Alternative protein packaging megatrends: How plant-based F&B producers are aligning with the industry

20 Sep 2023 --- Consumers with and without meat-restricted diets are increasingly purchasing plant-based foods. This growth demands that packaging solutions for plant-based alternatives advance alongside it and appeal to the typically eco-conscious customer base.

Innova Market Insights indicates an exponential growth of plant-based alternatives. The market researcher tracked 49% annual growth in plant-based F&B launches between 2017 and 2021. Over half of these launches were packaged in plastic.

Packaging Insights speaks to experts at Sealpac, Amcor Flexibles and SIG about consumers’ and producers’ interest in eco-friendly packaging solutions for plant-based foods and how the packaging industry is keeping up with demand.

“At SIG, we are committed to providing sustainable, innovative and versatile packaging solutions for every product category, especially in the plant-based category. We are focusing on packaging solutions that set a [environmentally] sustainable benchmark while maintaining the high quality, flavor and functionality of the plant-based beverages,” says Julia Trebels, category and consumer insight manager at SIG.

Environmental trend
Kevin Groten, marketing and communications coordinator at Sealpac, says the market for products based on alternative proteins is “booming.”

“Packaging alternative proteins is not a short-term hype but a megatrend that will prevail.”

Vegan minced meat in Sealpac’s eTray.“Whether flexitarian, vegetarian or vegan, more people are choosing these foods for reasons of [environmental] sustainability. This is a trend that we see growing over the past few years. Not only from a consumer’s point of view but from the manufacturer’s perspective. They are expanding their product portfolio with plant-based food or other alternative protein products,” states Groten.

He continues that the plant-based industry seeks packaging concepts to combine product safety, resource conservation and extended shelf life. Groten says he has noticed that the target group for alternative proteins values ecological packaging designs.

“We see manufacturers changing their packaging from plastic to, for example, paper-based or monomaterials,” Groten asserts.

Amcor witnesses the same trend of alternative protein consumers finding value in eco-conscious packaging – specifically, in a reduced carbon footprint in their food and the associated packaging. It uses the example of its AmFiber trays for alternative protein as a solution that appeals to these customers, as it allows for recycling into the paper stream.

“Other [examples] include incorporating advanced recycled materials, post-consumer reclaim, or even certified recycled content, all improving the circularity of the packaging.”

Trebels echoes that environmental sustainability is a trend for the packaging choices made for plant-based beverages, driven by consumers’ eco-consciousness.

Sustainable solutionsPackaging producers are switching from plastic to paper-based solutions for plant-based foods to appeal to customers.
Trebels illustrates how SIG’s packaging for plant-based beverages aligns with consumer demands for environmentally friendliness and shelf appeal. 

“The SIG Terra packaging material innovations provide a range of industry-leading firsts and exclusives that offer on-shelf appeal and stand-out environmental credentials. SIG Terra forest-based polymers, linked to up to 95% forest-based renewable materials through a mass-balance system, is, for instance, one such solution that companies filling plant-based beverages increasingly request,” she states.

Sealpac gives an example of successful plant-based protein packaging from the Spanish market, where plant-based cold cuts were previously packaged in plastic. The manufacturer eventually switched to a paper-based packaging concept called FibreStyle. The flexibility of the Sealpac thermoformer made it possible to change to paper-based packaging on the same base machine.

Sealpac has developed packaging solutions that can be used for plant-based proteins, such as the FlatMap and FlatSkin, which are paper-based. Groten says these packaging innovations use resource-saving use of materials.

Sealpac also offers the option of using a paper-based tray. Despite the low weight of these trays, the Sealpac Amax-series traysealers still “guarantee” product safety, particularly in its handling and processing in high-speed applications.

“The primary focus concerning packaging is to guarantee a maximum shelf life of the product inside and protect the product as well as possible,” asserts Groten.

Shelf life optimization remains a key concern when packaging plant-based meat.Peterka also says that shelf life is a critical factor for plant-based protein packaging. “Amcor’s oxygen barrier-containing packaging portfolio and expertise is well suited to protect alternative protein products on the store shelves for as long as possible, reducing food waste and enhancing the consumer experience,” he explains.

According to Amcor, consumers in North America are looking for clean labels, freshness and transparent packaging.  Matt Peterka, senior director of R&D at Amcor Flexibles North America, tells us that 71% of food shoppers seek clear nutritional information on packs enabled by simple appearance, straightforward messaging, and see-through packaging labels.

Amcor’s AmFiber portfolio includes high-barrier paperboard trays. Peterka asserts that the trays are perfect for plant-based protein and made with lightweight recycled materials that are easy for consumers to recycle.

Future innovations
According to Groten, creating packaging solutions for vegan minced meat poses manufacturing challenges and is the company’s current focus.

“At Sealpac, we believe the future of packaging (vegan) minced meat is within reach. One of the alternatives is thermoforming with flexible film under a modified atmosphere. It offers improved, eco-conscious packaging – thinner plastic films, better stackability, controlled gas processes and endless packaging possibilities on a single machine.”

Another common way to package vegan minced meat is by using pre-formed trays. Sealpac, in close cooperation with its partners, has reduced the material of the 190x144 mm tray from 18 g in 2003 to now below 10 g.

Trebels adds that she does not think the packaging industry needs to create more solutions for plant-based products but instead needs to optimize the current solutions so they are more customizable. She advocates for collaboration between producers and providers of the packaging to “make a difference long-term.”

By Sabine Waldeck