Confoil and BASF cooperate to develop certified compostable dual ovenable paper tray for packaging of ready-to-eat meals

The Australian food packaging manufacturer Confoil and BASF have cooperated to develop a certified compostable and dual ovenable food tray based on paper. The paper tray is coated on the inside with BASF’s ecovio® PS 1606, a partly bio-based and certified compostable biopolymer especially developed for coating food packaging made of paper or board. The trays called DualPakECO® are certified according to the Australian standard AS4736-2006 and food contact approved according to international requirements. They can be used for ready-to-eat meals like lasagne, curries and stir-fries available as cold or frozen in supermarkets as well as for catering and take-away from restaurants.

The trays extend the end-of-life options for paper-based packaging by being organically recyclable: They can be commercially composted with the organic waste collected in organic waste bins. Thus the new packaging solution supports organics recycling of food residues and food-soiled packaging which increases the diversion of food waste from landfill and incineration.

Alternative to PET plus sustainability benefit
This new certified compostable solution is an alternative to conventional PET packaging for ready-to-eat meals: The trays can be heated in conventional ovens and microwaves, can be chilled or frozen. They show excellent barrier properties against fats, liquids and odors helping to preserve freshness and flavors. “We wanted to create a paper-based food tray that meets all the food industries’ requirements but with the added benefit that it is certified compostable”, said Alison Buxton, CEO of Confoil. “With BASF’s certified compostable biopolymer ecovio® PS 1606 we have found the ideal component to take the next step towards sustainable solutions in our portfolio and to help our customers reach their sustainability targets at the same time. Our joint development represents a shift to paper-based and certified compostable material in order to support the Australian 2025 National Plastics Plan which aims at reducing the impact of packaging on the environment.” Composting trials have shown that the DualPakECO® trays break down into water, carbon dioxide and nutrient-rich compost within four to six weeks under commercial composting conditions.

ecovio® PS 1606 extends end-of-life options for paper applications
The paperboard for DualPakECO® can easily be formed and allows for printability. The board is lightweight yet rigid enough for in-line production facilities. It also offers secure sealing across a variety of film substrates and machinery. The paper tray is coated with ecovio® PS 1606 in a mono-layer extrusion process. Due to its excellent migration barrier properties the BASF biopolymer also enables the use of recycled paper in food applications. The high content of renewable raw materials leads to a reduced material carbon footprint, which allows savings of greenhouse gas emissions. “Composting is the most resource-efficient process for food waste recycling”, said Rowan Williams from Market Development Biopolymers at BASF. “This packaging solution supports a circular economy as it contributes to the diversion of food waste and food-soiled packaging from landfills and incineration, thus avoiding associated greenhouse gas emissions. Currently available PET food trays are not reusable, they are difficult and uneconomical to recycle mechanically – so in reality they mostly go to landfill or incineration. With Confoil we found the ideal partner to develop a solution that proves the feasibility of a food package that combines sustainability with high technical performance.”

ecovio® PS 1606 can be used in applications with cold or hot contents as well as for bowls and plates with dry, solid, fluid or fatty contents. BASF offers ecovio® grades for both extrusion coating and lamination technology. Depending on the ecovio® grade used in combination with the type of paper or board, home and industrial compostable solutions are possible.

Market introduction at the Australian Organics Recycling Association Conference
The DualPakECO® trays were introduced to the market at the Annual Conference 2022 of the Australian Organics Recycling Association (AORA) in Glenelg, Australia. On this occasion, the chairman of AORA, Peter Wadewitz, said: “The Australian standards are the most stringent ones for compostable plastics in the world. Commercial composting is an integral part of a circular economy where organic waste can be turned into a valuable resource rather than be disposed of in landfill or incinerated. Compost from organic recycling can be used in agriculture to improve degraded soils and return organic matter to soils ensuring future productivity.” The new packaging solution is suitable for organics recycling such as the Australian FOGO (Food Organics and Garden Organics). This is a kerbside collection service that allows food scraps to be added to the garden waste bin so it can be recycled into high-quality compost. Through the National Waste Policy Plan, Australia’s states and territories have committed themselves to increase FOGO collection services, agreeing to introduce them to all households and businesses by the end of 2023.