Quorn has made significant strides in food and drink sustainability by updating the packaging for its Cauldron Cumberland Sausages, Cauldron Lincolnshire Sausages, Quorn Brilliant Bangers, and Quorn Mozzarella & Pesto Escalopes. The transition to surface-printing on the existing top-web, combined with a base label, utilizes current manufacturing lines and necessitates minimal adjustments in the equipment already in place.
A critical advantage of this change is the substantial reduction in packaging materials. Traditional cardboard sleeves demand resources such as raw materials, energy, and water for both production and recycling. By eliminating these sleeves, Quorn contributes to enhanced waste reduction and moves towards more sustainable packaging practices.
This efficient packaging solution significantly lowers the use of excess carton board, thereby minimizing material waste at the consumer level and reducing the overall carbon footprint. Quorn’s streamlined approach decreases packaging weight by approximately 20% per SKU. Coupled with a redesigned Escalope tray, which reduces plastic usage, this initiative has resulted in an estimated annual saving of 87,000 kg CO2 based on 2024 figures. To put this into perspective, the savings equate to eliminating around 424,000 road miles of carbon emissions.
Furthermore, by phasing out carton sleeves for these SKUs, Quorn diminishes the energy-intensive processes associated with paper production. The switch to lighter, more compact printed film packaging also yields transportation efficiencies, contributing to fuel savings and lowering carbon emissions related to supply chain logistics.
A company statement noted: “Carton sleeves serve minimal functional purpose in protecting the product itself, unlike the primary packaging, which ensures product safety and shelf life. Ensuring alignment with brand identity and consumer presentation is critical when implementing packaging changes at a retail level. Quorn has collaborated closely with its suppliers to refine a robust, surface-printing technique that maintains ink integrity in seal areas especially, where there is high intensity from temperature and pressure of moving parts.”
While a reverse-printing method could have provided another means of protecting the ink finish, it involves additional processing steps, including printing on the inner side of transparent film. This would necessitate extra polymer layers and lamination through the application of adhesives and bonding.
The adoption of surface-printed film in Quorn’s new packaging approach is significantly less energy-intensive to manufacture. By avoiding these extra steps, Quorn reduces both energy consumption and material use, opting for a thinner 25-micron PET film instead of the 40-micron film commonly used for products employing a reverse-printed process. This method not only enhances sustainability but also allows for the application of a registered matt finish, improving packaging aesthetics without additional treatments. This innovation clearly illustrates Quorn’s dedication to achieving sustainability goals while maintaining product performance and consumer presentation.
The company further asserted: “By actively reducing unnecessary packaging, Quorn aligns with the growing consumer preference for responsible packaging consumption. As a brand with sustainability embedded in its ethos, Quorn reinforces its commitment to eco-friendly practices by implementing impactful and sustainable packaging changes. This demonstrates that reductions in environmental impact are achievable through strategic packaging design choices and materials efficiency.”
