LEAMINGTON, ONTARIO, CANADA - The word “cutting-edge” might not immediately come to mind when one thinks of produce packaging, but AIRVIA Technology—born from a partnership between Excalibur Plastics and Tychon Packaging—is looking to change that. The two collaborators have developed an innovative solution designed to keep snackable fruits and vegetables fresher for longer.
I turned to Kevin Kantati, President and Chief Executive Officer of Tychon Packaging, and David Boutros, Chief Executive Officer of Excalibur Plastics and part-owner of Tychon, to learn more about how this partnership and innovation came into being.
Tychon Packaging began in 2018 when Kevin saw an opportunity to create packaging designs for the cannabis industry. In doing so, Tychon Packaging created innovations such as child-resistant pouches, patented pre-roll containers, and the patented TyCann child-resistant cannabis drink topper, which is still the market leader in North America today.
“I got back into the produce industry after a friend asked me to help him out with his supply chain to see where we were able to save him money, but I was shocked to see nothing had really changed in the 10-plus years I’d been out,” Kevin said.
For an innovative thinker like Kevin, this was the antithesis of what he wanted to bring to produce packaging. Already in talks with Excalibur Plastics, Kevin knew he’d made the right choice when David instructed him to focus on innovation first and foremost.
The merger was settled in November of last year.
“Now we’re off to the races getting Kevin doing what he does best, and doing what we do best, which is manage companies,” shared David.
Shortly after the merger, Kevin texted David late at night with his latest idea. What appeared to David as a mere scribble of a Bundt cake was poised to be an exciting breakthrough in packaging technology.
The result was AIRVIA Technology, available in 1.5 lbs, 2 lbs formats, and an 18 oz clamshell, featuring a central—or in some cases—multiple protrusions that extend up into the packaging. Beyond these initial offerings, the technology can be integrated into various packaging designs already in use in the market today. The team is eager to collaborate with major chain stores and marketing companies to integrate AIRVIA into existing product lines and explore how far the innovation can go.
“This allows for better ventilation, which helps to eliminate any crowding effects such as yeast, mold, and bacteria,” David explained.
After finalizing the designs, Tychon partnered with A&L Laboratories in London, Ontario, to conduct independent testing. The results, as Kevin and David shared with me, were more than promising: the packaging reduced molding by an average of over 70 percent compared to conventional designs.
With this win behind them, the team applied for funding and received a $300,000 grant award from Intellectual Property Ontario (IPON).
“They believe in our product and we're really excited about that,” David said. “We’ve secured additional funding to help us complete this project and explore further innovations planned for the following year.”
The company’s aim to increase freshness is paramount in an industry concerned with customer eating experience and food waste. And while the science behind the design is impressive, the real impact shows up where it matters most—in the hands of the consumer. Fresher packaging means fruits and vegetables hold onto their color, texture, and flavor longer, so what shoppers bring home looks and tastes better.
Lower yeast counts also help prevent off-flavors or sour notes that can sometimes develop, which in turn drives people away from eating produce. Beyond taste, there’s the peace of mind factor: even if microbes aren’t always dangerous, consumers naturally associate lower counts with safer, cleaner food—something especially important for parents buying for their families.
All of this builds trust in the brand itself, according to David and Kevin. When customers see packaging that actively works to protect freshness, it strengthens confidence and loyalty, giving them more reason to choose that product over the competition again and again. These benefits make AIRVIA Technology especially attractive to chain stores and marketing companies, who recognize that packaging that protects freshness is also a compelling marketing tool that can set their products apart on crowded retail shelves.
“Seeing packaging that helps protect food essentially restores confidence in choosing that brand over competitors,” added Kevin.
There’s much more to this packaging than I can fit into one article. Stick around for more details from Tychon Packaging, and be sure to visit the team at this year’s Global Produce & Floral Show at booth #4430.
