Danish food packaging manufacturer Faerch Plast (Holstebro; www.faerchplast.com) has developed a “green” tray containing a minimum of 50% recycled plastic for Naturli’ Foods (Aarhus / Denmark; www.naturli-foods.dk), which makes plant-based foods. Faerch Plast worked with Naturli’ and NGO Plastic Change (Copenhagen / Denmark; www.plasticchange.org) to identify a sustainable and environmentally friendly packaging for the food manufacturer’s recently launched plant-based alternative to fresh minced meat.

Jesper Jensen, sales director North, ROW [Rest of World] & marketing at Faerch Plast, said they quickly determined that a tray containing a large amount of recycled plastic would be the ideal solution for Naturli’. All of the trays made with rPET have a top layer that serves as a function barrier for optimal food safety. By substituting virgin PET with rPET, Faerch Plast said CO₂ was reduced by 52%.

The company has also been granted a patent for a new tray design that enables ultra-low stacking. The design includes a secondary recess on the outer edge of the tray, which has lowered the stacking height from the current industry standard of 5 mm to 1 mm. For food manufacturers, a lower stacking height makes handling, storage and internal transportation increasingly effective.

“Three times as many trays can be stacked in the same stack, cardboard box and container. The low stacking height also reduces the need for internal transportation and storage by 67%,” said Jensen. He added that the design ensures the trays are produced in a uniform quality to enable flawless denesting, providing an effective and profitable production process.

Faerch Plast is currently reported to be in exclusive negotiations to acquire PSB Industries’ (Annecy / France; www.psbindus.com) thermoforming activities – see Plasteurope.com of 11.05.2018.