Getting to the Meat of Sustainable Packaging Innovations

As manufacturers and processors look for more sustainable packaging solutions in order to meet demand for reduced plastics and more recyclable packaging, many industries are reviewing packaging as a priority. Dave Berriman, Technical Sales Support Manager at ULMA Packaging UK, discusses how innovations in trayless minced meat packaging represent a step-change in sustainability. 

The sustainability agenda is gathering pace and in recent times has been driven forward by consumer demand, legislation and wider social responsibility to help preserve the planet and reduce the nation’s waste and carbon footprint. In fact, when it comes to packaging, 82 per cent of UK shoppers believe plastic use in food and drink packaging can and should be reduced. Furthermore, for over a third of Europeans plastic waste is even more concerning than climate change.

Going beyond public perception, legislation to incentivise companies to adopt more sustainable packaging operations has helped to start the countdown to a greener future. In 2020, the UK Government set out the introduction of a plastic packaging tax. It stated that companies using plastic packaging containing less than 30 per cent recycled content would be taxed £200 per tonne from April 2022. 

With these pressures in mind, more ways to reduce packaging and plastics inevitably need to be adopted. Not all methods will be appropriate however, so it is important that packaging decisions are carefully made.

What to consider  

A report published by the Green Alliance sustainability thinktank in 2020 demonstrated how some alternative packaging materials to plastic may actually not be better for the environment. This realisation has been made by factoring the recyclability and overall impact of these materials on carbon footprint, with the report highlighting that more coated cartons have been produced under the assumption that sufficient infrastructure exists to recycle them, when this is not always true.

The bigger picture must also be considered when replacing plastics. For instance, glass packaging which although recyclable, actually contributes carbon due to being much heavier and therefore more polluting to transport. 

Finding a solution that works 

For the minced meat industry, trayless packaging machinery can significantly reduce plastic and packaging waste by 60 to 70 per cent when using shrink barrier film. Shrink barrier film further allows for substantial plastic savings while possibly improving shelf life, without discolouration or leakage. By doing this, companies can eliminate the need for a tray by implementing modified atmosphere packaging (MAP) on horizontal flow wrap packaging lines. 

Alongside the environmental benefits of eliminating the need for a plastic tray, manufacturers can also achieve significant cost savings, as less film is needed. Additionally, storing premade trays is both an added drain on cost and space. By choosing rollstock film (reels) manufacturers can cut their storage requirements by circa 80 per cent, as they are no longer storing “air”.

How it compares to thermoforming 

Traditionally, minced meat is packaged via thermoforming. While this method is effective, it use a large amount of material, including a tray, cover, and additional labels. By contrast, a flow wrapper replacing rigid plastic trays with a flow pack using MAP will ensure all of the usual benefits of packaging are achieved, while limiting the use of unnecessary plastics in line with consumer expectations. This is due to flow wrappers using a single, efficient, in-line process from extrusion through to packing and crating of products. As a result, no additional tray is needed, resulting in an easier and more simplified packaging machinery line that also boasts a smaller footprint on the factory floor.

In terms of operational efficiency and sustainability, manufacturers choosing a flow wrapper machine stand to benefit from lower cost of maintenance and ownership. When compared with thermoforming machines, flow wrappers have a much simpler operational process and a smaller carbon footprint. Further benefits include the fact that no tooling is required to change between pack sizes, so switching between product lines is also quicker, with less downtime. ULMA’s MAP innovation is also compatible with existing portioning equipment, for seamless integration. On top of this, no labels are needed as the product information and overprint (date/batch code) can be printed directly onto the film.

Moreover, by using thinner, recycled films suited to shrink packaging, companies can achieve smaller pack volumes without having to decrease the volume of meat. This, in turn, is beneficial to the environment in a number of ways. For example, films used with minced meat in flow wrapper applications require 80 per cent less space to transport compared to the films and trays used in traditional traysealer and thermoformer processes. 

On top of this, shrink packaging allows for a greater crate fill, meaning 30 per cent less space is needed to move packaged products to retailers and supermarkets. Because vehicles can fit more products per crate and pallet than previously possible, logistical cost savings can be made and overall carbon emissions reduced.

Packaging machinery specialists, such as ULMA, can support with the specification, installation and ongoing maintenance of innovative technologies to offer an end-to-end solution for all packaging requirements.

No time to mince words

For minced meat applications, improving packaging all while reducing waste and plastic is an opportunity to be seized in order to start paving the way to a more sustainable future. Not only is it an excellent way to show a commitment to reducing waste, the benefits of opting for sustainable solutions like trayless minced meat packaging delivers significant materials and operational cost savings too. Not to mention all while helping to improve consumer confidence in the businesses who reduce pack size and waste.

To find out more about ULMA Packaging UK and minced meat packaging solutions, visit www.ulmapackaging.co.uk/en

This article first appeared in the May 2021 issue of Industrial News.