Field-to-Pack: Why Growers Are Rethinking Fresh Produce Packaging

Fresh produce growers across the UK and Europe are increasingly looking at packaging produce directly in the field as they face mounting pressure from labour shortages, rising costs, retailer demands, sustainability targets and unpredictable weather.

According to HortiDaily, Vernon Cooper, Director at packaging machinery supplier Redpack, said producers are taking a fresh look at how harvesting and packing operations are structured as margins and operational efficiency come under strain.

One trend gaining momentum is the use of on-rig or in-field packaging systems, where produce is packed at the point of harvest rather than being transported first to a central packing facility. Cooper said this approach is increasingly being recognised as a practical way to address some of the wider challenges facing growers across the fresh produce supply chain.

A key advantage is the potential to reduce handling. Fresh produce is at its most vulnerable immediately after harvest, with every additional touchpoint increasing the risk of bruising, contamination, dehydration and waste. By packing produce directly on the harvesting rig, growers can cut the number of handling stages before products enter the supply chain, helping to protect quality, improve presentation and reduce waste linked to transportation and repacking.

The approach is also being seen as a response to labour pressures. Seasonal labour remains a major concern for fresh produce businesses across Europe, while wage increases and employment costs continue to affect profitability. By combining harvesting, sorting and packing into a more streamlined field-based process, growers can reduce the need for separate labour-intensive packing operations elsewhere in the production cycle.

While Cooper stressed that technology does not remove the need for skilled workers, he said solutions that maximise labour productivity are becoming increasingly valuable.

Supply chain speed is another factor. Retailers are demanding fresher products, shorter lead times and greater responsiveness to changing consumer demand. Packing produce in the field can help shorten the journey from harvest to distribution by removing unnecessary transport and intermediate processing stages, allowing produce to move more quickly into cold storage, distribution centres or directly to customers.

For crops with shorter shelf lives, even small improvements in post-harvest handling times can have a meaningful impact on product quality and shelf life, helping growers capture more value from each harvested crop.

Sustainability is also helping to drive the shift. Growers are under increasing pressure to reduce food waste, improve resource efficiency and adopt more sustainable packaging materials. In-field packaging can contribute by reducing handling and transport requirements, lowering energy use and minimising product losses.

Modern packaging systems are also increasingly designed to work with recyclable and mono-material packaging formats, supporting retailer sustainability initiatives while creating tighter packs that can help reduce material use and cost.

The move comes as weather volatility continues to create uncertainty for growers. Harvest windows can be compressed, labour needs can change quickly and production schedules often have to adapt at short notice. Cooper said flexible harvesting and packing operations are becoming increasingly important as producers look to respond quickly to changing conditions.

He added that the growing adoption of on-rig packaging is not simply about investment in new machinery, but reflects a broader shift in how growers are approaching operational efficiency, labour management, product quality and sustainability.

For many producers, bringing packaging closer to the point of harvest is becoming an effective way to simplify operations and build a more resilient supply chain.

As pressures on fresh produce producers continue to evolve, Cooper concluded that the businesses most likely to succeed will be those that look beyond individual processes and focus on optimising the full journey from field to shelf.