The fresh produce export industry faces increasing pressure from rising refrigerated transport costs, inefficient packaging and postharvest losses. Conventional packaging often limits storage and shipping space utilisation, while inadequate airflow and uneven cooling can affect fruit quality and shelf life. Traditional packaging development also relies on repeated physical testing, making the process costly and time-consuming.
Stellenbosch University has developed a virtual prototyping approach for designing and optimising fresh produce packaging, combining computer simulations with physical testing to assess airflow, heat transfer, cooling performance and carton strength. The technology has been applied to the development of DuPack, a dual-layer ventilated corrugated carton designed for pomegranates. Unlike conventional single-layer cartons, DuPack accommodates two layers of fruit and incorporates an optimised ventilation design to improve cooling airflow and space utilisation during storage and refrigerated transport.
The technology offers the potential to reduce packaging development costs, improve cooling efficiency, increase shipping capacity and minimise postharvest losses, while reducing energy consumption and packaging material requirements. Potential users include fresh produce exporters, packaging manufacturers, fruit packhouses, cold-chain logistics providers and agricultural businesses handling fruits, vegetables and flowers.
The technology has undergone laboratory-scale validation under conditions simulating relevant operating environments. Physical packaging prototypes have also been manufactured and evaluated through experimental and storage trials, including warehouse stacking demonstrations. Further validation and optimisation under commercial operating conditions are required to support wider industry adoption. The DuPack carton design is protected by South African registered design F2020/01099.
Stellenbosch University is seeking commercial and development partners interested in adopting the virtual prototyping approach and commercialising the optimised packaging design. Potential partners include packaging manufacturers, fresh produce exporters and cold-chain logistics companies, with opportunities for industry validation, manufacturing, licensing and integration into existing supply chains.