Colman’s Meal Makers

Meal Makers 100% recyclable paper-based pouch / Source: Colman’s

EuropeFood & BeveragePackagingPaper

5 MINUTE READ

Nadine Smith

WHAT WE SAY:

When food industry giants, such as Unilever, start moving away from plastic, we know we are heading in the right direction. By swapping plastic composites for paper across its Meal Maker range, UK brand Colman’s has turned a product, which was virtually impossible to recycle into one that can be recycled kerbside.

It is a big win for waste-conscious consumers but there is one serious sticking point: it is not plastic free. By including a thin plastic layer, Unilever missed a huge opportunity to flex its significant influence and lead by example. Let us hope they do not rest here.

KEY FACTS:

Colman’s is swapping plastic pouches for recyclable Paper packaging, across its Meal Makers range in the UK and Ireland.
Unlike the original composite packaging made from plastic, aluminium, and paper, its new pouches are suitable for kerbside recycling in the UK, joining the household paper waste stream.
The coinciding redesign highlights end-of-life recyclability to consumers via the inclusion of the On-Pack Recycling Label (OPRL), recognised by more than three in four consumers.
Colman’s new pouches are not entirely plastic free, sadly. They have a paper content of 85% and an “ultra-thin functional plastic layer” that acts as a seal and barrier protection. Despite the fact that there are plastic-free innovations on the market, both Mondi and Unilever’s R&D teams claimed this mix was the minimum acceptable level of protection to ensure a long shelf-life and prevent food waste. The liner does not impact the recyclability of the pouch.
Unilever-owned Colman’s trialled the packaging with its Sausage Casserole flavour in 2021. By May 2022, 10 of the 19 classic Meal Makers recipe mixes in the Colman’s range were available to Tesco shoppers in the new paper-based packaging. The company has committed to making all Meal Makers packaging fully recyclable in 2022.

The new sausage casserole packaging design / Source: Colman’s

A Mondi working forest / Source: Mondi

DIVE DEEPER:

Every year in the UK alone, more than 10 billion composite food pouches are sold, but less than 0.005% are recycled. Two-thirds are sent to landfill sites and almost all the rest are incinerated. The recycling rate is 50 times worse than single-use coffee cups.
Although the technology exists to separate laminated material, it is not an economically viable process, costing an estimated GBP 53 (USD 63) per tonne, or more. According to WRAP, the net revenue from recycling laminated packaging may be lower than the cost of separation.
In creating an aluminium-free, paper-based pouch, Colman’s has ensured kerbside recyclability in the existing UK paper waste stream. The switch has the potential to save over 220 tonnes of material from landfill annually.
The pouch was developed in collaboration with packaging and paper solutions company Mondi. From the drawing board to implementation, the project took just over one year, demonstrating the opportunity within the industry for rapid change.
The move echoes a wider commitment by Colman’s to reduce its environmental impact, including increasing the sourcing of raw ingredients for products from within the UK. Parent brand Unilever has an environmental commitment to convert its entire packaging portfolio into recyclable, reusable, or compostable solutions by 2025. It plans to halve the amount of plastic used in its packaging by the same year.
The new Meal Maker packages currently retail at GBP 0.65 - 0.90 (USD 0.80 - 1.15) in UK supermarkets, including Asda, Tesco, Morrisons and Ocado.
Mondi has over 100 production sites across more than 30 countries. It produces six million tonnes of paper and pulp annually, and manages 2.7 million hectares of forests. 78% of its revenue comes from products that are reusable, recyclable or compostable.

"We are delighted to partner with Mondi, to develop this...paper packaging, becoming the first big brand within the category to do so. The new packaging...ensures that shoppers can enjoy the same great-tasting product...with the added benefit of [recycling]."

Fikerte Woldegiorgis - Foods Marketing Director, Unilever UK&I

Key Design Considerations:

Plastic pre-conceptions

Both Unilever and Mondi claimed they could not develop a plastic-free product, however products, such as Sirane’s heat-sealable Earth Film and MM Kotkamills’ Isla barrier solution prove that better, food-safe solutions are out there and commercially viable.

Recyclability after use

As with all food-contact materials, consider how contamination from the product can affect the recyclability. Does the product require cleaning to remove residue powder before entering the recycling steam? How can you communicate that?

Traceability of paper sources

100% of Mondi’s wood is sourced from responsible sources, with FSC and PEFC certifications. Working with manufacturers, which prioritise responsible sourcing should be one of your main focuses when switching to paper-based products.

The future of paper-plastic composites

The recyclability of paper-plastic composites relies on a minimal quantity of plastic entering the recycling system. As more packaging moves to paper-plastic replacements, consider how this will affect the makeup of the paper recyclate as a whole. The more plastic we add, the lower quality of recycled paper we will get.

Communication is everything

With all material substitutions where the product is familiar, be sure to highlight material change to consumers so they are aware of the new end-of-life potential for the material. If these pouches end up in the landfill, they will contribute to toxic methane emissions.