Technology
Darfresh® on Tray
Darfresh® on Tray is an advanced vacuum skin packaging solution designed to combine premium product presentation, extended shelf-life and zero top film waste. Developed through the long-standing collaboration between G.Mondini and Cryovac® Sealed Air, it delivers a high-quality skin pack with excellent vacuum performance, clean finishing and outstanding product definition.
* DARFRESH® is a registered trademark of Cryovac Inc., a subsidiary of Sealed Air Corporation
Combining a revolutionary pre-made tray system with versatile vacuum skin technology, Darfresh® on Tray has become a benchmark solution for premium vacuum skin packaging. Jointly developed by G.Mondini and Sealed Air, it combines Cryovac® skin film expertise with G.Mondini’s tray sealing know-how to deliver outstanding product definition, extended shelf-life and consistent pack quality.
Unlike conventional tray skin systems, Darfresh® on Tray combines an innovative top film cutting process with advanced vacuum technology. This ensures 100% top film utilisation, eliminates top film skeleton waste and can reduce top web film consumption by up to 40%.
The system is suitable for fresh red meat, poultry, seafood, processed meat, dairy products, ready meals, cheese and alternative proteins. Depending on the tooling configuration, it can handle pre-made plastic trays as well as paper, fibre and aluminium supports across retail, case-ready and e-commerce applications.
Its fast and efficient vacuum cycle can increase packaging speed by up to 35%, while maintaining strong film adhesion, clean finishing and excellent product definition.
The key differentiators of Darfresh® on Tray are:
- Unique cutting process delivering zero skeleton film waste, 100% top film utilisation and reduced waste handling requirements.
- Cold film cutting outside the vacuum tool for clean finishing without fringes or fish hooks.
- Elimination of blades inside the vacuum tool, improving reliability and simplifying the chamber design.
- Increased tool space, supporting higher productivity and format optimisation.
- In standard DoT configurations, a dedicated Darfresh® Valve enables a faster and more effective evacuation cycle.
- Vacuum is maintained until the valve closes, delivering outstanding product definition without compressing the product.
- Liquid Tooling extends flexibility in product placement and enables the use of paper, fibre and aluminium supports.
- DoT Super Pro enables high-protrusion applications up to 70 mm.
With more than 300 lines running worldwide, Darfresh® on Tray combines premium pack quality, increased productivity, maximum film utilisation and outstanding flexibility.
Darfresh® on Tray delivers premium vacuum skin packs with excellent vacuum performance, strong film adhesion, clean finishing and effective drip retention. The film follows the product shape without compressing or distorting it, while the true easy-open design with four pull-tabs improves consumer convenience.
- Excellent vacuum performance
- Strong film adhesion around the product
- Clean finishing without fringes or fish hooks
- Effective drip retention
- True easy-open with four pull-tabs
- Extended shelf-life
- Outstanding product definition without squashing
The zero-scrap technology ensures 100% top film utilisation and eliminates film skeleton waste. Combined with high automation, fewer rejects and optimised line performance, it reduces material consumption, waste-handling activities and the total cost per pack.
- Zero top film waste
- Zero bottom waste
- Reduced material consumption
- Lower scrap handling and disposal costs
- Optimised labour requirements
- Improved automation and OEE
- Fewer rejects and consistent line performance
A faster and more efficient vacuum cycle enables Darfresh® on Tray to increase production output while maintaining consistent pack shape, film adhesion and visual appeal. The packaging process can be up to 35% faster compared with other packaging systems.
- Faster and more efficient vacuum cycle
- Up to 35% faster packaging process
- Increased production output
- Consistent pack quality at high speeds
- Suitable for high-volume production
Darfresh® on Tray can handle different tray materials, formats, product shapes and positioning requirements. Depending on the tooling configuration, the system supports plastic, paper, fibre and aluminium solutions across a wide range of food applications and distribution channels.
- Pre-made plastic trays
- Paper, fibre and aluminium supports, depending on tooling configuration
- Multiple tray formats and product shapes
- Greater flexibility in product positioning
- High-protrusion applications up to 70 mm with DoT Super Pro
- Suitable for retail, case-ready and e-commerce applications
Details
Darfresh® on Tray uses a cold cutting process outside the vacuum tool, ensuring 100% top film utilisation, zero skeleton waste and up to 40% less top web film compared with traditional skin pack machines.
The absence of blades inside the vacuum chamber improves reliability and increases the space available for format optimisation and higher productivity.
In standard configurations, the dedicated Darfresh® Valve provides a fast vacuum cycle, maintained until valve closure to achieve strong film adhesion and excellent product definition without compression.
Liquid Tooling operates without needles or vacuum valves, extending flexibility to different product placements and paper, fibre or aluminium supports. DoT Super Pro also enables high-protrusion applications up to 70 mm.
The key technical advantages are:
- 100% top film utilisation with zero skeleton waste.
- Cold cutting outside the vacuum tool for clean finishing.
- No blades inside the vacuum chamber, improving reliability.
- More tool space for higher productivity and format optimisation.
- Dedicated Darfresh® Valve for strong adhesion and pack integrity.
- Liquid Tooling for flexible product placement and multiple supports.
- High-protrusion applications up to 70 mm with DoT Super Pro.
The result is a clean, highly defined vacuum skin pack with consistent performance, excellent product visibility and reliable quality across different products, supports and formats.
Applications
DO YOU HAVE A
MEAT LINE?
Whether it’s beef, pork or veal, in sub-primal or portioned cuts, G.Mondini delivers a total packaging system, keeping your meat fresh for longer.
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