Circular economy sandwiches: Greencore and ProAmpac innovate plastic-free packs for UK supermarket recycling trials

28 Jul 2021 --- UK convenience food producer Greencore is releasing a fiber-based, plastic-free sandwich pack for UK supermarkets Co-op and Sainsbury’s. Created in collaboration with ProAmpac, the solution is touted as a “world first” capable of reversing the environmental impact of the 1,100 prepackaged sandwiches consumed in the UK every minute. 

The release comes after 18 months of R&D by Greencore. The pack has a plastic-free window and is made entirely from paper-based material; crucially, due to the precise level of moisture resistance the pack provides, it will also ensure sandwiches have the same shelf life as those packaged in plastic. 

Subject to successful trials commencing in September, and the proposition meeting all parties’ performance criteria, the rollout of the new packaging will begin later in the year. 

“Consumers are increasingly aware not just of the importance of their own health but also of the impact their food has on the health of the planet. Developing a fully recyclable sandwich pack is one of the key ways we can reduce waste and help our customers do their bit to protect the environment,” says Andy Wright, head of sustainability at Greencore. 

“This is not a problem we can solve alone, though. The complexities of the challenges we face require collective action, inside and outside our industry.”

The UK consumers around 1,100 prepackaged sandwiches every minute, usually packaged in plastic.Greencore’s sandwich sustainability commitments
Greencore research shows consumers find it challenging to separate the plastic film from typical sandwich packaging, meaning recycling rates are “nowhere near” as high as they could be. 

Greencore also plans to make its new packaging techniques available to the wider UK market. Development of the fully-recyclable packaging is part of the company’s key commitments, outlined in its 2020 Sustainability Report. 

The Sustainability Report also contains a range of pledges across sourcing, manufacturing, and community engagement. 

It is estimated that some 600 million prepacked sandwiches are consumed in the UK every year. If the new packaging is adopted as an industry best practice, the potential for reductions in plastic usage and in improved recycling rates would be “immense,” says Greencore. 

Breige Donaghy, director of delicious food at the Co-op, says the trial aligns with the supermarket’s ambition to reduce the use of virgin plastic. “We’ve also worked to ensure all of our own-brand packaging is now fully recyclable. We’re looking forward to seeing the new packaging on shelves this autumn and are confident it will resonate with our members and customers.”

Sandwich pack innovation 
While recyclability for sandwich packaging is currently low, industry innovations have sought to address the issue for some time.ProAmpac’s Freshpack skillet.

Last year, UK compostable packaging specialist Sirane developed a plastic-free sandwich skillet alternative to the conventional PE-coated packs and laminated boards that still dominate the market. 

The packs, branded Earthwedge, are produced entirely from paper and coatings. Earthwedge is suitable for heat-sealing and in-store assembly and can be supplied fully printed or plain in standard and custom sizes.

Meanwhile, Coveris launched a lightweight sandwich skillet named RecyclaLite during Packaging Innovations 2020 in Birmingham, UK. Will Mercer, labels and board R&D director at Coveris, provides an overview of the easily recycled skillet for the food-to-go sector, which uses a minimum film content to maximize recovery, thereby meeting the UK Plastics Pact’s guidelines for less than 15 percent film content in board packs up until 2023.

Arjowiggins also developed a translucent barrier paper suitable for sandwich pack applications last year. Branded Sylvicta, the company says it could revolutionize the packaging industry. The material is translucent, recyclable, compostable, marine-degradable, and proven to preserve foods and cosmetics.

Edited 

By Louis Gore-Langton