Driving trends – packaging’s eco evolution.

Healthier options, including more vegan and plant-based dishes, along with the importance of being more sustainable is driving the food to go sector, with 2023 seeing packaging Extended Producer Responsibility (EPR) reforms close to being finally implemented and last year’s Plastic Packaging Tax (PPT) already taking effect.

EPR FEEDBACK SOUGHT

With what the company describe as “once in a generation packaging” Extended Producer Responsibility (EPR) reforms close to implementation, environmental compliance data specialists at Ecoveritas are seeking to canvas the opinion of its client base and the wider packaging sector. 2023 is set to be the year EPR is finally lined up to go, meaning that the packaging sector is on the cusp of securing the much-needed confidence to support its transition to a world beyond waste, feel Ecoveritas.

EPR’s implementation has moved at a glacial pace, owing to the lengthy consultation process started in 2019 and the decisions made by government based on the responses, not to mention the delays caused by the pandemic and political turmoil, they claim. And with some producers still confused and, at worst, completely oblivious of what’s coming their way, Ecoveritas adds that it is committed to gauging the mood of those on the frontline.

“Whilst we accept it is our duty as a sector to communicate and communicate, we must ensure we have the necessary tools to help businesses navigate this significant change transition,” says the company’s global EPR director, Andrew McCaffery.

“The whole process has been plagued by uncertainty, and what we’re seeing at ground level is overwhelmed producers realising just how much time and resource will be needed to scale up their data management process to comply with the new regulation requirements.

“With required actions under EPR finally underway, some four years after it was announced by government in the Resources and Waste Strategy for England, outlining how the new regulation will work in practice for UK businesses that need to comply with this new legal requirement must become our priority.

“We must now move beyond discussing its merits and instead help businesses unpick the intricacies in already challenging times.

“We’d encourage anybody affected to take a few minutes to note down your thoughts, or make your voice heard.

“The online obligation checker and convening a business readiness forum are proof that coherent messages are heard, and that is what we’re looking to provide by understanding the anticipated pain points and contributing workable and accessible solutions.”

Their short survey comprises 11 key questions with Ecoveritas encouraging key businesses and media outlets to share far and wide (http://tiny.cc/gzf3vz).

REDUCING CONTAMINATION

In response to the Confederation of Paper Industries’ effort to reduce contamination in the paper waste stream from plastics, ProAmpac have devised their RAP solution - a complete line of fibrebased food to go packaging.

Comprised primarily of carton board, ProAmpac’s RAP products can have film linings that are easily removed from the packaging and meet the 90/10 ratio of board to film target for OPRL labelling as Recycle, say the company.

Beyond meeting the 90/10 goal, ProAmpac says that it is working toward 100% fibre packaging with their RecycAll packaging product. So far, RecycAll has been market tested for sandwich wedges, and soon, ProAmpac will be introducing trays for hot and cold food and grab bags for high-end sandwiches and bakery products.

“ProAmpac continues innovating to meet future legislation with a goal of 100% fibre packaging for food to go,” says Graham Williams, senior vice president, ProAmpac.

BANS AND TAXES

The Plastic Packaging Tax (PPT), introduced last April, alongside various single-use plastic bans have put the emphasis onto seeking alternatives to plastic, and packaging suppliers are working hard to introduce more, and better, sustainable options.

“While sandwich bars and food to go operators value the opportunity to enhance their environmental credentials, more effort is needed to educate customers about how best they should dispose of each packaging type at end of life,” says Celebration Packaging managing director, Nick Burton.

“The national recycling system is inadequate, with different councils adopting different systems, leaving the public confused, and recycling targets missed.

“We created the EnviroWare® brand over 14 years ago and continue to introduce and recommend a wide variety of sustainable packaging options, made from paper, bagasse, and wood. With plastic packaging, we are focusing on using recycled PET (r-PET) with a minimum content of 30% to both avoid the PPT and supply a more sustainable product.”

Single-use plastic items were banned in Scotland last June, and in September the Welsh government announced the Environmental Protection – Single-use Plastic Products – Wales Bill. On 14 January 2023, following a long consultation, the Department for Environment, Food and Rural Affairs (DEFRA) announced that a range of single-use plastics will be banned in England from October 2023.

The ban in England covers items including single-use plastic plates, trays, bowls, cutlery, balloon sticks and certain types of polystyrene cups and food containers. It also applies to items made from bio-based, biodegradable or compostable plastic. However, the ban will not apply to plates, trays and bowls used as packaging in shelf-ready, pre-packaged food items, as these will be included in the government’s plans for extended producer responsibility scheme.

While there is a clear desire to use more sustainable packaging, the cost is often higher than traditional packaging. Customers who continue to use plastic packaging find that it can be cheaper to buy virgin plastic and pay the PPT, than it is to use recycled plastic products – because of the rising cost and limited supply of recycled plastic resin, point out Celebration.

A MISSED OPPORTUNITY?

“The PPT was very rushed and ill-conceived, and the government missed an opportunity to promote the use of reusable plastic products, which make an important contribution to reducing the use of plastic,” says Nick Burton.

“The rushed implementation, with little publicity, means a significant number of obligated suppliers are not aware of the PPT and have not registered for it.

“The stated aim of the PPT was ‘to increase the use of recycled plastic in packaging’, but there is a lack of clarity around reusable packaging, as while plastic storage boxes are exempt, the tax still applies to reusable foodservice packaging. The tax is applied on a weight basis, and to be serviceable, reusable packaging is generally thicker and heavier. However, one of our restaurant customers is saving many tonnes of plastic a year by using our recyclable microwavable reusable portion packaging, instead of single-use plastic packaging. It seems a significant opportunity has been missed by not considering reusable items.

“If foodservice operators are looking to improve their sustainability credentials or understand the issues created by the PPT, they need to work with a consultative supplier to ensure that they’re choosing the right packaging – that’s functional, fit for purpose, popular with consumers and above all, sustainable.”

MEETING DEMANDS

While differing views and opinions persist on the best way to tackle the problem of waste packaging, in the meantime the demands on food service operators are ever increasing as they adapt their offering to meet the varied needs of consumers themselves, as well as legislation.

As a UK-based designer and manufacturer of food packaging, Colpac, for instance, reports that it is now working with many operators within the sector to create food to go packs which further support these evolving trends.

“Above all, due to our UK-based manufacturing facility, Colpac is able to remain agile and adapt its ranges to suit specific needs. These include sustainable sourcing, recyclable and compostable materials, bespoke printing, efficient storage, ease of fill, and maximising shelf density. Remaining flexible and understanding the complexities of packaging material is paramount as foodto-go trends are unlikely to stay stagnant,” says Kate Berry, Colpac’s head of marketing and product.

Working with a food to go producer who supply a British bakery chain, the packaging company utilised its Stagione® range to create a flexible solution. Versatile to work across all areas of the supply chain, Stagione is suitable for chilled displays, as well as being able to meet the complex needs of hot hold cabinets and microwaves.

Requiring a pack to suit its salad range, which included both hot and cold elements, the food to go producer selected Stagione, which comes in nine different sizes. Colpac then worked with its customer to incorporate a sleeve which would clearly depict the brand and detail the ingredients within.

As consumer trends continue to influence the food to go sector, having versatile packaging is essential but of equal importance is having the ability to offer customised packs through sleeves and wraps which can help differentiate a brand on the shelf, propose the company. For example, the leakproof Stagione pack features a PP lid, giving a secure closure to retain heat, whilst providing ventilation to let out condensation. Delivered nested and with a rigid construction, the pack provides efficiency of storage too, as well as excellent stacking and shelf density for merchandising. A stackable packaging option was a requirement of another Colpac customer, who manages a franchise chain of food to go shops. Rigid in design and nestable, Colpac’s multifood pots were selected by this customer to showcase the quality of its high-end, fresh salads. Offering leak resistance, even from oily dressings, the multi-food pots have a PE coating providing a barrier to moisture and grease. With a large surface area, each pot is fitted with a clear, secure, anti-mist lid. This high level of visibility was vitally important to the customer, as it provided their consumers with an excellent view of the fresh salad within.

While available in kraft material, the customer chose a white finish for the multi-food pots as their brand was printed on the exterior of the packs, offsetting the vibrancy of the salads. Underpinning both packaging solutions, was the need for recyclable materials to meet sustainability goals. While consumer demand for environmentally friendly packaging is driving innovation in the sector, legislation is making it a necessity too. Colpac’s Stagione and multi-food pots are manufactured from FSC® certified paperboard and are in line with OPRL 2023 guidelines for recyclability, say the firm.

Food trends and consumer demand will inevitably evolve, and choosing the right packaging requires partnership with a manufacturer that can meet supply chain and point of sale requirements, along with the materials and waste expertise to support environmental goals and legislation.

Last year, Luton-based Seal Packaging (Seal) was acquired by experienced industry professionals Kevin Curran, Sally Gabbitas, and Kevin Prosser, as a vehicle to launch new ranges of innovative and sustainable packaging. With the motto ‘Packaging with integrity’, Seal says that it is aiming to help their clients achieve net zero by ensuring the sustainability of its products’ raw materials, usage, and end of life, to protect the environment.

NOT STRAIGHTFORWARD

“Being ‘environmentally friendly’ is not entirely straightforward,” say Kevin Curran and Sally Gabbitas.

“We need to consider how materials are sourced, how they are transported, what alternatives may be available, can the final product be recycled and can the final product be composted? But can we go further? If a product can be composted, how likely is that to happen? In theory, this may be the most environmental approach, but if the infrastructure is not available then perhaps a recyclable option is more sustainable.

Birleys was one of the first to adopt Seal’s Compostabowl.

“Our role here at Seal is to advise and help our clients navigate the vast number of options to work together on the right packaging approach that is affordable, practical, ethical and sustainable.”

Seal have already launched several new innovative products, including the Itsnotpaper bag range – a viable and sustainable alternative to traditional paper bags, claim the company. Itsnotpaper bags look, feel and handle like paper, but not one tree has been chopped down to make them and are set to revolutionise the UK and world bag markets over the next few years, claim Seal.

“By using renewable sources such as agri-fibres as a raw material, instead of wood, the production of Itsnotpaper bags have up to 38% less carbon emissions than conventional paper bags,” says Sally Gabbitas.

“They contribute to a reduction in deforestation, and the material used has so far saved more than a million trees. The agri-fibres we use to make the material for Itsnotpaper bags are abundant and renewable. By turning what would otherwise be waste into a valuable resource, we are supporting communities in India by paying farmers for something they previously burnt, causing air and land pollution.”

Itsnotpaper bags are made in the UK, and the material used to make them has been through a rigorous Life Cycle Assessment to ensure that it is sustainable, end to end, say Seal. They can be printed just like conventional paper bags and behave in the same way, with the same flexibility and wet-strength.

“In fact, to sight and feel, you cannot tell the difference,” says Sally Gabbitas. “This is the first time in my career that I’ve been able to promote a product which is certified marine degradable. Add to that the fact that Itsnotpaper bags are 100% recyclable and can be recycled in conventional paper recycling streams, and that we also have 100% compostable certification, makes these innovative bags a genuine sustainable alternative to traditional paper bags.”

London-based award-winning sandwich and salad bar chain, Birleys, was one of the first to adopt Seal’s Compostabowl™, which combines a high-quality bagasse bowl with an optional high-clarity lid made from 100% recycled and 100% recyclable rPET. Bagasse is an abundantly available, natural and sustainable plant-based material that can be used instead of traditional foodservice packaging materials, and Compostabowl is certified to TÜV Austria (S0086) – the highest standard for home compostability.

Also available are Flustix and home-compostable certified plastic-free paper cups which are recyclable, repulpable, and biodegradable. Living up to its ‘Packaging with integrity’ mantra, many more sustainable food to go packaging solutions are already in the pipeline, report the firm.