Plastic food trays overcome pandemic hygiene concerns as lightweighting and recyclability inspire innovation

15 Sep 2021 --- Plastic food trays, including MAP trays (modified atmosphere packaging), remain a popular choice for meat, fish, cheese and other food products. With the COVID-19 experience heightening consumer hygiene concerns, plastic trays offer supreme product protection. However, environmental sustainability demands drive innovation in this category, with material reduction and convenient recyclability top of the agenda.

According to Innova Market Insights, trays are the second most popular format for packaged deli and cold cut meats like ham and salami globally, behind resealable pouches. However, in warmer climates like Brazil, trays are the most popular format (37%).

PackagingInsights explores the latest trends in plastic food trays with Irene Buzzoni, marketing and communications coordinator at Sealpac, with additional insights provided by Innova Market Insights. We also spotlight some of the latest NPD in food trays.

“From our perspective, the main trends are downgauging the thickness of plastic trays, the introduction of trays made out of mono-plastics, and the rapid growth of hybrid trays with a paper base and thin plastic liner or inlay,” pinpoints Buzzoni.Sealpac’s FlatMap can achieve 75% plastic savings against average retail options. 

“The overall aim is to improve sustainability and recyclability. We have optimized our traysealers to handle these so-called ultra-light trays, and offer eTray as a paper-based MAP tray. Furthermore, we enable our customers to run mono-trays on their Sealpac traysealers.”

Product protection priorities
The COVID-19 pandemic has heightened consumer hygiene concerns, giving rise to touch-free packaging designs and antimicrobial technologies. According to Innova Market Insights, 59% of global consumers believe packaging’s protective function is more important since the virus outbreak.

Moreover, consumers mostly support the increased use of plastic for hygiene during the pandemic, including conventionally unrecyclable films. While 20% of global consumers favor more plastics, 42% see them as an undesirable necessity at this time, according to the global market researcher.

“As a company specialized in tray-sealing technology, our main purpose is to provide a hermetic seal for maximum product safety, regardless of the type of tray that our customer is using,” explains Buzzoni.

“Additionally, in certain segments, we have seen a growth in pre-packaged products. For example, instead of consumers handpicking their bakery products at retail or foodservice, they now offer pre-packaged goods, like croissants or bagels with cream.”

“What we have also seen is the introduction of so-called ‘no-touch packaging,’ such as special trays with a spout, which allows you to pour the product, like nuts, into your hand.”Sealpac’s fiber-based FlatSkin enables easy separation of the cardboard and plastic for recycling. 

Additionally, Sealpac’s traysealers and thermoformers are easy to integrate into full-line solutions, guaranteeing hygienic handling of trays and products across the entire line. 

Innova Market Insights found 51% of global consumers see product protection as a top priority for the packaging of packaged deli and cold cut products.

Sustainability meets shelf appeal
Regulatory action and consumer concern is increasing demands for recyclable packaging. For example, the EU Plastics Strategy requires all packaging to be recyclable or reusable in an economically viable way by 2030. Moreover, the EU’s recently introduced plastics tax imposes a €0.80/kg (US$0.94/kg) levy on unrecycled plastic packaging waste.

“For reasons of sustainability and recycling, we have seen several hybrid packaging systems enter the market, such as our own FlatSkin and FlatMap systems,” continues Buzzoni.

“These are based on a flat cardboard carrier, which can be printed on both sides, giving endless possibilities in terms of branding and product information. Combined with full product visibility, these packs are true eyecatchers at retail.”

Buzzoni recently presented FlatMap, the company’s most environmentally sustainable solution for ultra-flat packaging of sliced meat, seafood and cheese, to PackagingInsights in an exclusive video interview.

The FlatMap can achieve 75% plastic savings against average retail options and full recyclability through easily separable cardboard and plastic components. Buzzoni also discusses Sealpac’s EasyLid solution for 25% plastic savings in snack packaging and explains how the company’s solutions meet the EU Plastics Strategy’s requirements.Sealpac’s EasyLid trays are perfectly suited for in-mold labeling. 

Consumer appetite for waste separation is strong. Innova Market Insights found 85% of global consumers already separate packaging waste at home.

Plant-based expansions
Plastic and plastic-cardboard trays are also the natural choices for the proliferating meat substitutes market. Buzzoni says Sealpac is monitoring a “huge increase” in vegan and plant-based products on the market.

“Probably more than average, these products are packaged in a sustainable manner to match the consumer’s goal of creating a greener world, so we experience an increase in the demand for sustainable packaging solutions for these types of products,” she explains.

“However, from our perspective as a packaging equipment supplier, we do not see any difference in packaging actual meat products or meat alternatives. All common packaging solutions, be it FlatSkin, EasyLid or FlatMap, are used in both segments. The main difference is most likely on the processing side, not on the packaging side.”

PackagingInsights recently discussed the challenges and opportunities in packaging plant-based alternatives with experts from GEA, Multivac and Wipak.

Food tray NPD
Innovation in food trays is proliferating, spurred by regulatory and consumer demand for recyclable packaging that contributes to the circular economy without compromising on user convenience.

For example, GEA recently launched the cardboard tray-plastic film FoodTray for packaging marinated meat, which the company says reduces plastic by up to 80%.

With GravityTray, liquids automatically and permanently flow to a unique bottom chamber. Meanwhile, Stora Enso unveiled a 95% fiber-based microwavable food tray called Trayforma. The PET-free solution boasts a low share of polypropylene and a lower carbon footprint than traditional meal trays, the manufacturer shares.

In the absorbent pad space, Elliott Absorbent Products has developed a carbon-reduced meat and fish pad with reported 50% material savings.

Eradicating the need for absorbent pads entirely, the GravityTray innovation permanently traps juices from meat, fish, poultry or fresh fruit in a bottom tray chamber.

However, not all retailers are convinced trays are the best option for meat products. PackagingInsights spoke with Fuji Packaging Benelux at Empack 2021 in the Netherlands as it showcased its flowpack machine specially designed for minced meat.

“At the moment, Albert Heijn is introducing minced meat packaging in a flow pack instead of a tray,” says Frank Kwantes, Fuji sales manager. According to the Dutch supermarket, the switch to flow packs results in 60-70% plastic savings, amounting to 500,000 kg of saved plastic annually. 

“A tray can range between 200-300 mcg in thickness, but a flow pack can be as thin as 45 mcg. Four to five flow packs can amount to the same weight as one tray,” Kwantes adds.

By Joshua Poole