SPAR Austria has cut fresh meat packaging plastic by 70%[1], saving 14 tons of plastic annually, by switching from a traditional tray-and-lid packaging system to CRYOVAC® brand MonoPP Flowpack.
The packaging pilot at SPAR Austria’s TANN facility in Marchtrenk also saw the food retailer reduce CO₂ emissions by around 70%. Further analysis of the pilot is now underway to determine plans to roll out the CRYOVAC® packaging solution to other TANN plants and SPAR sites across Europe.
SPAR Austria decided to review fresh meat packaging ahead of the Packaging and Packaging Waste Regulation (PPWR) being phased in across the EU. Previously, it packaged fresh minced meat products using a tray-and-lid system and partnered with Sealed Air to explore the bold move of completely eliminating the tray.
Roman Auinger, Plant Manager at SPAR TANN Marchtrenk, explains: “Tray-and-lid systems have dominated fresh meat packaging for decades, offering product visibility and structural support. However, we wanted to look at packaging innovations that could support new regulatory requirements to reduce packaging material usage, while also addressing rising material costs.
“Working closely with Sealed Air, a tray-free solution was specified, CRYOVAC® brand MonoPP Flowpack, which has helped us to cut plastic by 70%, whilst keeping shelf life and line speed unchanged.”
CRYOVAC® brand MonoPP Flowpack features a range of flexible, high-barrier rollstock and films, which are certified as recyclable by Cyclos-HTP Institute and can integrate seamlessly with existing recycling infrastructure in countries with established PP recycling streams[2].
In the Marchtrenk pilot, the CRYOVAC® solution’s barrier performance matched conventional tray formats for the product range tested, maintaining equivalent shelf life without compromise. SPAR Austria maintained high-speed packaging of 44 packs per minute, without any increase in waste or reject rates. The reduction in packaging material usage means warehouse operations now require 176 fewer pallets per year, helping contribute to around a 70% reduction in CO₂ emissions[3].
Markus Zavec, Sales Director for Austria, Germany and Switzerland at Sealed Air, added: “SPAR Austria’s conventional tray-and-lid system was linked to escalating costs, including environmental, operational, and financial. The packaging consumed substantial material, required intense warehouse operations, and complicated recycling pathways. The pilot was a decisive and early move to address these challenges.
“In addition to reducing packaging material usage and CO₂ emissions, CRYOVAC® brand MonoPP Flowpack has also delivered wider brand benefits for SPAR Austria. Two-thirds of shoppers responded positively, appreciating the product visibility and ease of opening delivered by Sealed Air’s packaging solution.”
Roman Auinger, concluded: “Transitioning from established packaging formats involves operational, commercial, and consumer considerations that require thorough evaluation. Working in partnership with Sealed Air has enabled us to think carefully about such factors and find a solution where responsibility meets performance by evolving our packaging for the circular economy. With frameworks like PPWR emphasizing recyclability and material reduction, mono-material packaging solutions offer a more future-aligned pathway.”
[1] Based on the verified pack weight comparison (0.02 kg for MAP Tray + Film vs. 0.005 kg for MonoPP), the new packaging format uses 70% less plastic per unit. This improvement results in a yearly plastic saving of around 14 tons.
[2] Recyclability assessed according to CHI Cyclos-HTP Institute: The MonoPP material is compatible with flexible polyolefin recycling streams in accordance with European standards (EN 13430, ISO 14021).
[3] Proportional CO₂ reduction of 70% because of the tray elimination.