Cryovac Packaging - Extend Product’s Shelf Life & Reduce Waste

Whether you’re an established brand or a startup, building strong trust with people is essential to standing out and boosting sales. Preserving your product’s quality and boosting its longevity are among the most important factors in satisfying your customers and strengthening the brand’s reputation in the market. That’s the reason various advanced-quality packaging solutions have emerged in the industry. Nowadays, cryovac packaging carried out by the industry-leading cryovac machine is highly trending among brands of different businesses. 

This revolutionary vacuum-sealing packaging was developed by W.R. Grace and Company (original developers of Cryovac company) in the 1950s. Providing reliable, cost-effective, and highly functional packaging solutions to businesses of all sizes, this advanced system has completely transformed the overall packaging trends of different industries, especially the food service sector. Today, it’s widely accepted by countless companies as a vital part of their supply chains. Let’s explore what’s cryovac packaging, what are its benefits, and why it’s becoming so famous over time. 

What is Cryovac Packaging? The Introductory Section 

Though Cryovac is a company’s name, not a generic term, you need to break down this word into two parts for a better understanding. Is derived from the Greek “Kryos” meaning “cold” and “vac” leading to “vacuum”, cryovac meaning “cold vacuum”. When combined with packaging, the term cryovac packaging refers to the advanced cold vacuum packaging method where the product is packaged in an air-tight plastic film to protect products against external contaminants, preserve their freshness, and extend their shelf life to boost customers’ satisfaction and ultimately a brand’s revenue.  

What’s a Cryovac Machine? Working Mechanism, Components, Types, & Core Techniques 

It’s  a specialized packaging system that remove air from the packaging, seal content, and even shrink-wrap product by heating. This state-of-the-art machine professionally operates using Cryovac-branded vacuum films and pouches, known for their high barrier properties and top-notch shrink ability features.  

Here’s how this machine works: 

1-  Product Loading 

First, a product, such as fresh meat or cheese, is placed into Cryovac vacuum pouches or roll stock films. This film is pre-sized or custom-formed depending on the machine setup.  

2-  Pouch Incorporation into Vacuum Chamber or Inline Vacuum Sealing 

Then, the filled pouch is placed in the vacuum chambers when chamber machines are used or moved along the conveyor system in inline machines. Both these machines extract air from the pouch using high-powered vacuum pumps.  

3-  A Complete Pouch Sealing 

After proper vacuuming, the machine applies an adequate amount of heat and perfectly and tightly seals the open ends of the pouch. This step creates an airtight and tamper-proof seal that hinders the product’s contamination and air’s re-entry.  

4-  Application of Shrink Tunnel or Hot Water Dip (if applicable) 

For shrinkable cryovac films, the sealed package is passed through a hot water tank or steam shrink tunnel. This heat causes the film to shrink tightly around the product and improves the overall appearance by eliminating excess materials. 

5-  Cooling & Discharging of the Package 

After shrinking, the package is cooled under fans or using cold water. This sets the final shape of the custom package and strengthens its seal. Here, the final product is ready and exits the machine to enter the secondary packaging steps, such as labeling, boxing, and many more. 

Main Components of the Cryovac Machine & their Roles 

• Vacuum Chamber/Pump: It removes air from the pouch. 
• Sealing Bar: It provides heat-sealing of the pouch after vacuuming. 
• Film Feeding Unit: This part automatically feeds roll stock films. 
• Shrink Tunnel/Water Dip: It tightly shrinks the film around the product. 
• Cooling Zone: This component stabilizes and professionally sets the final shape of the package. 
• Conveyor System:  It moves products through each phase of the cycle in the Cryovac machine. 
• PLC Control Panel: This functional part allows the customization of vacuum levels, seal times, and optimal working temperatures in the machine.  

Top 4 Types of Cryvoac Machines – Advanced Solutions for Quality Results 

The following are the top 4 Cryovac machines, highly used by businesses for effective and best-quality results in no time: 

1-   Chamber Vacuum Sealers 

They are compact-sized machines where the whole product and vacuum pouches are directly placed inside a sealed chamber. Best for small to medium-sized food processors, this machine stands out for the following key features: 

• High vacuum pressure 
• Simplest operating mechanism 
• Ability to perfectly seal liquids and soft items 
• High-end portability 
• Affordability for small businesses 

2-  Rotatory or Inline Vacuum Sealers 

Widely used in industrial packaging lines, rotatory or inline vacuum sealers are fully automated and high-speed systems. In this machine, products follow a constant flow and pass through different phases with vacuum sealing occurring inline. Preferably used for high-volume food processors, such as meat, poultry, seafood, cheese, and other such items, the rotatory or inline vacuum sealers are known for the following unique characteristics: 

• Non-stop operations for high throughout. 
• Massive reduction in labor cost. 
• Best-quality sealing. 
• Integration-ready mechanisms with other systems.  

3-  Rollstock Thermoform Machines 

These fully automated Cryovac techniques form high-end vacuum pouches from roll stock films, fill them with product, vacuum-seal, and cut the final package. This all is done in one line. Unlike chamber vacuum sealers, the Rollstock Thermoform Machines are ideal automated machines for large-scale food manufacturers providing packaged meat, cold items, refrigerated snacks, sliced cheese, and many more delicious edibles. This industry-leading machine is also a preferred packaging solution for various medical and sterile items. With Rollstock Thermoform machines, you are expected to get the following perks: 

• High-speed & continuous packaging process. 
• 100+ custom shapes, pocket depths, and film types. 
• High-volume SKUs, standard-sizing of the packaging. 
• Labor-free and cost-effective automated systems. 

4-   Shrink Packaging Machines & Systems 

This state-of-the-art Cryovac type combines vacuum sealing with a professional heat shrink process. In this machine, the package is run through a hot water tunnel or steam chamber after sealing. It’s the point where advanced-quality Cryovac films tightly shrink around the package. Shrink packaging machines are highly preferred for retail-ready packaging and vacuum-packaged consumer goods that need a memorable visual appeal. Here are the key perks that businesses can get by using this premium Cryovac machine: 

• Attractive, clear, and tamper-evident product’s display. 
• Removal of excess films and wrinkles. 
• Increased protection against moisture and oxygen. 
• Enhanced shelf appeal of the package and memorable presentation.  

Top 7 Recycle-Ready Materials for Advanced-Level Cryovac Packaging 

The following six are some of the most-demanded recyclable materials for making high-end Cryovac packaging solutions: 

Polyethylene (PE)  

It’s a mono-material, highly used in making flexible packaging films, vacuum bags, and pouches. Featuring a lightweight composition and excellent sealability characteristics, polyethylene (PE) is one of the most widely used recyclable materials for Cryovac packaging.   

Polypropylene (PP) 

This mono-material is one of the best picks for making rigid trays and some unique food packaging film structures. Increasingly accepted in curbside programs, polypropylene stands out for high heat resistance, rigid, yet lightweight manufacturing.  

EVOH-PE Multilayer Structures 

It’s a multi-layer material with unique recyclable designs. EVOH-PE is highly used in making custom barrier films for vacuum packaging. This top-quality material has a high oxygen barrier and is completely processable in PE recycling systems.  

Recyclable Nylon-PE Structures 

This engineered multilayered manufacturing material is best for creating meat and cheese vacuum pouches. Using advanced mechanical or chemical systems, this material is specifically designed to fully comply with different recycling programs. Recyclable Nylon-PE also stands out for maintaining high-grade rigidity and oxygen barrier properties.  

Monomaterial Polyethylene Shrink Films 

Replacing complex laminates, this premium-quality material is fully recyclable via store drop-off. It’s widely used in making custom shrink bags for proteins’ packaging.  

Paper-Laminated PE Films (With Detachable Layers) 

These special materials have a unique paper that adds more tactile feel and aesthetic look to Cryovac Packaging. The inner layer of paper-laminated PE films is recyclable and specifically designed for separation.  

Bio-Based PE Films (Fully Recyclable with Conventional PE) 

Made from renewable feedstocks, the bio-based PE films are functionally identical to fossil-based polyethylene (PE) films. These best-quality materials are fully recyclable with conventional PE method.  

Phenomenal Applications of Cryovac Packaging 

Nowadays, the next-level Cryovac Packaging is trending in almost all industries, where the food market comes on top. Here are some of the phenomenal applications of custom Cryovac Packaging. Have a look at them for better understanding: 

1- Food Packaging 

Famously associated with food packaging, Cryovac has advanced vacuum sealing, modified atmosphere packaging (MAP) and skin packaging technologies. These industry-leading systems are extensively used to preserve a wide variety of food items, such as: 

• Fresh meat & poultry 
• Processed meats 
• Cheese & dairy products 
• Fresh products & vegetables 
• Seafood & fish 
• Ready-to-Eat & prepared meals  

Offering vacuum packaging, Cryovac is an excellent solution to extend the shelf life of food items and prevent their oxidation, spoilage, and freezer burn. It reduces the need for preservatives, ensuring the health and hygiene of consumers.  

2- Pharmaceutical Industry 

In medicine and pharmaceutical industry, Cryovac Packaging is ideally used to package different types of medications, devices, and pharmaceutical products. This advanced packaging type ensures the product’s protection from contamination, moisture, and temperature fluctuations, ensuring the maintenance of medicine’s integrity during the transit and display on store’s shelves. 

3- Consumer Electronics & Components Market 

Vacuum-sealed Cryovac is widely used for packaging sensitive electronics, circuit boards, and other important parts of electronics items. It protects the products against moisture and environmental damage during shipping and storage.  

4- Gifts & Premium Products Packaging 

Preserving product appearance during transport and display, Cryovac is highly used for packaging luxury items, such as high-end gifts, branded merchandise, or promotional items. It provides a sleek, high-quality, modern, and memorable visual appeal to the product’s packaging to help it stand out on store’s shelves.  

5- Retail & Shelf-Ready Packaging 

Special shrink-wrapped Cryovac packaging solutions are available for retail products’ packaging. This technology is preferably used to package bulk products, such as sliced meats, cheese blocks, fruit trays, and many more such items. Besides enhancing product presentation and ensuring consumers’ health, the Cryovac Packaging tamper-evident. 

Let’s Retain Product’s Quality & Boost your Brand’s Revenue! 

Offer the best-quality food, pharmaceutical, and other items to your potential buyers and boost brand’s trust among audience. Reach out to CPP Boxes and avail the advanced-quality Cryovac Packaging for premium items at highly affordable prices. Contact us at 888-395-0493 or quotes@cppboxes.com and transform your product’s packaging to cast a lasting mark on buyers.