National Packaging Targets and businesses seeking sustainable alternatives to single-use plastic are driving demand for locally produced food packaging such as foil trays. Australia’s only foil tray manufacturer, Confoil, outlines the benefits such a switch can bring.
Environmental concerns about plastics and plastic waste as well as single-use plastic bans in some states is prompting businesses to seek alternatives for food packaging. Progressive businesses are looking for more sustainable packaging solutions for takeaway and ready meals.
When looking at alternatives to plastics, it is possible to find products with the same or similar characteristics. Many people don’t realise that aluminium foil trays are insulating, hold liquid safely and can be frozen, refrigerated and heated in the oven or microwave.
And foil has substantially higher recycling value than most other materials as it is endlessly renewable.
Recyclable
Aluminium foil doesn’t lose any of its properties in the recycling process and can be recycled over and over again. In fact, some 75 per cent of all aluminium ever produced is still in use, in some form or another. What’s more, recycling aluminium saves energy when compared to what’s required for its primary production. Confoil Smoothwall trays are recyclable provided they are free of food debris and oil.
Confoil Smoothwall foil trays are made from extra tough, heavy gauge aluminium with a smooth flange to accommodate sealing films as well as clip-on lids for selected trays. Smoothwall Aspire trays come in stylish black or gold to improve shelf presence and presentation. The extensive range is ideal for preparing, displaying and cooking chicken, fish, meat, prepared meals and deli counter ranges. Smoothwall foil trays are an especially popular choice for butchers and fishmongers.
Smoothwall trays can go straight from the fridge or freezer and into the microwave or oven. They are strong and durable enough to hold their shape in transportation from production to the store to home.
Local manufacturing
Confoil is a local, family owned and operated business which has been producing foil containers in Australia for over 55 years. In fact, they are now the only foil tray manufacturer in the country.
Director of Sales, Tammy Arhontissas, explains, “Being a local manufacturer in Bayswater, Melbourne, means we can be more responsive to our customers’ needs.
“We aim to be an active part of our community and support local jobs. It also allows us to control our own destiny in terms of sustainability, making decisions to improve our energy use, manage our sourcing, and reduce our waste and carbon footprint.
“Our facility is FSSC 22000 certified, ensuring our products are manufactured to the highest standard and to give our customers peace of mind when it comes to food safety.”
Recently, Confoil has made a multimillion-dollar investment in new presses to significantly increase Smoothwall and Smoothwall Aspire production. Growth has been driven by renewed interest in locally produced packaging and businesses seeking more sustainable options.
The company also manufactures DualPak pressed board trays, including the recently launched DualPakECO tray range, which is certified compostable.
Reducing energy use
Confoil CEO, Michael Parrington, says, “We have also invested in improving our sustainability. We installed over 2000 solar panels on manufacturing site rooftops to power production, which reduced our CO2 emissions by more than 441 tonnes in 2023. That’s the same as taking 96 cars off the road.”
As well as producing its own energy and sourcing renewable energy, Confoil is exploring ways to reduce usage throughout the business and run as efficiently as possible. In 2023, energy usage was decreased by six per cent compared to the previous year and CO2 emissions from energy use was reduced by 5.4 per cent.
Through reuse, repurposing, and recycling, Confoil has also reduced waste to landfill substantially. In 2022, 49 per cent of waste was diverted from landfill, 64 per cent in 2023 and for 2024, it is on track to achieving a 76 per cent reduction.
Circularity
As the world works towards a circular economy with goals of zero waste and lower impact, businesses need to be looking to products that can be designed and manufactured to reduce raw material use and be reused or recycled after use, rather than be sent to landfill.
Design and manufacture play a big part in the circular economy equation. And ease of recyclability is critical.
Confoil has been leading the way in circularity; 90 per cent of Confoil aluminium foil trays currently contain recycled content – and it is looking to increase that number.
Australian Packaging Covenant
The Australian Packaging Covenant Organisation (APCO) is a not-for-profit organisation leading the development of a circular economy for packaging in Australia.
As those in the industry know, the 2025 National Packaging Targets include 100 per cent of packaging is to be reusable, recyclable, or compostable by 2025; 70 per cent of plastic packaging recycled or composted; 50 per cent average recycled content across all packaging; and problematic and unnecessary single-use plastic packaging is to be phased out.
Confoil achieved an APCO score of 75 and is considered a leading organisation.
Good looks
When it comes to the food presentation, Confoil Smoothwall and Smoothwall Aspire foil trays complement their contents and provide a more premium appeal than plastic containers.
And for consumers, being able to use the same container for storing food in the fridge or freezer, to heat or cook food in the oven or microwave, and even serve to the table is a great benefit.
When the meal is finished, a foil tray without too much residue can be scrunched up and placed in recycling.
Once recycled, that piece of aluminium might end up in a window frame, an aluminium boat or another foil tray – over and over, and over again.
This article first appeared in the August/September 2024 edition of Food & Drink Business magazine.
