The most popular, most economical, and in some cases the only way to package produce is in bags. In the long run bags are easier to handle and much cheaper; due to savings in material costs and labor costs. Some operators use bags almost entirely in the packaging of produce. Bags can be purchased either plain or printed in color. Colored bags offer three big advantages. First, the color adds attractiveness to the package. Second, labeling is printed on the outside of the package, thus eliminating label heat sealing or placing the label inside the package. And third, price marking is made easier because of the predominent price marking spot. To retard deterioration due to dehydration and wilting, produce must have ventilation. Purchasing bags that are already perforated saves time and perforating equipment costs. Cellophane bags are perforated with minute, almost invisible holes. The polyethylene bags are perforated along the sides with a series of one-eighth or one-fourth inch holes. The one-fourth 12. Lapides, Op. Cit., p. 31. 17 When trays are used, perforations must be made in the film wrapping. A perforating wheel may be used. Manufacturer perforated film is available with fine slots cut in the films. The slots are almost invisible but provide adequate ventilation. There are several types of trays on the market. The molded and the treated trays are the ones recommended for produce prepackaging. The trays are available in a number of sizes; ranging from five to ten inches in length and three to six and one-half inches in width. All trays are approxi— mately one inch deep. Colored trays have recently been made available and do much to beautify the packaged produce. Back boards are also used in prepackaging produce. They are similar to those used in prepackaged meat operations. Citrus fruits, plums, apples, etc. , are wrapped on these boards to obtain a rigid and firm package. Labels Label manufacturers have done an excellent job in designing labels. Labels fall into three general classifications: intra-package, heat seal and saddle. The saddle label is placed over the top fold of the bag and then affixed by staples of heat sealing. When using plain bags, a saddle label is used for brand and price identification. The saddle label can be purchased custom made or from dealer's stock. The intra—package and heat seal labels can be purchased either custom made or from dealer's stock. The intra-package label is moisture proofed to l8 prevent smearing and deterioration. The heat seal label has a thermoplastic backing which permits permanent affixation to the package. National Cash Register Company manufacturers a machine for marking labels. It operates like a cash register and ejects a label size piece of tape, either plain or multi-colored, with all the necessary information printed on it. Toledo Scale Company also manufacturers a machine which does the labeling and weighing in one operation. The label is ejected from the label dispenser, then placed in a slot in the machine after the merchandise is weighed. The accurate weights are printed onto the label automatically. Merchandising can be done through labels as well as in the store operation itself. New ideas in labeling, within the plain or printed colored bags, help carry the merchandising ideas right into the home. In the era of "service in self service markets", the idea of label menus has become very popular. Meat market operators have used these "talking" labels very successfully to suggest cooking preparations for the various cuts of meat. Produce operators can take the cue from the market managers and merchandise their produce through the use of menus and "talking" labels. Women welcome cooking suggestions and recipes for new methods of pre- paration. Operators should remember that women do not blame their cooking if produce is tasteless, etc. She blames the produce. A merchandise-wise operator will suggest preparation for fruits and vegetables through his package advertising. l9 Illustrated or "talking" labels can be used very effectively with either cellophane or polyethylene bags and also as inserts in "trayed" merchandise. Labels can be obtained in heat seal stock, board stock for stapling, or in greaseproof stock for package insertion. Bag top and other large size packaging labels can be quickly and economically imprinted by an automatic labeling machine called the " Roto Kimco" . This machine will produce a label from a minimum size of 1" by 5/8" to the maximum size of 6—5/15" by 4—3/8", at a speed of 160 labels a minute. The Rote Kimco prints from easy-to-use metal logs or from rubber mats which slide easily into grooves. Changes are made by slug inserts. 'Ihe Roto Kimco labeling machine will accommodate heat seal, pressure sensitive gum, greaseproof or plain labels. This new piece of equipment also has a cut-off knife and a stacking devise. It is equipped, too, with a reset counter so that the operator can actually keep track of the numbers of each item name labeled. These labels come in fan-fold or roll form. Tape Tape used in the packaging operation can be of three types: twistems; that used by the Tapelock machine and; a gummed Kraft tape. Twistems are covered pieces of wire which can be twisted around the tops of polyethylene or cellophane bags. These twistems are manufactured in one—fourth and one- half inch widths and in lengths from three to twenty inches. They can be ob- tained in various colors and with the super markets name, price, and other data imprinted on them. 20 The tape used with the Tapelock machine can be obtained from the machine manufacturer. This tape is dispensed from a roll and bound around the bag tops. Tapelock machine tape is available in several colors. The gummed Kraft tape can be used for an item such as bananas. The tape is used as a wrap around and usually has a price marking spot. Paper jobbers or label manufacturers sell this gummed tape. Ta gs Most operations have occasional need for clip tags which clamp onto the packaging material. Also available are self sticking "reduced for quick sale" tags. Both the self sticking and clip tags are used for marking sale items or older merchandise. This type of merchandise should be sold in plain packages or dump tables so as not to confuse customers with regular merchandise. Tags are relatively inexpensive and should be used on such items that are not taped or bagged. Storage Bags and sheets should be stored in their original containers until used. Storage should be in a cool, dry place. Care should be exercised in selecting a storage area where the temperature is around 65 to 75 degrees. Storage should never take place in an area where the temperature is below 32 degrees. A humidity of about 65 percent is recommended to keep the films from drying out. 21 The following are some general rules for proper use of prepackaging material and supplies: 1. Determine the best type package for each produce item. 2. Use the smallest size bag, sheet, or tray for the individual package which will conveniently accommodate an item. 3. Store all packaging material in a safe, convenient, cool and dry place. Appendices l and 11 contain recommended procedures for prepackaging fruits and vegetables at store level. The packaging details presented in these charts are as follows: preparation, type package, material type, material size, closure, packaging method. CHAPTER III PREPACKAGING EQUIPMENT Mechanization of the prepackaging operation is a necessity if the fullest utilization of space, materials and labor is to be obtained. Packaging equipment plays an important role in mechanization of the prepackaging operation. The establishment of a mechanized assembly line operation tends to reduce labor costs which are the second highest operating expense; second only to merchandise costs. Equipment, therefore, plays an important part in the development of a successful prepackaging operation. Equipment manufacturers have greatly aided operators by designing and producing equipment that is readily adaptable to almost any type of prepackaging operation. The experience of the writer indicates that manufacturers fully cooperate with operators in adjusting their equipment to a specific operation. Equipment manufacturers also offer suggestions, backed by research, as to the latest packaging techniques and layouts. The equipment required for prepackaging is not expensive when con- sidered in the light of its utility; nor does the equipment have to be elaborate. The value of any equipment is measured in terms of the efficiency it produces and the type of work that it performs. Equipment and equipment costs will 23 vary with the size of the operation. At the end of each equipment description is an estimate of the minimum dollar volume which can most economically support the equipment. The cost of the equipment (where available) is also given . Wash and Trim Unit The wash and trim table is much more than just a sink. It should be constructed so as to have adequate space for washing, trimming; and a holding bin for rewashing and draining. Average specifications for such a wash and trim table are as follows: approximately 5 feet long, 30 inches wide and 36 inches high. This type of unit can fit into any line of production and is very efficient. For large scale operations, two such tables may be utilized. Cost, approximately, is as follows: without disposal $ 265.00 with light disposal 695. 00 with heavy disposal 1385. 00 Used in conjunction with the wash and trim table is the waste disposal. Its specifications are: height, 36 inches; width, 23 inches; and length 50 inches.- It can and should be incorporated in or between trim and wash tables. In one operation viewed by the writer, the disposal equipment was the basis of the wash and trim table. Its length was extended by wooden shelving covered with metal. The operator stated that he had found greater utility in such an arrangement because it can be tailor-made to the stores operation . 24 Packaging Table The packaging table described here is one of the many on the market today. Its many features simplify the packaging operation. Its construction tends to eliminate lost motion because all the required smaller equipment and supplies are handy to the operator. The table is constructed of gray metal throughout except for the table top which is of meat board construction made of hard laminated two inch strips, two inches thick. The table is eight feet long, 30 inches deep and 36 inches in height to fit in with the wash table specifications and other such equipment specifications. The packaging table is wired to four outlets which accommodate all the electric sealing devices as well as scales if required. There is a complete set of bag bins; enough to satisfy the varied bag size requirements. Beneath the bag bin are fluorescent tubes whichilluminate the work table. There is also a shelf for sheet materials and other miscel- laneous items which the operator may need and use. The lower front edge has a metal strip all the way across it to hold any or all funnels. This allows the funnels to be placed at any spot along the table edge. Adjustable shelving is also a feature of the table. They are located under the funnels for holding hampers or crates of merchandise. Drawers are also built in to hold clip tickets, tape, rubber bangs, etc. Operations anti- cipating $1500 a week or over should have and use such a table. Approximate cost of such a table is $335. 00. 25 Methods of Filling There are two methods of filling bags. One is by hand and the other is by semi-automatic equipment. For the majority of operations and for most stores, the funnel system of bag filling seems to be the best. These funnels enable the item to be put into the bag more quickly and easily. For items such as lettuce and celery, which have a great tendency to cling, these funnels are almost a necessity. The funnels can either be clipped onto the packaging table or fitted into slots provided on the table. Lettuce funnels have fingers on them which fit into the bag, so that when the lettuce is placed inside the bag it does not stick to the bag sides. The celery chute provides the same feature for celery or other long stemmed or leafy items. Funnels may be purchased in sets or individually, according to the needs of the operator. The fimnels are available with varied opening sizes. Three of the most papular and utilizable sizes are: 3-1/8 inch, 4-1/2 inch, and 5-1 /2 inch. It is advisable for any operator to have these three funnel sizes, a celery shute and a lettuce funnel. Also available on the market is a new type lettuce packaging machine. It operates as follows: a head of lettuce is first placed on a sheet of cut-to- size cellophane over the feeder opening. The operator pressed the lettuce down into a metal basket (inside the machine), then throws a switch which seals the cellophane overwrap. After it is sealed, the complete package is 26 automatically ejected. This machine should be used only in extremely large volume operations. Costs of the funnel sets are as follows: set of three funnels $18. 00 celery chute 10.00 lettuce funnel 12. 00 $40.00 Scales All of the national scale manufacturers have scales which are ade- quate for packaging produce. In the majority of cases, the standard prepack scales are used. Some operators use a curved scale pan or scoop type top to prevent items from falling or rolling off. This also aids in the bagging operation. Approximate cost of standard prepack scales is $85. 00. Toledo Scale Company has developed a prepack scale called "Serv-a- Label". This scale automatically prints the weight, price, dates the package, and the name of the super market on the label. The scale price reading is punched into a key board much like that of a cash register. This machine and others like it are most economically fitted to large scale operations. Sealing Equipment The most popular method of closing cellophane is by heat. Three of the most popular devices used for sealing are: the hand iron, the hand crimp sealer, foot crimp sealer. One or more hand irons are required in any packaging operation. They are used in sealing trayed and direct wrap 27 packages, as well as for putting on labels. The newer irons have thermostatic controls on them so that films requiring different sealing temperatures may be properly sealed. (cost $9. 95) The hand heat crimp sealer is a portable sealer which is used for heat sealing bag tops. It has an adjustable thermostat for changing the temo perature for the different types of films. It has a teflon cover. 14 (cost $9.95) The foot crimp sealer is a permanent attachment to a table and is foot operated. It is used for high volume bag sealing operations and can be obtained with a teflon cover. (cost $69. 50) Sealing may also be accomplished in a number of other ways, such as: hand dispensed gummed tape paper covered metal twist metal crimp band plastic slip tag electric taping machine staplers automatic heat sealers sew-ing and sticking machine. (”\IO‘UTAOONF— Per forations Proper perforations are a necessity for a successful prepackaging operation. Consequently a perforator is a required piece of equipment. Since all items don't require the same amount of ventilation, some additional perforating is necessary. However, it is economical both in time and materials to purchase bags which have already been perforated. l4. Teflon is a plastic which is placed between the sealing surface of the iron and the film, in order to prevent sticking of the film to the iron. 28 Marking Equipment In selecting the proper marking equipment, care should be exercised to see that all the necessary information can be printed with it. Information such as pounds, ounces, price per pound, for the- and other pertinent in- formation such as dollars and cents must be printed by this equipment. N. C. R. marking sets, N. C. R. Stampers, etc., are the most popular types of marking equipment. The approximate cost of stamping sets is $11. 95. In addition to Stampers and marking sets, ball point pens and felt ne bbed pens are also quite popular. The felt nebbed pen is quite effective for writing on cellophane and polyethylene. The pen uses quick drying ink which has a good adhesion quality. This pen costs approximately $1.75. Automatic Baggers Automatic baggers are most economical for large scale operations. They are designed for high speed bagging of such items as onions, potatoes and citrus fruits. One man can operate the machines. They will bag and weigh items from one to fifteen pounds automatically. As was mentioned previously, this type of equipment is economical only for a large scale opera- tion. The approximate cost of an automatic bagger is $865. 00 Other equipment such as conveyors and rolling equipment is also avail- able. However, it is the intent of the writer to enumerate only such equipment that is basic and fundamental to a produce prepackaging operation. CHAPTER IV LAYOUT In order to understand better the design and layout of the prepackaging operation, it is necessary to give a complete description of the packaging work flow. Work Flow Most packaging should take place in the rear of the store. By so locating the packaging area, the operation will gain the economy of short distances between the receiving door, the work area, the cooler and the sales area. The work flows between these areas and is described by Mr. Lapides as follows:15 "The work flows in a simple logical sequence, which if followed, will make the operation easy to handle, and will turn out a product which will be attractive and will hold up for a maximum length of time is as follows: 1 . Receive and check. 2. Items which require refrigeration should be put into the holding cooler at once and left there imtil the packaging room is ready for them. There is a direct proportion between the refrigeration of the produce and its holding time in the case. The better the refrigeration, the better and longer the holding time. 15. Lapides, Op. Cit., p. 10. ——_—— 3O 3. Whenever the produce is required in the case or according to an established work schedule, it should be taken to the wash and trim area. There it is trimmed to the re- quired limits, and then either washed or sprayed with a pressure hose and allowed to drain. The next four steps are interchangeable and will be treated as two separate operations. The reasons for this are as follows: if the items are random cpacked, or catch weighed, they can be weighed after they have been packaged. If the item is a set-weighed, then it must be weighed prior to packaging. Catch Weights 4. Fill the package to a predetermined point. 5. Seal the package with the type of closure being used. 6. Weigh the package in order to determine the weight and price which must be put on it, taking care to allow for the tare weight of the package. 7. Mark the required information on the package. Set Weights In using set weights, the package can be premarked since the amomit that is going to be put into each package is already known. This changes the sequence of the last four steps. 4. Mark all packages with the required information. 5. Weigh the merchandise to the predetermined weight. 6. Fill the package with the merchandise. 7. Seal with the type closure that is being used. The last two steps remain the same regardless of the weighing method being used. 8. Put the mercharrlise into storage or under refrigeration as required. 9. Place the merchandise in the sales cases." 31 Layout The following figures are reproductions of successful packaging room layouts. The writer selected these layouts for presentation for the following reasons. First, the layouts represent prepackaging operations with different sales volume, employee, and space requirements. Second, work flow and merchandise movement are clearly indicated. 32 FIGURE I The layout is one that is now installed in a new Hudson and Thompson Piggly-Wiggly, Montgomery, Alabama. Permission. for reproduction was granted by Mass Distribution Publications Co. , Inc. 33 LOADINL 2: 17002 P i l r- __.._ F V VZUDULL (00192 i _. 1+ 6AZBAA£ DISPOSAL V UNIT _ j . . AU‘TDMAIIL bAéLiNL STOZAM- AND WI-ILHINL SHLIVINL MALHINE TL ‘i /%./. arr—f" i A K W WJZAP VATLAEALE‘E % T1918 AND AND WI-ILH TABLE StALI— 3/16" x 1‘ i TOSM£S AREA FibUZE— I 34 FIGURE 11 The packaging room illustrated in Figure 11 is in the Be-Wise Food Store , Biloxi, Mississippi. Reproduction permission was granted by Mass Distribution Publications Co., Inc. 35 4a~< Nona maze“ an 233$ a £3 42: l imass