Recent packaging innovations have primarily been focused on sustainable packaging formats and solutions that are focused on incorporating renewable or recycled content, reducing packaging use and making packaging formats compostable or recyclable.

Hugh Crouch, flow wrap packaging product manager for Taunton, Mass.-based Harpak-Ulma Packaging, continues to see a continued push for sustainability heading into 2025, especially thinner films for the different market segments.

“The need to maintain throughput with the newer films is the key to efficiencies,” he said. “These require testing across the many different machine platforms — flow, vertical, thermoforming, tray sealing and stretch tray over wrap.”

And while many consumers are asking for more recyclable and composting packaging, there are difficulties in meat and poultry packaging due to the required shelf life and keeping the throughput for efficient production.

“Meat and poultry require specific film structures and the struggle for recyclability or compostable options plays into the overall picture for reducing product waste,” Crouch said of supplier challenges. “The consumer push for sustainability has to include the shelf life discussion. Our goal is to help our customers reach their goals for sustainability.

“We are continuously testing the newer films and adjusting designs where possible to help make the films machinable to keep the production efficiencies.”

As manufacturers, retailers and consumers seek more sustainable options for meat and poultry packaging, so too is the packaging industry shifting toward circular material choices and lightweight options.

In response, the relationship between film and equipment continues to drive innovation for the protein processing industry. Producers are looking to lower total packaging costs while boosting performance.

“Key performance indicators such as throughput, first-time quality and labor requirements can measure the impact that advanced automation equipment like Amcor’s Moda Packaging Solutions can deliver and help processors improve the bottom line,” said Matt Peterka Sr., director of R&D for Oshkosh, Wis.-based Amcor Flexibles North America. “Shrink bag and flow-wrap, like Amcor Flow-Tite, provide the multi-layer engineered film structures that ensure product safety, quality and are more sustainable.”

Packaged deli meatKorozo Group specializes in flexible packaging and film products for meat and poultry. (Source: Korozo)



Sustainable Mindset

Sustainability can be addressed in a number of ways, Peterka noted, such as through materials science. Packaging films and bags can be engineered to be recycle-ready for both mechanical and advanced recycling technology, or light-weighted such as Amcor’s Eco-Tite shrink bags which are 29% thinner than conventional shrink bags.

James Diprose, food flexibles business unit director at Istanbul-based Korozo Group, noted meat and poultry are some of the most demanding food packaging applications, requiring sophisticated solutions that optimize preservation and presentation.

At the same time, demand for more sustainable packaging is increasing.

“This trend must be balanced with the need to meet and exceed requirements around product protection, shelf life, and food safety,” he said. “As a result, the latest and greatest innovations in flexible packaging offer the necessary barrier properties and high product protection for meat and poultry applications. These innovations can be used in place of rigid plastics and other difficult to recycle packaging structures.”

One example of this in action is the use of fiber-based trays to replace polystyrene.

“When combined with a high-barrier skin film, pack constructions are created that enable food manufacturers to move away from harder to recycle rigid plastic trays while maintaining product protection and integrity throughout the supply chain,” Diprose said.

Pouches and vacuum-packed bags are also becoming more popular for meat and poultry thanks to their versatility and cost-effectiveness.

“Another significant trend is a move to value added proteins in vacuum packaging formats,” said Joe Lambert, vice president food marketing for Charlotte, NC-based Sealed Air Corp. “The packaging innovation in this space is focused on features like reclosing, portioning and case presentation.”

The industry perspective

In December, leaders from the packaging world spoke on the Meat Institute’s webinar, “Achieving Sustainability Goals: The Role of Recycling Programs and How to Incorporate Corrugated Packaging.”

Sean State, president of Pratt Recycling, a subsidiary of Atlanta-based Pratt Industries Inc., emphasized the importance of conducting waste audits to identify recyclable materials and starting with easy wins to build momentum in recycling initiatives.

For instance, State championed a closed-loop system in Pratt’s packaging operations, where packaging materials are created from 100% recycled content. The company collects used corrugated boxes and other recyclable materials, processes them at their facilities, and transforms them into new packaging solutions. This model not only minimizes waste but also supports a sustainable supply chain for businesses looking to reduce their environmental footprint.

Also during the webinar, Joe Lennon, director of strategic sourcing at Hudsonville, Mich.-based Kent Quality Foods, discussed how its recycling programs have resulted in significant cost savings and additional revenue, highlighting the role of sustainability in attracting larger customers. Additionally, Jason Glenn, corporate sustainability director at Maple Leaf Farms, underscored the need for measurable data to substantiate sustainability claims and the importance of building a corporate sustainability culture across all business divisions.

The panelists suggested companies should conduct thorough assessments of their existing waste streams, start small and celebrate early wins to build internal advocacy for sustainability initiatives, invest in data collection and analysis to demonstrate the impact of recycling efforts and collaborate with recycling experts to navigate more complex recycling challenges.

Grass fed beef round steakAmcor packaging solutions are fully compatible with QR and serialized-QR codes. (Source: Amcor)



Intelligent tech

One thing expected to take off in 2025 is a stronger focus on smart packaging technology. For instance, Amcor packaging solutions are fully compatible with QR and serialized-QR codes to track packages throughout distribution and enable brands to communicate directly with consumers.

“The Amcor Moda Vac rotary vacuum packaging equipment is now enabled with the DSS digital seal system which customizes the sealing variables for each discrete package as it is formed,” said Jamie Key, Amcor’s executive strategic advisor for protein. “This allows for varying the time, temperature and vacuum strength in real-time to optimize each package and cut. This results in optimized first-time quality results and fewer defects.”

Technologies such as time-temperature indicators (TTI), oxygen scavengers, and gas sensors are becoming more common across the sector to ensure product quality and freshness.

“Deeper in the supply chain, RFID and QR codes are already enhancing security and product integrity,” Diprose said. “This benefits consumers by giving them greater peace of mind about the provenance of their meat and poultry products, as well as helping to reduce spoilage and waste.”

Looking ahead, advanced manufacturing technologies like automation, digital printing, robotics and connected equipment are all expected to improve efficiency and service levels in the upcoming years.

“These technologies reduce the impact of changeovers and improve service levels by reducing lead times and efficient order quantities so packers can optimize, streamline and reduce their inventory,” Lambert said. “When applied to packaging processes, they are helping to maximize labor efficiency and improve the quality of jobs.”

The overall demand for sustainability across all categories is clearly shaping the meat and poultry industry. Packaging innovations will improve the industry’s sustainability credentials by simplifying recycling, with solutions like ready to recycle VSP helping to design challenging materials such as polystyrene out of the supply chain.