Brazil is ranked in the top three in poultry production worldwide and it is also the highest in per capita consumption at 104.5 lbs. (47.4kg) per year. C-Vale, one of the largest poultry cooperatives in Brazil, supplies much of the chicken that satisfies this ongoing demand. 

C-Vale was quick to recognize the shifting consumer preferences toward packaging that was easy-to-open while also extending the shelf life of its contents. As such, C-Vale opted for a flexible package solution that included zipper closures with its packaging. 

In developing the Aurora packaging solution, Zip-Pak, a provider of resealable packaging, worked closely with Plastrela, a converter and supplier of the Inno-Lok closure system in Brazil. Inno-Lok is a patented product and method for attaching reclosable fasteners transversely to packaging films, thereby producing a roll of pre-zippered film that can be used for products requiring either barrier or non-barrier packaging. In this particular case, the Inno-Lok system was chosen for its ability to meet stringent moisture and oxygen barrier requirements needed to preserve product freshness and flavor.

"This is the first use of Inno-Lok closure system for a poultry package in Brazil," said Daniel Richena, commercial director for Zip-Pak Brazil. "Working closely with C-Vale and Plastrela enabled us to help deliver a reliable flexible packaging solution quickly and easily."

The new reclosable pouch has a front panel zipper that works to provide convenient access to its contents. Incorporating this pre-applied Inno-Lok feature into the manufacturing process required minimal adjustments to C-Vale's vertical-form-fill-seal (VFFS) machines. Zip-Pak Brazil's Field Service Engineer, Flávio Zampirolli, played an important role providing technical expertise and on-site support to ensure the project's success, the company said. 

"Our technical knowledge and expertise with the equipment used in the manufacturing process enabled us to anticipate problems, eliminate delays, and make the integration of the Inno-Lok closure a smooth, and easy process," commented Zampirolli. "We're grateful to have been part of this collaboration with Plastrela and C-Vale, as both are highly respected companies in Brazil. As we continue to expand our regional resources, we certainly look forward to many more opportunities like this."

Zip-Pak currently supports and supplies resealable products, technology and equipment to a number of multinational consumer packaged goods (CPG) companies that market to Brazil, Brazilian-based CPGs, and numerous other leading Brazilian brands. In furthering its local presence, Zip-Pak opened a new 46,000 sq-ft manufacturing facility in Cabreúva, São Paulo, Brazil last year that produces food-grade zippers for food, pet household consumer and many other products.

"Brazilian consumers are continuing to show preference for packaging that is both convenient and extends product freshness," Richena said. "Zip-Pak's resealable solutions directly support this trend, while enhancing the consumer's experience and elevating brand perception."