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BASF and Confoil jointly develop certified compostable double oven trays for ready-to-eat food packaging

Company News > BASF and Confoil jointly develop certified compostable double oven trays for ready-to-eat food packaging

BASF and Australian food packaging manufacturer Confoil have teamed up to develop a certified compostable paper food tray for dual function ovens. The inside of the paper tray is coated with BASF's ecovio® PS 1606, a partially bio-based, certified compostable biopolymer designed for the production of coatings for paper or cardboard food packaging. Called DualPakECO®, the trays are certified to Australian Standard AS4736-2006 and certified for food contact according to international requirements. In addition to being used in ready-to-eat meals such as lasagna, curries and stir-fries, they can also be used in cold or frozen meals in supermarkets, and even in catering and restaurant takeaways.

The trays can be recycled organically, extending the life of the paper packaging: they can be commercially composted with organic waste collected in organic waste bins. As a result, new packaging solutions for the recycling of food scraps and organics stained with food packaging increase the diversion of food waste from landfills and incinerators.

BASF and Confoil jointly develop certified compostable double oven paper trays for ready-to-eat food packaging

Replacing PET with sustainable benefits

This new certified compostable solution is an alternative to conventional PET packaging for ready-to-eat meals. Not only can this tray be heated in conventional ovens and microwaves, but it can also be refrigerated or frozen. They have excellent barrier properties to fats, liquids and odors, helping to maintain food freshness and taste. Alison Buxton, CEO of Confoil, said: “We wanted to create a paper food tray that met all food industry requirements, with the added benefit of being certified compostable. Biopolymers certified compostable by BASF With ecovio® PS 1606, we have found the ideal ingredient to take the next step in sustainable solutions for our product portfolio, while helping customers achieve their sustainability goals. Our joint development represents the A shift in composting materials to support Australia’s National Plastics Plan, which aims to reduce the environmental impact of packaging by 2025.” Composting trials have shown that DualPakECO® pallets decompose within four to six weeks under commercial composting conditions A compound fertilizer rich in water, carbon dioxide and nutrients.

ecovio® PS 1606 extends the life of paper applications

The paperboard used for DualPakECO® can be easily formed and allowed to be printed. The board is lightweight and rigid, making it suitable for in-line production equipment. It also provides a secure seal on a variety of film substrates and machines. The trays are coated with ecovio® PS 1606 in a single layer extrusion process. Due to the excellent mass transfer and barrier properties of BASF biopolymers, it is also possible to use recycled paper in food applications. The high content of renewable raw materials leads to a reduction in the carbon footprint of the material, which can lead to savings in greenhouse gas emissions. Rowan Williams, Biopolymers Market Development at BASF, said: “Composting is the most resource-efficient food waste recycling process. This packaging solution supports a circular economy as it helps keep food waste and food-laden packaging out of landfills. The PET food trays currently on the market cannot be reused, they are difficult to recycle mechanically and are not economical, so in real life they are mostly landfilled or Incineration. We found the ideal partner, Confoil, to work together to develop a solution that proves it is feasible to produce food packaging that combines sustainability with high-tech performance.”

ecovio® PS 1606 can be applied to containers with cold or hot contents, as well as bowls and dishes with dry, solid, liquid or fatty contents. BASF offers ecovio® grades for extrusion coating and lamination technology. Combining ecovio® grades based on paper or cardboard also provides compostable solutions for home and industry.

Market presentation at the Australian Organics Recycling Association Conference

The DualPakECO® tray was launched at the Australian Organics Recycling Association (AORA) 2022 Annual Meeting in Glenelg, Australia. AORA President Peter Wadewitz said at the event: “Australia’s standards are some of the most stringent in the world for compostable plastics. Commercial composting is an integral part of a circular economy, where organic waste can be turned into a valuable resource instead of going to landfill. Or incinerated. Compost from organic matter recycling can be used in agriculture to improve degraded soils and return organic matter to the soil, ensuring future productivity.”

New packaging solutions are available for organic recycling, such as Australia's FOGO (Food Organics and Garden Organics) recycling service. This is a curbside recycling service that allows food scraps to be added to the garden bin so they can be recycled into high-quality compost. Through the National Waste Policy Action Plan, Australian states and territories committed to increasing FOGO recycling services and agreed to roll out the service to all households and businesses by the end of 2023.

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BASF and Confoil jointly develop certified compostable double oven trays for ready-to-eat food packaging

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