Sealpac: Innovations for fresh and processed fruit
The packaging makes all the difference: at the Spanish company Frutas Montosa, high-pressure processing preserves the freshness and flavour of the processed fruit while extending its shelf life.
11 September 2020
The successful product from Frutas Montosa is guacamole. (Image: Sealpac)
With around 80,000 tonnes per year, Spain is the most important producer of avocados in Europe. One of the renowned market leaders is Frutas Montosa. The company is constantly working to optimise its product portfolio. In combination with high-pressure processing (HPP), the packaging systems from Sealpac in Oldenburg support the company in achieving its goals.
Frutas Montosa was founded in 1982 and is based in the heart of the avocado-growing region in the south of Spain, near the city of Málaga. Based on strong marketing and innovative research and development, the company now offers a wide range of avocado products. Wide range of fresh and processed fruit from delicious guacamole to whole avocados and mangoes.
Federico Montosa, Managing Director Frutas Montosa (Image: Sealpac)
Federico Montosa explains: „Our aim is to always deliver the finest and perfectly ripe fruit. We have even developed our own index for the physiological ripeness of avocados (APM), which we use to recognise the internal condition and ripeness of each avocado.“
A genuine family business
Early on, founder José Luis Montosa dreamed of supplying the Spanish market with first-class fruit. Frutas Montosa has experienced significant growth in recent decades and currently employs around 400 people, generating an annual turnover of around 100 million euros. As a member of a genuine Family business Federico Montosa, the founder's son, had always been closely involved in the day-to-day business before officially becoming Managing Director of Frutas Montosa five years ago. What characterises Frutas Montosa is its commitment to highest quality.
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Fully automated processing and packaging
For sensitive products such as mangoes and avocados, a flawless processing and Packaging crucial. This applies not only to Frutas Montosa's successful product (guacamole in 200 or 500 gram trays), but also to the recently launched mango dip. The general process is the same for both products. First, the fruit is peeled by hand and the stone is removed. Then it goes into the fully automated process of squeezing and mixing.
Fully automated destacking, dosing, sealing and weight checking for maximum performance. (Image: Sealpac)
The resulting dip is then pressed through pipes into the dosing system, which is located above the Packaging line is located. This line begins with the destacking of the tubs using the AS-LS1200 servo linear stacker from Sealpac. The tubs are transported to the Dosimaq filling system, which fills the exact amount of guacamole or mango dip required. After hermetically sealing with a Sealpac traysealer and a weight check, the tubs are collected on a turntable.
The operator places the cups in a torpedo and loads them into a High-pressure processing plant, where they are subjected to a pressure of 6,000 bar. In the final step, the pressurised cups are removed from the torpedo and transported to the lid system.
Advantages of letterpress processing
„Our company prides itself on using the most advanced technology to create our healthy and delicious recipes. We are pioneers in the Application of high-pressure processing technology (HPP) for our avocados and mangoes. With this technology, which kills pathogens, we are able to Preserve the original freshness of the fruit and at the same time their Increase durability. As no heat treatment, additives or chemicals are used, the structure and flavour of the product are retained. Thanks to HPP technology, the shelf life of our guacamole is 35 days, and we specify a shelf life of 25 days for our mango dip,” emphasises the Managing Director.
Frutas Montosa currently produces with two Avure HPP systems: the AV-30 system for guacamole and the AV-10 system for salsa de mango.
Hermetic sealing of the Frutas Montosa mango dip. (Image: Sealpac)
When using the HPP, the choice of the right combination of film and tray due to the enormous pressure exerted on the sealed product. The challenge. „To make matters worse, we chose a cup with a narrow sealing edge and wanted to use a peelable film. Together with Sealpac, we carried out several tests to optimise the process and reduce leaks to an absolute minimum,“ explains Federico Montosa.
The cups are produced with an in-mould label. This label not only ensures a higher barrier and therefore better shelf life, but also greater stability in the HPP process. In addition, IML technology offers Excellent branding options.
The Sealpac A4 traysealer for the recently launched Mangodip. (Image: Sealpac)
Trusting cooperation connects
In order to meet the increasing demand for guacamole, Frutas Montosa invested in the first A6 traysealer from Sealpac back in 2012. This machine was installed by EMO S.A., the sales partner for Sealpac thermoformers and traysealers in Portugal and Spain.
„The performance of this traysealer, which Flexibility with high output was significantly better than other systems. We now have four traysealers of this type and one Sealpac A4 traysealer for packing our entire product range. We chose a smaller A4 for our recently launched Mangodip as we felt this was suitable for this new product during the launch phase. Now that sales have started, we are already discussing the options for a higher capacity, for example in the HPP and lidding system,“ summarises Federico Montosa.
However, a good partnership is more decisive than the ability of the sales partner to offer immediate service and maintenance for these machines. EMO supports the company Proactive in product development and the further optimisation of production processes.
Continuous product development
Traditionally, the main product of Frutas Montosa is the Guacamole, which is sold to retailers in Spain, but is also exported to various European countries (particularly France and Germany) and even to Mexico. The company also sells whole fresh avocados, for which it acquired a New type of packaging has developed.
Securely sealed on a Sealpac traysealer, the avocados are easy to stack and transport. (Image: Sealpac)
Through the Packing two avocados in a two-piece tray, with each part shaped like an avocado, the company can market this basic product with added value. Securely sealed on a Sealpac traysealer, these products are easy to stack and transport. In addition, the sealed tray enables an attractive and tamper-proof presentation at retail, which is why the new packaging design has now also been adopted for whole fresh mangoes.
Montosa: „One of the advantages of the Sealpac traysealers is that they are Various packaging systems thanks to simple mould change can handle. This enables us to run new packaging designs on the same basic machine even after several years.“
Packaging trends
When asked about Trends in packaging Federico Montosa addresses the topic of Sustainability „Retailers demand packaging that optimises transport, minimises waste and encourages consumers to buy. Although our PP trays are functional, we cannot ignore the fact that some of our target markets less and less on plastic set. This will lead to the use of recyclable materials that generate less waste. We see further trends in the increasing demand for ready-to-eat products and portion packs. And we will continue to develop new products and packaging formats in the coming years.“
„We utilise the excellent conditions of our environment and have set ourselves the goal of differentiating ourselves from other companies - with employees who all share the same passion: the best fruit in the world We are proud to be able to offer a wide range of quality avocados,“ explains Federico Montosa, son of the founder and managing director of Frutas Montosa, proudly presenting his company's quality avocados.
