By Shahana Jahangir, Nerac Analyst
Ever try to heat up your morning coffee in the microwave and finding out the gilded design created fireworks? You probably learned very quickly that metal and microwaves aren’t compatible.

Consider this admonition included in 20 Tips for Safe Microwave Oven Operation from the Office of Engineering Safety at Texas A&M University: “Do not use … any metal containers, metal utensils, metal objects, or objects with metal or foil trim in the oven. Such items can cause arcing, damaging the oven and creating a fire or burn hazard.”

But that concept is changing. Metal lids have been around for some time now, with plastic caps preventing arcing. But now, as the demand for microwavable food continues to increase, many companies are seeking packaging alternatives to increase shelf life and convenience. “The enthusiasm for the microwave oven isn’t about cooking, but about time,” says William Doyle, professor of history, Pennsylvania College of Technology. “People like the microwave because it is a time-saving device, not because it helps them cook. Time … is the new frontier.”

Ball’s Fusion-TEK Opens Possibilities
Recently, Ball Corp. came up with an innovative design called Fusion-Tek that for the first time allows food companies to use steel cans. It took Ball 11 years to develop the technology, with R&D cooperation from its Aerospace division. Interestingly, it was developed with an $89 microwave oven.

The result is a low-cost alternative that makes for easier preparation for on-the-go meals and easy cleanup. Ball’s packaging is kid friendly, microwave safe, recyclable and durable. The can, made from recycled steel, uses an insulated foam label to protect consumers from burns, and an easy-open ring top.

Design’s Role In Microwave Cooking
From a practical standpoint, package design plays an important role when it comes to microwave cooking. A regular steel can does not heat in the microwave because microwaves do not pass through the container’s surface. Ball’s proprietary technology fuses a polypropylene bottom to a steel can that, combined with a plastic lid, creates a channel for microwaves to pass through the can. The result is that food heats quickly (in 2-3 minutes) and more evenly.

Ball is promoting the packaging as puncture resistant, and because the plastic end has an oxygen barrier, it ensures product quality and freshness for at least 18 months, far greater than the shelf life of microwave packaging made from polymeric or paper-based materials. Ball’s Fusion-Tek packaging, which currently is available in a 15-ounce size suitable for soups and stews, is designed to run on existing filling lines, and it can be stacked and shipped like steel cans. Ball also says pricing is comparable to other microwave packaging.

The new packaging was unveiled late last year, and full production is expected to begin this year.