Coveris equips Tesco with recyclable pouch for ready-to-eat chicken as circularity demands grow

28 Oct 2021 --- Coveris is launching recyclable stand-up pouches for UK retailer Tesco’s ready-to-eat chicken in partnership with poultry producer Moy Park.

The product was previously packaged in a rigid tray format with mixed lidding films, but Coveris’ MonoFlexBE stand-up pouch presents “an entirely new format for the category.” 

Mark Robinson, Coveris flexibles technical sales manager, tells PackagingInsights that creating the PE-based monolaminate film barriers was one of the main technical challenges, as their properties are essential to maintaining freshness and shelf life.

Creating the pouch
Developing high-seal integrity and sealing capabilities to ensure safety and operational efficiencies was complicated throughout the R&D process. 

“The inner seal layer is specially designed to seal at lower temperatures to deliver improved efficiencies and energy savings. We have therefore achieved a 55% plastic weight reduction on the current format and full recyclability,” Robinson highlights.

The pouches are now available for Tesco BBQ Chicken Breast Pieces, but also target “many other applications requiring recyclable, lightweight stand-up pouches with high barrier properties,” he notes. These applications range from meat to fish and poultry to dairy applications in the culinary convenience sector.

The resealable pouch features a zip-lock function for improved convenience and reduces food waste through better storage.What’s driving recyclable pouches?
A series of industry developments are driving demand for more environmentally sustainable solutions, and consequently new packaging formats.

According to Innova Market Insights, 33% of UK consumers are willing to pay more for environmentally sustainable packaging. Moreover, 56% are prepared to switch their usual brand for a brand with better environmental credentials. These figures rise to 50% and 65%, respectively, for the average global consumer.

Currently, the UK is faced with limited curbside collection for PE films. To tackle this supply shortage, Tesco provides a dedicated in-store soft plastic recycling stream for flexible packaging. 

Establishing better plastic recycling infrastructure within the UK will be crucial, as the UK government proposes a £200 (US$275) per metric ton tax rate for plastic packaging with less than 30% recycled plastic produced or imported into the UK from April 2022.

Coveris is ready to eat 
Coveris has made waves in the ready-to-eat sector through various recyclability initiatives. This year, Coveris developed two separate sandwich skillets to meet the different shelf life requirements of mainland Europe and the UK. 

The modified atmosphere RecyclaPEel sandwich skillet – launched at FachPack 2021 – is designed to provide extended shelf life for the European food-on-the-move and convenience sectors. 

Meanwhile, the RecyclaPaper monomaterial skillet – launched at Lunch! 2021 – is an entirely paper-based, recyclable solution featuring a translucent window for product visibility, intended for UK markets. 

Coveris is also converting a “potentially revolutionary” new paper into flexible packaging for dry foods to meet growing demand for recyclable alternatives to plastic-based solutions. Notably, the material’s barrier properties are competitive with plastic, mitigating food waste. 

By Anni Schleicher