Fiber-based consumer packaging leader Graphic Packaging has partnered with food processor ABP Food Group (ABP) to develop two new lines of chilled meat packaging for UK supermarket giant Aldi.

The pressed board trays, developed for Aldi's core and premium steak lines, use around 90 percent less plastic when compared to the previous packaging format and were developed to support Aldi's goal of removing 2 billion pieces of plastic packaging from its supply chain by 2025.

A fiber-based solution designed with consumers in mind

The vacuum skin packaging (VSP) pressed board trays have been designed with an easy-peel film to promote recycling of the paperboard tray at home by consumers. The hybrid design means plastic is reduced to a minimum while still offering equivalent barrier performance and shelf life to traditional plastic trays. The trays were designed to ensure smooth running on ABP's packing lines, with no machinery investment or retooling required.

Create differentiation through design

To create differentiation between Aldi's core and premium lines, two trays were developed, one with brown kraft-look board, which was used for the premium 30+ day aged steak lines, and a second white option for the core lines. Both offer outstanding structural and barrier performance to cope with the rigors of the modern cold supply chain.

A smooth launch

The precision of the design process ensured operational efficiency and as a result, the ABP team described the whole project as one of the best launches they had seen on their production lines, saying it ran "like a Swiss clock".

Paul Tye, business development director for food & convenience, tray & cup solutions at Graphic Packaging, commented, "Everything we do is geared toward making our customers' transition from plastic into fiber-based packaging as seamless as possible, and we are so delighted that we were able to achieve that for ABP and Aldi."