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EVALUATION

WAY 37 1962

CURRENT SBRIAL RECORDS

AND P. FOR
PEARS AND
APPLES /

Marketing Research Report No. 530

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a
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U. s. Department, of Agriculture ,

Agricultural Marketing Service ;

iigaeportation and Facilities Research Division

—
a

Growth Through Agricultural Progress

PREFACE

| The study on which this report is based is part of a broad program of
research seeking to increase the salability of farm products and to lower the
‘cost of marketing them. This phase of the research aims at the development of
new or improved packages, shipping containers, packing materials, and methods
of packing a variety of agricultural commodities. By reducing damage and
deterioration in transit and extending shelf life, these improvements make pos-
sible the delivery of a better product to the consumer.

Recent related reports on improved packages and containers for fruits and
vegetables include:

| Evaluation of Shipping Containers for Washington Cherries,
MRR 426, September 1960
Packaging California Cauliflower, MRR 414, July 1960

Prepackaging California Grapes at Shipping Point,
MRR 410, July 1960

Prepackaging Early California Potatoes at Point of
Production, MRR 401, June 1960

Prepackaging Firm Ripe Peaches, AMS-312, June 1959

Evaluation of Shipping Containers for Western
Lettuce, MRR 248, July 1958

Evaluation of Shipping Containers for Florida
Avocados, MRR 228, May 1958

Packing California Potatoes in Fiberboard Boxes,
MRR 214, February 1958

| Development of Carrot Prepackaging, MRR 185, June 1957

Fresh Fruit and Vegetable Prepackaging, Northeastern
Region, MRR 154, February 1957

New Shipping Containers for Plums, MRR 128, June 1956

sa (a
Washington, D. C. April 1962 ~

ACKNOWLEDGMENTS

The following Northwest apple and pear shippers and suppliers cooperated

in this study:

Apple Growers Association Gleed Cold Storage and Packing Company
Perham Fruit Corporation Michelsen L. P. Company
George F. Joseph Company Friday Pack Company
Marley Orchards Keyes Fibre Company
CONTENTS
Page
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Description of experimental packs 22.2 6.0.00 0 sc 3 60 nc emo 8 osne wees sie caciels 8
Polyurethane Pplace-pack for applies) 25 25s ccie capes sec fies ere cere 8
Polyurethane place-pack for pears ........-eeeee sleisierakeuaicrers Siaveneleraiels 8
Apple ‘tray-pack for: pears gocifer <<’. ksveus oie, ss isic + eins ost ener ec eperaueneeemenerenete 8
Five-layer pack for size-88 apples ..... ater azsneyelorstaveueretets SEIS RBIS O 10
Cost of packing materials ..cjetveicc.scic- sys ate ozs; versione sis leis) apace) clslcicus (ehsverouetetenonet see LO
Polyurethane place-pack for ‘app les cis). o2'c.c-< oie ws eiaraie orelevoieie crete regener 10
Experimental packs for pears: : .s/ac «<.dests «6 ss 5,50 b syevesios sonsloxetoyerens 10
Five-lLayer pack for size=88. apples < vci 2 Seis o ciccicis occ a evorcis cieverctonenots 11
Amount and cost of direct labor for packing ......... Se cron cods ac Seb ob OS 1:
Polyurethane place-pack for appleS <2. 23s sce+sewicis sc 50 ces hare sroctele ig
Apple tray-pack’ for Pears. .< 2. <u sicn cece 0 o oe elses creo gee aineie te eietoere creas 12
Comparative transportation costs ...... a) s'/s\icl wie) 10} 85 os) sol sueys ioncionce cust stateisEonolonees 13
Polyurethane place-pack for apples «5 o6.<c sce bee ee eee a oeeusiets 13
Polyurethane: place-pack for peers... 22. ccsene cee Foy 5S}
Apple tray -pack: for pears) 2 o¢csciecs ace egioece conte a eee lists a.cieeererareut oye) exehe man Les
Five-layer pack for size-88 apples ...... MIO OT OC OO BO COU G8 13
Evaluation of packs at terminal markets ..... gifoi Gr -eccobantee taneholecevenetede ai eethetorsuorens 13
Polyurethane place-pack for pears ...k se.ccttee eee eee Ssvereletorss 15
Apple ‘tray-pack for pears) «occ. sca soc amemiswee See eee 16
Five-layer pack for size-88 apples ...... ve ia a wwcetasatenenstexcuene mie Saetogeteioneke Ny,
Polystyrene foam pads for apples .............0. ate ea setereas be eioteterers he 20

SUMMARY

Washington and Oregon apple and pear shippers are seeking more efficient
ways of getting their product to the consumer in better condition.

To help them, packaging specialists of the Agricultural Marketing Service
during the 1960-61 season evaluated experimental shipping containers and pack-
ing materials for these fruits. These were: (1) Polyurethane place-packs for
apples, (2) polyurethane place-packs for pears, (3) apple tray-packs for pears,
and (4) a 5-layer tray-pack for size-88 apples.

Polyurethane Place-Pack for Apples.--Apples were place-packed on an
1/8-inch polyurethane pad in each layer of the shipping container. The pad

was the same, regardless of the size of the apples. In the conventional
molded pulpboard trays, the number of cups per tray varied with the size of the
apples packed. Place-packing apples on a single-sized layer pad in a master
container smaller than the conventional one allowed savings in inventory,
materials, storage and shipping costs. However, the polyurethane cushioning
material used was not adequate in thickness and density to protect the apples
from bruising. Although three test shipments of medium-size to small Red
Delicious apples made early in the season in the polyurethane place-pack and
standard tray-pack showed almost equal amounts of bruising, shipments of

larger apples late in the season showed more than 25 percent bruising in the
place-pack in contrast to about 10 percent in the standard tray-pack. Winesaps
sustained about 21 percent bruising in the place-pack in contrast to 8 percent
in the standard tray-packs, and Golden Delicious sustained 18 percent in the
place-pack in contrast to 3 percent in the conventional cell pack with a par-
tition for each apple. Too, the bruising was usually of a more serious nature
in the polyurethane place-pack.

Polyurethane Place-Pack for Pears.--The same economies of material and
shipping costs and less tare weight, as mentioned above, are true for pears as
well. The experimental polyurethane place-pack carried the pears to market
with almost no bruising and little discoloration, largely because of the shape
of the pear and its ability to stand more pressure. The shape of pears, with
their necks, allowed better "nesting" and the polyurethane is so resilient that
this pack for pears is very comparable to a bulk pack in a standard wooden box.

Apple Tray-Pack for Pears.--Many pear shippers who are also apple ship-
‘pers would like to economize by using apple pulpboard trays for pears to permit
the use of the same size master container. Apple trays from two different
manufacturers were tested. No material difference was noted in the arrival
condition of the pears by type of trays. The pears arrived with less bruising
in the tray-pack, 2.1 percent, than in the standard pack, 7.8 percent. How-
ever, more discoloration was found in the tray-pack, 9.6 percent, as compared
to 1.7 percent, because the pears in the tray-pack could move more than those
in the wooden box. The use of a better compression pad on top to avoid head-
room might help. It is probable that the pears would move less if a tray was

15) i=

designed to conform to the shape of pears. More testing is needed before any
conclusions are drawn.

Five-Layer Tray-Pack for Size-88 Apples.--The size-88 apple is usually

packed in pulpboard trays 4 layers deep in the master container. Many shippers
reported more excessive bruising in the size-88 pack than with other sizes of
apples. New pulpboard trays, designed with 17 and 18 cups per tray, were
packed alternately 5 layers deep per box, in contrast to the 4-layer-deep pack
of the conventional 22-unit trays. Controlled test shipments showed apples
packed in the new five-layer pack sustained less total bruising--about 10 per-
cent--than comparable apples in the standard four-layer pack, which was
approximately 24 percent. The bruising also was of a less serious nature.

The pressure on the apples seemed more widely distributed in the five-layer
pack with staggered cups than in the four-layer pack.

X EVALUATION OF SHIPPING TRAYS AND PADS FOR PEARS AND APPLES,

Transportation and Facilities Research Division, i
Agricultural Marketing Service

BACKGROUND

The Washington and Oregon apple and pear industries, aware of rising costs
of labor and materials, long have wanted less expensive packs which would pro-
vide more protection for their fruit in transit from the packinghouse to the
retail store. With new materials being developed, the industries are uncertain
about the advantages and disadvantages of changing a substantial part of their
production from the conventional packs to new experimental containers.

This study was undertaken to evaluate new experimental shipping containers
and packing materials proposed for apples and pears. When possible, direct
labor requirements, material costs, and shipping costs were recorded at four
packing plants. Limited supplies of the new materials and pilot methods of
packing made the use of time studies for some packs not feasible. Condition
on arrival of the fruit and trade acceptance of the new packs were determined
at terminal markets by specialists of the Agricultural Marketing Service.

The following are the more promising of the newly developed packs. They
were test-shipped by rail from Washington and Oregon packing plants to eastern
markets.

Polyurethane place-pack for apples:

shipments of Red Delicious from plant A
shipments of Red Delicious from plant B
shipments of Winesaps from plant B
shipments of Golden Delicious from plant C

WHEW

Polyurethane place-pack for pears:
5 shipments of Anjous from plant A

1/ Mr. Fountain is in charge of the Division's field station in Yakima,
Wash.

os ee

Apple tray-pack for pears:

2 shipments of Anjous from plant E

Five-layer tray-pack for size-88 apples:
3 shipments of Red Delicious from plant D

DESCRIPTION OF EXPERIMENTAL PACKS

Polyurethane Place-Pack for Apples

The container generally used for the new polyurethane place-pack for

apples
J. 3/8
tainer
tainer

by 11 inches.

BN 15080-X

Figure 1.--Apples are place-packed on
polyurethane layer-pad in convention-
al fiberboard shipping container.

was a full-telescope fiberboard box with inside dimensions of 18 1/8 by
This box is known by the trade as the bulk bushel con-

and is smaller than the tray-pack container.
was possible because apples in a place-pack are closer together than

Use of a smaller con-

apples in a tray-pack. One shipper
used an "all flaps meet" bottom. The
usual box was a half-slotted container
whose flaps did not meet on either top
or bottom. The polyurethane pads were
1/8 inch thick and were used between
layers in lieu of molded pulpboard
trays (fig. 1). A pad of shredded
paper encased in a paper envelope--
hereafter called a shredded-paper pad--
was used on top.

Polyurethane Place-Pack for Pears

The container used for the poly-
urethane place-pack for pears was a
full-telescope fiberboard box with in-
side dimensions of 18 1/8 by 11 1/8 by
11 inches. The polyurethane pads were
1/8-inch thick and were placed on the
bottom, between layers, and on top
(left, in fig. 2).

Apple Tray-Pack for Pears

The tray-pack tried for pears was
the same as the conventional apple
tray-pack (right, in fig. .2).. The
container was the standard full-tele-
scope fiberboard box with inside di-
mensions of 19 3/4 by 12 by 11 3/4
inches. The molded pulpboard apple

trays with a cup for each fruit were made by two different manufacturers. A
shredded-paper pad was used on top.

BN 15110-X

Figure 2.--Pears are place-packed on a polyurethane pad (left). Pears are
packed in the rounded cups of a standard apple shipping-tray (right).

The following list shows the apple tray sizes, the pear size packed in
each, and the number of trays per box of pears:

Apple tray Number of trays
size Pear size per box
80 100 5
88 110 >
100 120 6
ES 135 6
125 150 6

Five-Layer Pack for Size-88 Apples

The master container used for the new five-layer 88-size molded pulpboard
trays was exactly the same as that used for the standard tray-pack for apples.
The conventional four-layer size-88 trays hold 22 apples per tray, four trays
per master container. The new trays were designed to hold 17 and 18 apples
per tray; three layers held 18 apples each, two held 17 apples each, giving a
five-layer pack with the same total of 88 apples per box. When packed with
four layers of the conventional trays, the master containers usually were
slack upon arrival at the terminal. With five layers of the new trays, the

pack was tight.

COST OF PACKING MATERIALS

Polyurethane Place-Pack for Apples

Table 1 compares the cost of materials used in the standard tray-pack and
in the polyurethane-pad place-pack for apples. The experimental place-pack
cost just under a tenth of a cent less per pound of apples packed.

Table 1.--Comparative cost of materials used in standard tray-pack and in the
polyurethane-pad pack for apples, 1961

: epetdeed Polyurethane place-pack
Materials : nape : with
: ee :shredded-paper top pad

: Cents : Cents

Box, toprand bottom. sc <iejcsreters BOA / : 28)55)
5 molded pulpboard trays .....: 20555 : ---
5 polyurethane pads) ie ose Sic6 0's 02 --- 5 19:7
Shredded-paper top pad .......: 20 : 2.0
ed’ S SUES Bd: Shei cyatinna dalla stsicnelabeesesre tener e 8.0 8.0
Staples is Css Meee the eee ates 0.6 0.6
POC AL Wor) sitesi chate e.0/a ehaicvarouemtenee ss 61.8 58...6
Cost iper pound st /) 4st. tas. scan eg 1.4

Q °
e e
—— SS

1/ At 42 pounds net per box.

Experimental Packs for Pears

Table 2 compares the costs of packing materials for Anjou pears in the
standard wooden box and in two experimental packs--the polyurethane-pad place-
pack and the converted apple tray-pack.

=e tO aS

Table 2.--Comparative costs of materials for packing Anjou pears in standard
wooden box, polyurethane-pad place-pack, and converted apple-tray pack, 1961

eee

Micartatls Standard ; Polyurethane ; Apple

; wooden box ‘ place-pack * tray-pack
: Cents = Cents H Cents
SOOM i kepacspey avereaesenene oyere dyeieue' spedere a Doak --- : ---
MrdwandicCleatS) 6. cis-2.0 0110 «5.06 0/5 : 8.5 --- ---
INGRtp IS imei aleeleore: 6 o.6 ays oN! 65.4 js 6.0 0 016 oS De --- eas
Habel Wand Paste «2... scene ceces ‘ 0.6 os mits
Chipboard Liner .....cessesse0e? 8.5 --- —,
Polyethylene liner ...........: 6.6 6.6 6.6
Tissue wraps, printed ........: 825 8.5 8.5
6 polyurethane pads ..........: --- 7 se a | : -<=
5 pulpboard trays .......... ears --- -- 20.5
MODU DAO ie nero sifeiaic' sp 546 Sis esis oles acd --- --- 2.0
FLDE EDO ATG DOK!) i pare) oie esse ois cies f --- 27.0 31.0
NOtal? per. DOX | 2.5, Fs.caie'd's cisia. : 67.1 65.8 68.6
1.49 1.46 1252

Total: per pound 1/ ........%

1/ At 45 pounds net per box.

The experimental place-pack with polyurethane pads between layers had a
slim advantage of 0.03 cent per pound of pears packed as compared with the
standard wooden box. The apple tray-pack converted to use with pears cost
0.03 cent more per pound packed than the standard wooden box. Many growers
pack both apples and pears; savings in inventory costs resulting from dual use
of the same packing materials for both apples and pears probably would outweigh
the slight difference in purchase costs.

Five-Layer Pack for Size-88 Apples

Costs of containers and accessory packing material for the new five-layer
tray-pack for size-88 apples are the same as the costs for the standard tray-
pack with the addition of one tray per box. The additional tray costs about
4 cents, depending on quantity purchased. Costs for the average standard

tray-pack are in table l.

AMOUNT AND COST OF DIRECT LABOR FOR PACKING

Polyurethane Place-Pack for Apples

One man performed all the operations in packing both the standard tray-
pack of apples and the new polyurethane place-pack for apples. With a 15-per-
cent allowance for fatigue and personal time, it required 3.42 man-minutes for

- ll -

the standard pack and 3.66 for the polyurethane pack. At an assumed wage of
$1.50 per hour, the direct labor costs were 8.6 for the standard pack and 9.2

cents for the polyurethane pack per box.

These time studies were taken over a period of only 2 days. Therefore,
the packers did not have the opportunity to acquire great skill in packing
apples with the new method. The additional time required for the place-pack
method was due largely to the polyurethane pad slipping as the packer placed
the apples. This required frequent adjustment of the pad in order to make sure
the entire layer beneath was covered.

Apple Tray-Pack for Pears

Table 3 shows the direct labor requirements and costs for packing pears in
the apple tray-pack as compared to the standard wooden box for pears. An
hourly wage of $1.50 was assumed.

Table 3.--Direct labor requirements and costs of packing size-100 Anjou pears
in specified types of containers, 1961 1/

Standard wooden box : Apple-tray pack

Operation : Labor : Direct : Labor”: Direct
*requirements: labor cost‘requirements: labor cost

:Man-minutes : Cents :Man-minutes : Cents

Packino™ Sh tees soos ene : 3473 : 973 4.10 : 10.2
Tying polyethylene liner : . 36 : 0.9 262/ : ---
SEAM AIP ays csc eteveseie st otek cies heath : O25 : - 10 : 0.2
Closing: bOxX® gaigsts ecient: O07 : Oe 2 ere, : ht
Gluing Wabel (25 2 acienete ac .08 : 0.2 --- é ---
DOC ANG oecc ero he ee tersGueteesece 4.45 : ies FE 4.20 $ 10.4

1/ Includes 15 percent for fatigue and personal time.
2/ Packer also ties polyethylene liner and closes box.

Packing pears in the apple tray-pack made possible a saving in direct
labor costs of 0.7 cent per box.

Labor requirements and costs were not determined for the polyurethane

place-pack for pears and the five-layer tray-pack for size-88 apples because
all work with them was on a limited experimental scale.

-( 12 =

COMPARATIVE TRANSPORTATION COSTS

Polyurethane Place-Pack for Apples

| The tare weight of the polyurethane place-pack is 1 pound less than that
of the standard tray-pack for apples--3 pounds instead of 4 pounds. Using the
freight rate of $2.26 per 100 pounds from Washington and northern Oregon ship-
ping centers to New York City, the lower tare weight permits a saving in
transportation costs of 2.26 cents a box, or $18.98 per carload of 840 boxes.

Polyurethane Place-Pack for Pears

The tare weight of the polyurethane place-pack for pears also was 3 pounds.
The wooden box and accessory materials for the standard pack of pears was 5
pounds. With a cross-country freight rate of $2.05 per 100 pounds, not includ-
ing refrigeration, the lower tare weight permitted a saving of 4.1 cents per
box, or $38.05 per carload of 928 boxes.

Apple Tray-Pack for Pears

The apple tray-pack used experimentally with pears was 1 pound lighter
than the standard wooden box for pears, thus permitting a saving in transporta-
tion costs of 2.05 cents a box in a cross-country shipment of pears.

Five-Layer Pack for Size-88 Apples

The experimental five-layer pack for size-88 apples was heavier than the
standard four-layer pack only by the weight of one additional tray. With such
a slight difference it probably would be assigned the same billing weight, thus
neither adding to nor subtracting from transportation costs.

EVALUATION OF PACKS AT TERMINAL MARKETS
In order to evaluate the protective qualities of the experimental polyure-
thane material for apples, 13 test rail shipments to eastern markets and 1 test
truck shipment to California were initiated in 1960-61.
Table 4 shows the arrival condition of Red Delicious apples packed in the

standard tray-pack and the experimental polyurethane place-pack; three of the
shipments were made early in the season and four late in the season.

- 13 -

Table 4.--Condition on arrival of Red Delicious apples by type of pack, 3
early-season and 4 late-season shipments, 1960-61

a
; ; Amount of bruising
2 Size :
Season and - : Gapeaene ; 5
Dyer Eapses apples : Slight °by bruising: Serious : Total
———— -— mann wvrrvrvrne oT a
Percent : Percent : Percent : Percent
Early season: ; : $ : :
Standard ‘tray 22... 100 . 10 0 : 0 PaO
DOs aetaver re seis ee : 113 : 8.8 O59 = 0.3 LOZO0
DO ve siciaters olera eas 125 Da 9 0.3 5 0 6.2
AVEYES Cllew ites ctecerelees ee OF 0.1 Ties
sae suaieee 2 8.7 0. 0 9-0
Roasters ince: : 4.4 0. 0 510
aus wi ousi6 se. okens : 8.5 0) ) SD
Siiev stole evecetere ok 0. O; (EE)

Late season:

Standard tray ..0... 1/7 Herve Vie) See pene Sees
De as aes terse est 80 6.9 053 0.0 Tie

DGo ecsnere costes: 100 750 OF2 0.0 Ward
Bielavatesenet cereus 6.0 Za8 Be 9
Polyurethane ......: 72 : 15.6 10.1 ; 11.8 Sie5
IDO caer cyst te fs ts oe : 80 veal 4.4 : 8.8 2253

Dow, a aetna: 100 14.52 310 5 0.8 18.0
AVEGTASE sascies ces 13.0 Syste} qa 259

The upper half of table 4 indicates that Red Delicious apples in the ex-
perimental polyurethane-pad packs sustained about the same amount of bruising
as apples in the standard tray-pack early in the season. The lower half of the)
table shows that late in the season apples in the polyurethane-pad packs sus- |
tained substantially more bruising than apples in the standard packs. The
shorter apple holding-times, the smaller size of the apples and the use of a
more rigid box probably contributed to the lesser bruising in the polyurethane
packs in the early shipments.

Tables 5 and 6 show the comparative condition on arrival of Extra Fancy
Winesap and Golden Delicious apples in test shipments in experimental and
conventional packs.

a) 5/7

Table 5.--Condition on arrival of Winesap apples in specified packs, average
of 4 test shipments to eastern markets, 1960-61

Demet et.

: ‘ Amount of bruising
e of pack : Siz
| Typ Pp e ee + Damage ? :
| : by bruising: Serious :;: Total
TS
\ Number : Percent : Percent : Percent : Percent
(‘Tray-pack ........: 72 : Sat : 5 : 0.5 : 8.8
| Dye oe Brae 80 : 4.4 : 0.9 : 0.3 : 5.6
DO iistcve sees ot 100 : 7.5 : 222 : 0.0 : Fes
Average ....... : : Sed : Zell : 0.3 4 8.0
Polyurethane .....: 72 : 1352 : ey : 1.0 : 16.2
| DOR ciiieie ces : 80 : 18.8 : 6.9 ; 4.7 : 30.4
| DOs cis cess! 100 16.5 : 13:0 : 0.0 : P75
Average .......: 16.3 Dee 1.9 21.4

‘Table 6.--Arrival condition of Golden Delicious apples in specified packs,
average 3 test shipments to eastern markets, 1960-61

: Amount of bruising
Type of pack : Size

Damage :
: 3 Slight -by bruising: Serious : Total

Number : Percent : Percent : Percent : Percent
[\Cell-pack.........3 80 & 96: 2.6 : 0.1 : 0 : Qi
Polyurethane .....: 64 to 100: 10.2 : Va2 : 0.6 : 18.0

Both the Winesap and Golden Delicious apples in the polyurethane packs
sustained substantially more bruising than in the conventional tray-packs and
cell-packs. The cupped pulpboard trays and the cells in the conventional packs
isolated each apple and held it in the position in which it was packed. This
was not true in the polyurethane packs. Terminal arrival inspections showed
that many apples in the experimental packs were on their sides and on their
calyx ends. Analysis of the bruising showed that the pads provided relatively
inadequate protection from overhead weight.

Polyurethane Place-Pack for Pears

To evaluate the use of polyurethane pads for pears, five full-carload
commercial rail shipments were inspected upon arrival in eastern markets in
1961, by specialists of the Agricultural Marketing Service.

- 15 -

Anjou pears from controlled-atmosphere storage were tissue-wrapped and
packed in full-telescope fiberboard boxes with polyurethane pads on top and
bottom and between layers.

The pears arrived at terminal markets with but 0.2 percent slight bruising)
and no damage by bruising or serious bruising. Slight discoloration amounted
to 5.3 percent; damage 0.4 percent; and serious discoloration, 0.1 percent.
The condition of the pears in the experimental boxes was considered excellent,
in comparison with similar pears reaching the market at the same time in stand-|
ard wooden boxes. |

Most of the discolored pears were found in a few boxes that had been
packed with a "hump" instead of a flat pack. A "hump" pack causes looseness |
in the sides and ends and allows movement of the pears in the box during trans-
it. The fine condition of the pears was attributed mainly to their shape and
the fact that, in comparison with apples, pears can stand more pressure. The
shape of pears, with their necks, permits better nesting of the fruit. Care
should be taken in packing pears in the polyurethane place-pack to avoid exces-
sive headroom, which results from the settling of the pack during transit. Com
pression pads on top, such as excelsior, should help.

Apple Tray-Pack for Pears

Two controlled-test rail shipments of size-110 Anjou pears experimentally
packed in conventional pulpboard tray-packs for apples and in the standard
wooden boxes for pears were shipped to an eastern market in 1961. The apple
trays differed slightly in design and came from two different manufacturers.
Table 7 shows the condition on arrival of these pears.

Table 7.--Condition on arrival in eastern markets of Anjou pears in conventiona
and experimental containers, an average of 2 test shipments, 1961

Bruising é Discoloration
Container : Damage : : Damage g ;
: Slight ‘ by bruising? Serious: Slight .: by bruising: Serious
: Percent: Percent :Percent: Percent: Percent : Percent
Standard wooden : : : ; : :
BOX ers iehele cisiaiste clonic 71:8 =: O20 2. 70 one se 0.0 R 0.0
Apple tray-pack: : : ; : : :
dni 0) ee, GR SOAR iy Aaa 0.0 eNOS ODE sr binge ee 0.0 2 0.0
DV DCONs eciecoscin s as ea 0.0 Os Ore: 3 Sse Speeess Onl : 0.0
AVERAGE Foe nce Px) DP 0.0 o. OOM me 9216" 32 0.05 : 0.0

- 16 -

The greater amount of bruising of fruit in the wooden boxes was due large-
ly to lid cuts and pressure bruises from the wooden lid. These bruises, while
slight on arrival, showed more clearly when the pears ripened. More discolo-
ration occurred in the tray-packs than in the wooden boxes, because the wooden
boxes can be packed more tightly. The pears apparently moved in the rounded
apple cups during transit. This caused discoloration and may also cause a
"duller" look on the skin of the pears. Better compression pads, such as
shredded wood (excelsior), might help maintain a tighter pack in the pulpboard
apple trays. Because of the different shapes of apples and pears, however, it
may well be impossible to completely immobilize pears in tray cups designed
for apples.

There may be storage problems in using a fiberboard box for pears, es-
pecially in cooling them. Pears in fiberboard boxes generally mature faster
than pears in wooden boxes during the same storage time. Further study of
this problem may result in better methods of storage.

Five-Layer Pack for Size-88 Apples

The newly designed pulpboard trays for size-88 apples were evaluated in
three controlled-test rail shipments to an eastern market. The new trays were
designed to hold 17 and 18 apples. They were packed alternately five layers
deep per box. The conventional size-88 trays held 22 apples per tray and were
packed 4 layers per box. Table 8 shows the comparative condition on arrival
of size-88 Red Delicious apples in both new and conventional packs.

Table 8.--Condition on arrival of size-88 Red Delicious apples in specified
trays, average of three test shipments to an eastern market, 1961

Amount of bruising

Pack :

Slight by eae Serious Total
Percent : Percent : Percent : Percent
Standard: : : : :
4 trays of 22 apples ..: VIII. : 1 ae : 0.1 : 23.8
Experimental: : : ; ;:
3 trays of 18 and 2 3 : $ :
Ofal7 sappliess oS. oP. s.« : 932 : 0.5 : 0.1 9.8

Apples in the new trays sustained almost 60 percent less total bruising
than apples in the conventional trays. With the alternating 17- and 18-place
experimental trays the apples were staggered from layer to layer and their
weight was more widely distributed than in the conventional trays (figs. 3 and
4). In the conventional trays the pressure was concentrated on the tops and
bottoms of the apples and the bruises were deeper.

2 17 «

BN 15000

Figure 3.--This is the standard 22-unit tray for size-88 apples.
The direction of the tray is reversed (rotated 180 degrees)
in alternate layers in the master container. Thus an apple
in cup "A' in second layer (above) would be directly over the
narrow space "A" (below). An apple in cup "B'' (above) would
be over space "B" (below), and so on. Each apple in the
second layer, therefore, would exert its own weight, and the
weight from higher up, primarily on two apples directly be-
low it. This overhead pressure was the chief cause of a
substantial amount of bruising.

BN 14999

Figure 4.--This photograph illustrates how the new trays for
size-88 apples reduce bruising by better distributing overhead
weight. The packer places the 18-unit tray (below) in the
bottom of the shipping container and fills the cups with
apples. He then inserts the 17-unit tray (above) and fills
it. Note how apple in cup "A" (above) would nest down in space
"A" (below). Similarly, apple in cup ''B" (above) would nest
in space "B" (below). In the first instance pressures from
above would be distributed among three apples and a box wall;
in the second instance among four apples.

219%

The height of the pack of the conventional four-layer box at time of
packing was even with the top of the inner case. Inspection upon arrival
showed headroom, due to settling, of % to % inch. The experimental five-layer
pack, however, was about 4 to 1 inch above the inner case at time of packing.
Upon arrival the pack had settled so that there was 1/8- to 1/4-inch headroom.

Less headroom contributes toward less bruising.
&

Polystyrene Foam Pads for Apples

Polystyrene foam layer pads in the conventional fiberboard apple box were
tried out in limited experiments. The pads--3/8 inch thick--cracked and rup-
tured, permitting direct contact among apples in adjoining layers (fig. 5).
Bruising, much of it severe, was in excess of 50 percent. Polystyrene foam
has proved a good cushioning material for many other products and because it
does not absorb moisture and become misshapen, as do some molded pulpboard
trays, it offers promise in these respects. Also, it is comparatively inex-
pensive. Further tests are planned to test various densities and thicknesses
of the pad.

Fan cs = wr ee nme

Do ate

BN 15081-X
Figure 5.--A layer of apples has just been removed from the top of the white
polystyrene foam pad in this box. Note ruptures in pad and unprotected

apples in layer below.
Se Once

* U. S. GOVERNMENT PRINTING OFFICE: 1962 O - 633220

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