Food packaging companies Faerch Plast and Colpac have joined forces with Bakkavor, the fresh prepared foods manufacturer, to develop an “exciting” new pack design for Tesco’s latest range of food-to-go products.
The eye-catching yet functional pots are produced from a combination of crystalline polyethylene terephthalate (CPET) and paperboard, which allows a choice of six meal options to be heated in store before being displayed in hot cabinets for purchase.
The latest dual-ovenable C-vis packaging concept, which is the result of a nine-month collaboration between the businesses, comprises a high-quality black CPET pot from Faerch Plast and Colpac’s biodegradeable paperboard outer sleeve and lid. In line with Tesco branding requirements, the packs are litho-printed with bold graphics by Colpac using specialist heat resistant inks.
Ideal for convenience and ready meal products, Colpac’s C-vis packaging solution was originally developed in 2012, firstly as a microwaveable option and then using Faerch Plast’s CPET pot to provide a dual-ovenable version. Utilising approximately 30% fewer materials than a standard CPET sleeved product, the very thin inner and outer trays and paperboard or plastic lids are fully recyclable and supplied ready-assembled for reduced handling time and costs.
Although Colpac’s C-vis concept was readily available and well-established in the food-to-go market, a considerable amount of development work was involved in the project to determine the correct style and size of CPET pot, Faerch Plast said. With lightweighting a major focus, the container selected by Bakkavor measures 112.5mm in diameter and 85mm in depth.
In addition, Bakkavor had not used a paperboard packaging product before so needed to approve C-vis for use. As part of this process, numerous C-vis samples were supplied for extensive on-site testing, whilst Bakkavor’s production manager visited Colpac to ensure there were no potential contamination risks during the manufacturing process.
The pots are available in six different variants: porridge, macaroni cheese, bolognese pasta, chicken tikka and rice, chicken jalfrezi, and barbecue pulled pork with rice.
Once filled, the packs are film sealed and lidded, and distributed to Tesco retail outlets for heating in-store using either microwave or conventional ovens. They are then displayed in hot cabinets for purchase by the consumer, who simply removes the film and lid to eat the meal directly out of the pack.
Their launch will seek to capitalise on the “flourishing” food-to-go market and increasing demand for portable meal options, particularly during the breakfast and lunchtime occasions. As consumers buy products to consume off premises, retailers are beginning to demand new packaging formats that make eating on the move easier, while also reflecting the authenticity, quality and health credentials of the food, Farch Plast said.
The CPET trays, available in a variety of sizes, shapes and colours, offer temperature tolerance of between -20°C and 220°C. With the CPET tray, Denmark-headquartered Faerch Plast continued, there are no negative effects on the food’s flavour or aroma, ensuring consumers benefit from well-protected, more versatile and better tasting products.
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