A Colwick-based packaging giant has unveiled a major new innovation for the UK ready-meal food sector.
The new innovation called Greentrae, is an oven safe, MAP-sealable cardboard tray designed to reduce plastic use and make recycling far easier for consumers.
The Wilkins Group has spent several years developing the product in response to growing pressure on food manufacturers to move away from traditional plastic trays.
The business has produced board trays for more than 20 years, but Greentrae marks a significant step forward because it performs to the same technical standard as plastic while offering a cleaner, simpler recycling process.
Greentrae uses a sturdy cardboard base with a plastic liner that stays in place during cooking but peels away easily once the meal is finished. It means consumers can recycle the cardboard without any fuss, solving a problem that has frustrated the ready-meal / food market for years.
The tray is OM7 certified and suitable for MAP sealing / gas flushing. It can go in the microwave, freezer or oven, and offers the shelf life the chilled food sector depends on, helping to cut both packaging waste and food waste.
Justin Wilkins, Joint Managing Director of the family run firm, said the development had been driven by a desire to improve the environmental impact of ready meals / food packaging – an important staple for many busy families.
Justin said: “Plastic reduction has been a priority for us for many years, and we have always tried to stay ahead of the curve.
“Board formed trays are the natural long-term replacement for plastic trays, but it must perform just as well. Greentrae does that. It is MAP-sealable / gas flushable and stable in the oven, which many alternatives struggle to achieve.”
He said a visit to a recycling centre in Nottingham had been a turning point in the project.
Justin said: “It was a shock to learn how many packs labelled as recyclable never make it through sorting because the materials won’t separate. That is why we focused so heavily on ease of separation after cooking a meal. Consumers will be able to remove the liner cleanly after cooking, and retailers can add clear instructions so people know exactly what to do.”
Alongside the standard tray, the company has developed a skin-pack version with improved peelability, removing the need for scissors or a knife to get the product out – a common frustration for customers trying to cook food such as steak or fish.
The Wilkins Group is already in talks with major manufacturers and is preparing to scale up production at its Colwick headquarters, where capacity is planned to reach 30 million trays in its first year.
Justin said: “Food waste is a much bigger issue than many people realise, and shelf life plays a huge role in tackling it. Many current board trays bond too strongly during oven cooking, meaning the liner can’t be removed and the tray can’t be recycled. Greentrae solves that without compromising performance, meaning consumers can still enjoy delicious dinners without the guilt of throwing away plastic trays afterwards.”
The Wilkins Group produces packaging for brands including Pukka Pies, Pizza Express, Harrods and Cadbury. The firm is also behind several innovative and award-winning products, including eco-friendly coat hangers and the M&S light-up glitter gin bottles that have become a Christmas favourite. Earlier this year, the company won at the East Midlands Business of the Year Awards.
