Techno Fresh processing method extends shelf life of cut lettuce

Spread Co has developed a processing method combining vertically farmed lettuce and dedicated processing design that will allow for the longest shelf-life of a cut lettuce product in Japan.

Techno Fresh allows for an increase in the shelf life of cut lettuce of up to two times, while preserving freshness, taste, and quality. Spread has also started construction on the first large-scale salad processing plant to utilise the method – Techno Fresh Hadano near Tokyo.

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.

Automation will allow for a drastic improvement in productivity, while the dedicated processing design developed in-house makes it extremely resource-efficient, lowering water usage by 55% (source: internal research. Compared to conventional fresh-cut lettuce processing factory).

Techno Fresh Hadano will produce and sell six types of cut lettuce under the Indoor Salad brand, starting from June 2024.

The Techno Fresh processing method uses pesticide-free, pristine lettuce, that is grown in a highly hygienic environment within Techno Farm and combines it with the in-house developed processing technologies that prevent bacteria from increasing.

Through this method Spread was able to enhance the shelf life of the cut lettuce by up to 2 times and has become the first company to achieve record-breaking six days shelf life for a fresh-cut lettuce product in Japan. Additionally, the Techno Fresh method prevents lettuce from browning/discoloration and doesn’t have the unpleasant smell that is associated with certain washing agents.

Food waste is a problem in Japan specifically, since it ranks as the 14th country with the highest amount of food waste, with over eight million tonnes of food thrown away in 2021 (source: UNEP Food Waste Index Report 2021).

One reason for Japan having a high food waste rate is its strict regulation concerning the expiration dates for products. For example, one of the standards commonly used for fresh-cut vegetables requires viable bacteria count to be lower than 1,000,000 for 1g of the product. Due to this, the shelf life for fresh-cut lettuce in Japan is commonly set at three to four days.

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