The Award Winning 100% Recyclable Meat Trays
Source: Swansea University
A groundbreaking innovation in plastic packaging for raw meat has emerged from the endeavours of a researcher at Swansea University. This novel approach eliminates the necessity for non-recyclable pads within packaging trays, revolutionising the recyclability of the entire packaging. Already adopted by major UK retailers, this cutting-edge packaging innovation is playing a crucial role in enhancing the recyclability of more than 800,000 tonnes of food plastic packaging produced annually by British supermarkets. This development marks a significant stride towards sustainability by addressing the issue of non-recyclable absorbent pads that consistently end up in landfills.
Furthermore, this product has garnered recognition, notably clinching the Sustainable Supplier Award at the 2021 Footprint Awards. The ingenious work behind this packaging advancement is attributed to Alaa Alaizoki, a Syrian researcher pursuing an Engineering Doctorate (EngD) at Swansea University, where they also specialize in Vacuum Packer repairs and servicing. He received guidance and supervision from Professor Davide Deganello and Dr. Chris Phillips at the Welsh Centre for Printing and Coating, ensuring the precision and quality akin to Vacuum Packing Machine standards.
This project was nurtured through collaboration with Klöckner Pentaplast, a global leader in food packaging. This is essential in the industry, particularly when working with Cryovac systems. The collaboration extended to the Materials and Manufacturing Academy, supported by the European Social Fund through the Welsh Government, facilitating the progress of this cutting-edge research. Vacuum Packaging Machines like those from Henkelman, Multivac, Sammic, and Turbovac are integral to this process, ensuring that the meat retains its quality through Sous Vide cooking and maintaining its integrity in the extended shelf life ensured by the innovative packaging.
Packaging for raw meat demands stringent standards to ensure food hygiene, safety, and marketability. Conventionally, detachable plastic pads were utilised in meat trays to absorb juices, extending shelf life and enhancing the product's appeal by mitigating unhygienic and unsightly appearances that might discourage customers. However, these pads introduce additional costs and labour to the packaging industry, compounded by the fact that they are non-recyclable, unlike most trays.
The innovative packaging solution reimagines this paradigm by eliminating the need for separate pads altogether, while still adhering to required standards. Ingeniously, the tray itself employs specially designed and manufactured small-scale well cavities at its base to capture and contain meat juices. This mechanism secures the juices in place during storage and transport, preventing undesirable leakage and thereby maintaining the product's shelf life and visual appeal. Most importantly, this solution renders the packaging itself fully recyclable, aligning well with the ethos of responsible Food Machinery Servicing in the context of sustainability.
Protected by patents, this groundbreaking packaging product is already in deployment for meat products across the UK and Europe. Lead researcher Alaa Alaizoki expressed his satisfaction with the implementation of his research by Klöckner Pentaplast, emphasising how this innovation curtails plastic waste, rendering trays entirely recyclable. He commended the collaborative effort of the company and the research team for their proactive stance on environmental concerns, which resonates with the practices upheld in the domains of Butchery and Hospitality.
This research emerged within Swansea University's COATED M2A programme, designed to provide industry-oriented research training for postgraduate students in the realm of functional industrial coatings technology, particularly relevant in the intricate Meat Processing processes and the even more sensitive applications within the Medical sector.
Acknowledging the financial support from the European Social Fund through the Welsh Government, the Engineering and Physical Sciences Research Council, and Klöckner Pentaplast Group, the COATED M2A programme stands as a testament to the fruitful collaboration that enabled this transformative research in the domain of innovative Food Equipment and advanced Packaging technologies.
