Replacing non-recyclable black plastic: Development of the first fully compostable, oven-proof, long shelf-life tray for ‘ready-meal’ and modified atmosphere packaging

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"**AMBITION**Our aim is to reduce and replace the use of black non-recyclable plastic for modified atmosphere packaging for ready-meals and ambient food items with development of a natural, fully compostable alternative packaging technology.Over 1.3 billion black plastic trays are used in the UK each year (~10 billion globally- [Greenpeace][0]) however low recycling rates (45% plastic recycling rate UK; 9% globally-Defra;2018) and the inability of IR recycling plant sensors to the colour black mean that 99% of black plastic food trays end up in landfill, or even worse in the ocean.Although work is being done to increase the recyclability of black plastic, high recycling costs coupled with low recycling rates mean that what is needed is move away from plastic all together, towards natural, sustainable alternative materials.**FOCUS**Working with a strong consortia of sustainable packaging and manufacturing experts, the project focuses on design and development of a fully compostable (6 weeks), heat-resistant (up to 240oc), microwavable and freezable food tray with unique biopolymer coating using seaweed algae and corn starch to provide up to 21 days atmospheric protection for ready-meal and ambient raw meat/fish market.Made solely out our natural materials, the tray will be designed and tested using a number of FSA (UK), EU and FDA (US) approved protocols to ensure it meets the required oxygen transfer, water vapour transfer, temperature, disease and thickness requirements of each food safety agency and target food producer customers**SIGNIFICANCE**Despite an increased focus on reducing plastic waste and significant consumer and supplier demand, the technical challenges associated with replacing black plastic with natural alternatives for modified atmosphere food packaging have not been solved. Our strong biopolymer barrier technology therefore represents a step-change in the industry, still dominated by black plastic.Furthermore as a fully-compostable solution, it is both significantly cheaper and easier to dispose of than recycled plastic alternatives.In line with UK GOVs 'Plastic Pact' 2025 commitment, all our materials are naturally-sourced and therefore have the potential to reduce the UK's reliance on plastics in this area significantly -- opening up a £32m turnover opportunity for us by Y5\. We have already been in advanced discussions with Iceland and Kerry Foods regarding early adoption of the technology when developed and see this as having global potential -- environmental friendly and significantly cheaper than developing new plastic recycling infrastructure.[0]: https://www.huffingtonpost.co.uk/entry/why-cant-black-plastic-be-recycled_uk_5b18f4e1e4b0734a993b00d0?utm_hp_ref=uk-lifestyle"