The global conversation about sustainability is louder than ever and at the heart of this dialogue is the impact of plastic waste. For years, the packaging industry has wrestled with the need to meet consumer demands for convenience while simultaneously reducing its environmental footprint. And, minced meat packaging, with its reliance on rigid plastic trays, has long been considered a culprit.

ULMA Packaging, however, is challenging the status quo with a fully recyclable package that reduces plastic usage by up to 70%. Brands can now imagine the rows of pre-packed meat we see in every grocery store without the clunky plastic trays. Instead, there’s a sleek, hermetically sealed flow pack that’s both visually appealing and environmentally friendly.

ULMA Packaging first introduced this innovative application in 2010 for the UK market, specifically for the Waitrose supermarket chain. Two ARTIC wrappers were installed and since then, the machines have been operating successfully. In an original press release, Waitrose highlighted the environmental impact of this packaging format, stating it would eliminate the need for trays and significantly reduce plastic usage – saving an estimated 90 tons of plastic waste annually.

‘Our goal at ULMA is to provide packaging solutions that meet the functional requirements of food preservation and significantly reduce plastic usage and waste,’ comments Eddie Rademan, managing director of ULMA Packaging Systems South Africa.

The next best thing in food packaging

At the core of ULMA’s innovation is the horizontal form fill seal (HFFS) technology. In simple terms, this system automates the entire process of forming, filling and sealing minced meat in a continuous motion, all while using a thin, flexible film instead of traditional rigid plastic trays. This film is typically recyclable, aligning perfectly with the increasing demand for environmentally responsible packaging.

By adopting ULMA’s flow pack solution, meat producers, retailers and packaging manufacturers can achieve multiple benefits that significantly enhance their operations. According to Eddie, this approach drastically reduces plastic waste, utilising up to 70% less plastic compared to traditional trays, making a substantial impact on environmental sustainability. ‘Additionally, the flow pack design improves shelf appeal, offering a modern and cleaner look that attracts eco-conscious consumers, thereby enhancing the product’s visibility on supermarket shelves.’ He continues: ‘Moreover, the gas-flushing and hermetically sealing feature extends the shelf life of minced meat and reduces food waste.’ Finally, the use of less plastic leads to lower packaging costs, resulting in savings down the supply chain that benefit producers and retailers alike.

‘The real game changer here is significant reduction in plastic usage and cost,’ Eddie enthuses. ‘Think about it: thermoformers are using around 400µm just for a 500g pack of minced meat. With our solution, we’re slashing that to 60µm. And, it doesn’t stop there. You can print all around the flow pack, minimising additional labels. There are so many compelling reasons why this is the future of meat packaging.’

At one point, there were concerns that the minced meat might fall apart in the packaging. Eddie says he visited the UK to inspect the packs at Waitrose. ‘I saw the solution firsthand. I picked one up and it’s genius – the wavy pattern holds everything in place – and a thin layer of wax paper underneath adds extra support. Together, they work like a charm. It’s an incredibly smart design.’

Sustainability and savings in one package

ULMA is deeply committed to sustainability, as reflected in its #ULMAweCare initiative, which drives the company’s eco-conscious mission. The packaging itself is made from mono-materials – whether polypropylene, polyethylene or PET – all of which are fully recyclable.

‘Our focus on recyclability is a major driving force and we’re also exploring innovations like monofilaments. Additionally, this solution drastically reduces plastic waste. It’s a straightforward, sustainable choice that aligns perfectly with the growing demand for eco-friendly packaging in South Africa,’ he asserts.

For retailers, the ULMA solution also opens branding possibilities. ‘The flexible film can be printed with high-quality designs, allowing for custom branding opportunities that help products stand out on shelves,’ Eddie adds. This visual edge, combined with the sustainability credentials, resonates well with today’s environmentally conscious consumers who prefer buying from companies that actively take steps toward reducing their carbon footprint.

A smooth transition

According to Eddie, one of the standout features of ULMA’s packaging system is how easy it is for producers to integrate it into their existing operations. The flow pack wrappers are designed to be compatible with current production lines, minimising the need for expensive overhauls or significant downtime.

For meat producers who are hesitant to change their packaging methods due to the perceived cost of upgrading machinery, ULMA offers a cost-effective and easy to implement solution. ‘The system is not only scalable for large operations, but also adaptable to small and medium-sized businesses looking to step up their packaging game,’ he remarks.

The machinery is also built for top-notch sanitation. The belts are easily removable for thorough washing and everything, from the in-feed to the exterior, is stainless steel. ‘Over the years, ULMA has perfected these machines to ensure easy cleaning and maintain hygiene standards at the highest level,’ Eddie states.

ULMA’s range of flow wrappers includes the FM 300, capable of speeds up to 70 pieces/min, and the FM 500, which reaches 100-120 pieces/min. These machines handle packs typically weighing 400-500g.

As the world continues to shift toward more sustainable practices, the role of packaging in reducing plastic waste will only grow in importance.

Eddie is optimistic about the future. ‘We believe this is just the beginning. As more producers and retailers see the benefits, we expect this technology to become the norm rather than the exception.’