Sealed Air Corporation’s packaging brand CRYOVAC has introduced ZeroPrep, a pre-filled hand-dispensing pouch system designed to streamline back-of-house condiment handling across commercial kitchens and foodservice operations.
The packaging format addresses common kitchen bottlenecks by removing the requirement to manually fill, wash, sanitise, and store rigid plastic squeeze bottles. By delivering sauces, dressings, and condiments in ready-to-use, handheld pouches, the system targets labour efficiency, hygiene compliance, and food waste reduction across high-volume assembly lines.
"We listen closely to customers to develop solutions that address everyday challenges and create meaningful value," said Joe Lambert, North America Vice President of Food at Sealed Air. "ZeroPrep reflects this ongoing commitment by removing the tedious task of squeeze bottle prep and cleaning, helping restaurants improve efficiency and the employee experience while supporting food safety."
Back-of-House Efficiency and Hygiene Controls
Standard restaurant and quick-service restaurant (QSR) setups typically rely on kitchen staff manually transferring bulk dressings into reusable squeeze containers, a process that consumes staff hours and creates contamination risks.
ZeroPrep pouches are hermetically sealed until first use, eliminating ingredient transfer and mitigating potential microbiological exposure during storage and prep shifts. Each unit incorporates an integrated, easy-open tear seal that requires no scissors or cutting tools, transitioning directly from inventory to active food prep lines.
The functional dispenser is fitted with a semi-rigid, drip-resistant spout engineered to open during manual squeezing and reseal immediately when pressure releases. This closure prevents line drips, preserves flavour integrity, and delivers up to a 97% product evacuation yield, lowering residual food waste compared to rigid plastic bottles.
High-Speed VFFS Machinery and Packaging Specifications
The pouches are manufactured using Sealed Air’s proprietary CRYOVAC ZeroPrep vertical form-fill-seal (VFFS) equipment, engineered specifically for liquid condiment packaging.
The automated system combines two specialised CRYOVAC barrier films to form the pouch body, semi-rigid dispensing spout, and hermetic seals within a single continuous process. Technical features of the platform include:
Production Output: Operating speeds reaching up to 80 packages per minute.
Format Flexibility: Sizing capabilities accommodating volumes from 8 to 16 fluid ounces (approx. 235ml to 475ml).
Ergonomic Architecture: Symmetrical, contoured pack shaping designed for stable one-handed dispensing during rapid meal assembly.
Liquid Packaging For Foodservice
The commercial debut builds on Sealed Air’s broader portfolio of food packaging and fluid-handling systems, which includes its Liquibox brand of flexible liquid packaging and bag-in-box solutions.
With rising overheads and staffing pressures facing commercial hospitality, the ZeroPrep launch targets food manufacturers, sauce co-packers, and restaurant operators seeking to reduce prep friction and standardise portion control across multi-unit operations.
