Every day more and more pressure is being placed on manufacturers to make sure that their packaging is sustainable at every point of the supply chain – from using more recycled material to tracking where their packaging ends up.
With Extended Producer Responsibility (EPR) for packaging now in affect and talks ongoing on how the UK can implement a Deposit Return Scheme, manufacturers need to know how they can not only monitor their packaging use, but also the ways they can cut down on materials like plastics.
Measure twice, cut once
Matt Harris, head of packaging at Pilgrim’s Europe, said packaging was a central focus of the meat processor’s sustainability strategy since its recent restructuring. Drawing on the collective expertise of Moy Park, Pilgrim’s UK and Pilgrim’s Food Masters, the manufacturer is guided by the principle of ‘doing the right thing’.
Effective measurement tools are the first step towards ensuring its packaging is sustainable, allowing the business to track progress, pinpoint areas for improvement and stay on course to meet its targets.
“At Pilgrim’s Europe, we utilise innovative software like Gabi, which enables us to compare the CO2 impact of different packaging types and make informed, data-driven decisions,” Harris explained. “This means we can accurately quantify the environmental impact of our packaging choices, guiding changes to help meaningfully to reducing our carbon footprint."
By relying on precise data rather than external influence, Harris explains that Pilgrims can ascertain a clear, objective perspective on the best path forward and make the right choices for both the business and the planet.
The manufacturer is exploring different ways in which it can close the loop on materials and reduce its reliance on virgin plastics. Key developments in the area of packaging design included the increased use of recycled content, a new tray design that removes the need for absorbent pads in the packaging and the use of monomaterial.
However, Pilgrims’ ‘Tray-to-tray’ trial is arguably its biggest success. A cross-industry collaboration, the initiative turns recycled plastics collected from UK homes into ready-meal trays that meet ‘the strictest food safety and quality standards’.
“As part of this groundbreaking trial, we packed 120,000 meals into trays made from previously used packaging,” Harris added. “The trays contained 73% recycled content, with 50% sourced from the UK and 50% from Europe. This marks a first in creating a closed-loop solution within our category.
“This initiative is a significant step forward – not only does it prove that recycled PET can meet the technical demands of dual ovenable food-grade packaging, but it also opens up the possibility for a UK-wide system where food trays are kept in circulation rather than ending up in lower-grade uses or landfill.
“By keeping high-quality recycled PET in the packaging supply chain, we’re actively reducing the demand for virgin plastic, promoting resource efficiency, and moving the industry closer to a circular economy. It’s an exciting project, and we believe it showcases a model that could lead to more sustainable packaging solutions across the food sector.”
On the topic of monitoring plastic waste, one company has made it their business to know where your waste ends up after consumers are finished with their products.
Real time data capture
While it can be all well and good knowing you’ve made your packaging from recycled materials, reduced the energy input of its creation or invested in alternatives to plastic, that effort could all come to nought if it just ends up in a landfill at the end of its journey.
Polytag is helping food businesses trace their packaging and track against sustainability targets through its plastic detection technology and has recently expanded its network to include one of the largest material recovery facilities (MRFs) in the UK.
Polytag’s Ecotrace Programme uses real time data captured at MRFs to track packaging lifecycle intelligence. Polytag’s invisible watermarks are identified by Detection Units at the MRFs using UV lights, providing data on what plastics are being recycled and from where they came.
Re-Gen’s Newry site is the second-largest MRF in the UK, processing 250,000 tonnes of commingled household waste each year. In addition to handling a quarter (25%) of Northern Ireland’s total waste, the facility also processes materials from England, Scotland, Wales, and the Republic of Ireland.
Data collected by Polytag can be used to form goals to help reduce the amount of plastic being wasted, especially at a time when ERP is forefront of many manufacturers’ minds.
Commenting on the partnership with Re-Gen, Polytag CEO Alice Rackley said: “Our technology will allow the site to manage packaging and waste on a truly large scale – a game-changer for improving recycling rates and driving us closer to a circular economy. After all, what can be measured can be managed, and our technology enables precise tracking, tracing, and detection of materials, which is essential for achieving these goals.
“Through the Polytag Ecotrace Programme, we aim to revolutionise how stakeholders navigate the circular economy and by deploying our technology at this high-capacity site, we are unlocking invaluable insights and driving innovation for the benefit of all.”
Polytag already partners with major brands and retailers such as M&S and Ocado Retail to enable the tracking and tracing of packaging, incentivise plastic recycling, and set and achieve meaningful ESG targets.
Re-Gem CEO Joseph Doherty added: “This collaboration demonstrates our commitment to adopting cutting-edge solutions that enhance recycling efficiency and provide valuable insights into packaging lifecycles.
“By embracing innovations like Polytag’s Ecotrace Programme, we’re driving the industry forward and contributing to a more sustainable future for today and generations to come.”
Retrofitting existing lines
Novel food and drink packaging materials are being developed all of the time, but the question manufacturers need to ask is ‘can I use new materials in my existing production line?’. Is it financially viable to replace an entire part of the line just to accommodate a new type of plastic, or shit completely to paper-based solutions?
“Cost to change of materials can vary wildly,” said Elliot Chrisp, materials business unit manager at Multivac UK. “Factors such as current equipment size, required line output and age have significant influences on project cost.
“If a project scope is to change from plastic into paper, often customers will have the need to run both packaging material types by utilising one production line for various packaging types. Doing this change can be cheaper than buying brand new full lines specifically designed for one packaging type.”
As Chrisp explains, any cost of changing to a new machine can be mitigated by the significant reduction in the cost of the packaging itself – switching from plastic to paper can see a 300% reduction in pack cost. However, considerations need to be made for packaging fresh proteins which still require a certain amount of plastic content to ensure shelf life can be maintained.
“One interesting new potential packaging types is the utilisation of Bagasse materials which use sugar cane or wheat straw as a source material,” he continued. “These materials still however require plastic content to create suitable replaceable alternatives. The main positive of these products being it is possible to utilise current packaging equipment when implemented in the right way.”
Chrisp noted that a lot of cost saving in material change can be found in creating lighter weight alternatives than current and more traditional packaging formats.
“If we in the UK wish to increase recyclability and reduce CO2 as much as possible, the largest gains can be made by replicating such changes like the recent mince packaging changes seen in the market,” he concluded. “When you review the numbers, currently there are no ‘new’ materials that can match those numbers.”
Less is more
While plastic is often demonised for its effect on the environment, the production of other forms of packaging material can still have a major impact on the health of the planet. For example, glass may be almost infinitely recyclable, but there is still a high energy cost required in its production.
One way to mitigate the energy cost of producing packaging is the reduce the amount of packaging being made in the first place, a route being taken by drinks firm Australian Vintage for its McGuigan Wines brand.
McGuigan is transitioning to a 300g glass bottle down from the traditional 400g seen across other wine products – a 25% decrease – while still maintaining the classic Bordeaux design.
The bottle itself is made from 30% recycled glass and is designed specifically for the wine sector. According to Australian Vintage, production of the lightweight bottle – which will replace 13.5 million bottles in 2025 – is projected to save about 336,000 kg of CO2 emissions annually during the glass production process.
Julian Dyer, chief operating officer at Australian Vintage, commented: “Sustainability is paramount to our success in the future. Our approach is a balanced one, encompassing our responsibilities across environment, social, and governance (ESG) pillars.
“Supporting Australian Vintage’s ambitious goal to achieve Net Zero by 2040 across our entire value chain, validated by the Science Based Targets initiative, is a key priority. The transition to the 300g lightweight bottle represents a significant step in reducing our carbon footprint while upholding the premium quality our customers trust and value.”
McGuigan will be the first major wine brand in the UK to be packed in the lighter bottles. To further its sustainability credentials the wine will be bottled at Greencroft Bottling, a site predominantly powered by wind and solar – including three wind turbines and a solar installation producing 4.6 megawatts of energy.
“This lightweight bottle is a game-changer for the wine industry,” Dyer concluded. “It’s a perfect example of how innovation and sustainability can work together to deliver both premium quality and meaningful environmental benefits.”