Lunch! 2021: ProAmpac debuts all-fiber sandwich skillet for recyclability and competitive shelf life

23 Sep 2021 --- ProAmpac (formerly Rapid Action Packaging (RAP)) is debuting its RecycAll Freshpack all-fiber sandwich skillet with a window today at Lunch! 2021 (September 23-24), stand D50, at the Exhibition Centre London, UK. 

The company describes the recyclable solution – developed in partnership with Greencore over 18 months – as “a market first, considered plastic-free in the UK and Europe.”

In July, Greencore confirmed the skillet would have the “exact same shelf life” as traditional skillets “due to the precise level of moisture resistance provided.” The skillets are currently in field trials this autumn at UK retailers.

“The challenge was to make sure the paper material could control water and air ingress and egress over the product’s life without rendering the internal protective paper layer of the carton unrecyclable,” Kevin Vyse, head of technical for fresh food packaging at ProAmpac, tells PackagingInsights.

“The coating was specially developed to be water-soluble over a certain water temperature (normally found in pulping mills). The key was to find the correct balance between food protection and recycling, and this was achieved through an iterative development of the coatings to meet the task.”

“The protective paper layer itself is also unique, being a microfibrillated structure, which also increases its transparency (important for seeing the product) and barrier to oxygen.”ProAmpac’s all-fiber skillet has the “exact same shelf life” as traditional skillets.

Heightened hygiene trend
Vyse says a key trend in food-on-the-move right now is food safety. According to Innova Market Insights, 59% of global consumers believe packaging’s protective function is more important since the virus outbreak.

“For the customer, it is important to see their food has been protected against contamination from other customers and packaged to prevent potential localized environmental contamination,” explains Vyse. 

“Another trend we are seeing is hot food-to-go. Uber Eats and similar companies are now delivering to home offices and main offices instead of workers going out to pick up food themselves.”

He adds that hot food is generally perceived as being healthier and fresher, while “to-go” products are expanding into fresh food options, like salads, pastas and specialty breads made on the day.

“The packaging trends are now firmly toward environmental sustainability through good resource use and recycling capability,” adds Vyse.

RecycAll Freshpack on trial
The skillets are in field trials at UK retailers this autumn. Pending successful consumer trials, “rollout will begin later this year,” Greencore says.

“The current trials are to understand if the consumer finds the reduced visibility of the product inside the pack a deterrent and if the ‘All Paper,’ ‘Plastic Free’ or ‘Fully Recyclable’ messages are getting across,” Vyse tells PackagingInsights.

“We are also looking for improvements in packaging production speeds and techniques as part of the trial.’’Vyse pinpoints food safety and environmental sustainability as the key trends in food-on-the-move.

ProAmpac’s development partner Greencore specializes in flexible packaging and material science with headquarters in Cincinnati, Ohio, US.

Earlier this year, ProAmpac expanded into flexible packaging for ready-to-eat and freshly prepared foods sold at retail with the acquisition of RAP.

The language of environmental sustainability
Vyse points out there has been a lot of publicity on UK TV around the non-recyclability of certain types of packaging containing plastic laminates and sandwich packs, leading to a groundswell of opinion that ProAmpac, and others like Coveris, are addressing with recyclable skillets.

There are several messages brands can use depending on “the sensitivity of the marketplace the pack is going into,” says Vyse.

In the UK, the emphasis has been on “Plastic Free” but Vyse also notes the use of the terms “Fully Recyclable” or “All Paper.” 

“The key is to tune in with the current media concentration and be prepared to move the messaging rapidly to suit,” continues Vyse.

“It is the very nature of food-to-go that it has to evolve with the trends and we predict, in the UK, the ‘Plastic Free’ message will reduce as more companies adopt the ‘All Paper’ solution for a variety of food-to-go applications driven by what they see going on with sandwiches.”

By Joshua Poole