The meat packaging industry is advancing rapidly to meet consumer demands for longer-lasting, visually appealing and durable products, and continues to prioritize durability, shelf life and presentation in bone-in meat packaging.
Recent innovations include high-barrier, multi-layer films that offer excellent puncture resistance without sacrificing clarity, and enhanced shrink bags with integrated bone guard layers.
Andrew Birdwell, vice president of sales for Battleboro, NC-based Ossid, noted Vacuum Skin Packaging (VSP) is also being refined for bone-in applications, while smart packaging, including sensors to monitor product integrity, is gaining traction for premium cuts.
“Trends we’re seeing include a growing focus on extended shelf life and puncture protection, demand for tight-fitting, visually appealing packages and increased pressure to adopt sustainable, recyclable or reduced-plastic materials,” he said.
Ryan Spencer, product marketing manager for Kansas City, Mo.-based Multivac Inc., has also noticed a clear shift toward the use of MAP (Modified Atmosphere Packaging) trays for bone-in steaks.
“This approach helps minimize direct contact between sharp bones and the film, significantly reducing the risk of leaks and improving product integrity during transportation and display,” he said. “Other advancements in Multivac Certified films have also contributed to a higher success rate of packages withstanding sharp bones.”
Variable data printing is another technology making waves in customizable packaging for bone-in meats.
“This allows producers to include specific, dynamic content on each package, ranging from traceability information to personalized branding, which can enhance consumer trust and engagement,” Spencer said.
Reiser's packaging machines are equipped to use thicker films for bone-in applications. (Source: Reiser)Meeting demand
Bert Broos, director of packaging for Reiser, Canton, Mass., noted the company’s thermoforming or rollstock machines have always been able to run various packaging concepts such as vacuum, MAP, VSP and both flexible and rigid film on the same machine.
“Obviously, bone-in products can have sharp edges, which can cause cuts in the film and therewith leak packages,” he said. “The way the meat is being cut has a great influence on the sharpness of these edges. We see more and more packaging materials that can handle sharp bones up to a certain extent. In case of sharper edges, bone-guards are being used. Several film suppliers have developed unique materials with a high puncture resistance. These tougher materials can still be formed flawlessly on the Reiser Repak and Variovac thermoformers, due to the machine’s Rapid Air Forming system.”
Multivac has responded to recent trends by introducing its next-generation TX Series traysealers,which deliver efficient use of available production space while consuming fewer resources.
“This line represents a major advancement in packaging technology, setting new benchmarks in output, quality and user-friendliness,” Spencer said. “Advancements in material science have enabled the creation of films that offer exceptional puncture resistance without sacrificing clarity.”
Ossid’s machinery is built with flexibility in mind, allowing processors to efficiently run a wide variety of bone-in cuts and packaging formats with minimal downtime.
“We work closely with film suppliers to test new materials and provide recommendations for optimal runnability on our equipment — especially important for bone-in applications where puncture resistance and seal integrity are critical,” Birdwell said.
What’s more, Ossid equipment offers processors the ability to adapt packaging to a variety of bone-in meat cuts.
“CNC-machined sealing dies ensure a precise fit, even for irregular or bone-heavy shapes,” Birdwell said. “Our forming and sealing systems are designed to accommodate different tray sizes or film types with minimal downtime. When labeling or date coding is required, we work closely with other ProMach brands to integrate the right solution for each unique packaging line.”
Diana Courtepatte, director of marketing for Montreal-based TC Transcontinental Packaging, said the greatest challenge for bone-in meat packaging is to provide excellent puncture protection while also presenting the most visually appealing product possible.
“Consumers will always choose the most visually appealing piece of meat in the case, and packaging is a major part of achieving that look,” she said. “TC’s Clearshield shrink bags utilizes patchless technology, which reduces the overall thickness of the bag, as compared to a traditional patch bag, providing outstanding gloss and clarity, without sacrificing any puncture resistance or barrier.”
Automation Innovation
Increased efficiencies, reduced labor costs and consistent results are factors that make automation an important element to the evolution of the meat packing industry.
TC Transcontinental has introduced its TC AB490 In Line Autobagger machine, which allows customers to create Clearshield bone-in bags on demand, directly on their packing lines.
“The TC AB490 is fed with rolls of Clearshield tubestock, and cuts and seals bags to the specific length and quantity needed,” Courtepatte said. “The AB490 is also capable of printing EST/SH instructions, date/time information and company/product logos inline.”
For Multivac, automation plays a significant role in improving both efficiency and hygiene.
“Tasks such as loading and positioning products in trays, once labor-intensive, can now be handled by high-speed pick-and-place robotic systems,” Spencer said. “These solutions increase throughput, reduce labor cost and enhance food safety by minimizing human contact.”
Durable packaging provides the flexibility to contain multiple bone-in products, including lamb chops. (Source: Ossid)Online Grocery
The popularity of online grocery shopping has influenced the development of new packaging technologies for bone-in meats, but it’s also presented some issues. While a leaky package in-store may simply remain on the shelf, one delivered to a customer can damage surrounding items and require a costly replacement.
“Online grocery has introduced new logistical challenges for bone-in meat packaging,” Birdwell said. “Packages now need to withstand longer shipping distances, more frequent handling and varying temperatures during distribution to consumers. Our machines support packaging formats that deliver strong seals and puncture resistance, helping protect product integrity through the entire supply chain.”
A Sustainable Mindset
Companies today are addressing sustainability in bone-in meat packaging without compromising the integrity and aesthetics of the product.
“We’re evaluating machine compatibility with recyclable and mono-material films, helping customers align with sustainability goals while maintaining operational performance,” Birdwell said.
For instance, Ossid machinery is compatible with a variety of sustainable packaging materials, including thinner high-performance films that reduce plastic usage and mono-material structures suitable for recycling.
“We also support the use of water-based inks for direct-on-film printing, which can eliminate the need for additional labels and reduce overall packaging waste,” Birdwell said. “When customers require only a simple code date, we coordinate with other ProMach brands to provide efficient coding solutions tailored to their sustainability and operational goals.”
Broos noted the Reiser Rapid Air Forming system allows for a better film thickness distribution, creating stronger corners and in many cases allowing customers to use thinner forming films.
“Besides financial benefits, the amount of material is reduced, contributing to the goal of less plastic,” he said.
Innovation continues to transform the way bone-in meats are packaged, ensuring greater freshness, safety and consumer appeal for years to come.
