Spread Co has developed a processing method that combines vertically farmed lettuce and a dedicated processing design to achieve the longest shelf-life of a cut lettuce product in Japan. This innovative method, known as Techno Fresh, allows for a significant increase in the shelf life of cut lettuce, up to two times longer, while maintaining freshness, taste, and overall quality.
The company has also commenced construction on its first large-scale salad processing plant, Techno Fresh Hadano, near Tokyo. This facility will be the first to implement the Techno Fresh system and is expected to revolutionize the processing of cut lettuce.
“Techno Fresh Hadano is the first processing facility by Spread and is the first facility to implement the Techno Fresh system. This next-generation processing factory will process eight tonnes of lettuce per day while automating 85% of the processes, including implementation of the world’s first AI-based lettuce core remover.”
By incorporating automation, the facility will experience a significant improvement in productivity, while the in-house developed processing design makes it highly resource-efficient, reducing water usage by 55% compared to conventional fresh-cut lettuce processing factories.
Techno Fresh Hadano is set to introduce six types of cut lettuce under the Indoor Salad brand, beginning from June 2024. The method uses pesticide-free, pristine lettuce grown in a highly hygienic environment within Techno Farm, combined with processing technologies that prevent bacterial growth.
Through the Techno Fresh method, Spread has successfully extended the shelf life of cut lettuce by up to 2 times, setting a new record of six days for a fresh-cut lettuce product in Japan. Additionally, the method prevents lettuce from browning or discoloration and eliminates the unpleasant smell associated with certain washing agents.
The issue of food waste in Japan is significant, with strict regulations on expiration dates for products contributing to high levels of waste. For instance, current standards for fresh-cut vegetables in Japan require a viable bacteria count lower than 1,000,000 for 1 gram of the product, resulting in a typical shelf life of three to four days for fresh-cut lettuce.
As highlighted by the UNEP Food Waste Index Report 2021, Japan ranks as the 14th country with the highest amount of food waste, discarding over eight million tonnes of food in 2021. This fact underscores the importance of innovative processing methods such as Techno Fresh in reducing food waste and improving sustainability within the food manufacturing industry.
