OVERCOMING PACKAGING CHALLENGES IN FROZEN FOOD: SUPPORT FOR BFFF MEMBERS

Sustainability, supply chain performance and customer experience are all important factors in a brand making its mark in the frozen food industry.  What connects them? High-performing packaging. With new regulations placing greater responsibility on brands and consumer expectations evolving quickly, packaging goes beyond keeping products protected. It’s an invaluable touchpoint that shapes the consumer’s overall experience and lasting impression of your brand.

 

As a proud associate member of the British Frozen Food Federation, Smurfit Westrock Mold can help members to overcome packaging challenges and access the opportunities that having the right packaging can provide.

 

Sustainability: Making Sense of Brand Responsibility

 

Sustainability is no longer just about choosing the right material and hoping for the best; it’s about accountability throughout the entire lifecycle of packaging. The introduction of new regulations, such as Extended Producer Responsibility (EPR), aims to reduce the environmental impact of products by holding producers responsible for the entire lifecycle of their packaging, from design to disposal. This moves responsibility from consumers and places it on businesses.

 

For frozen food producers, this means considering the impact of packaging at every stage – including sourcing, recycling, waste management and reporting – and demonstrating strict sustainability compliance. This is part of a bigger move towards a circular economy, where packaging is designed with reuse and recycling in mind.

 

Lianne Pemberton, UK&I Sustainability Lead at Smurfit Westrock, highlights: “With the right understanding and preparation, changing sustainability regulations are also an opportunity for brands in the frozen food industry. It’s the ideal way to reduce waste, improve transparency and encourage consumer trust.”

 

Innovation: Changing Consumer and Market Demands

 

Frozen food packaging must adapt to consumer demands for convenience and the specific needs of retail environments. This doesn’t mean simply finding a brand new type of packaging; it’s about improving existing designs to meet changing demands. By rethinking your packaging, you can ensure products stand out on shelves, reduce waste without compromising on product protection, and ensure boxes are easy for consumers to open, store and recycle. It’s about rethinking and improving existing designs to deliver better outcomes.

For example, when Smurfit Westrock proposed a top and bottom packaging solution for transporting frozen baked goods. Traditionally, these products are delivered to bakeries in a box with a separate plastic bag inside. The new approach eliminates the need for the plastic bag by introducing a bottom tray with reinforced sides for extra protection, ensuring the goods remain undamaged during transport. The tray features a protective coating that doesn’t affect recyclability, supporting both sustainability goals and regulatory requirements.

By approaching packaging with a focus on innovation, you have a better chance of staying competitive and responsive. It’s also an effective way of future-proofing packaging against regulatory changes and market shifts.

 

Supply Chain Optimisation: Streamlining the Frozen Food Journey

 

In the frozen food industry, supply chains must balance efficiency, cost-effectiveness and product production. Packaging plays a surprisingly significant role in finding this balance. For example, Smurfit Westrock Mold manufactures transit shippers using carefully optimised pallet layouts to maximise storage, transport and handling efficiency. Plus, with innovative pack designs that allow for speedier decanting, you can reduce all-important time and labour costs in store, which helps to streamline the supply chain even further.

 

By approaching packaging as a way to optimise a supply chain, rather than simply a way to contain frozen food, you can identify opportunities for improved speed, reduced cost and more sustainable operations.

 

Risk Mitigation: Securing Your Supply Chain

Disruptions in supply chains have made risk management a top priority across the frozen food industry. Packaging is no exception, and a reliable supply chain is essential to keep products moving from A to B and beyond. Reducing risk means working with suppliers who not only combine local expertise with global knowledge but also have the infrastructure to deliver continuity and confidence.

At Smurfit Westrock, we have the advantage of owning over 60 of our own paper mills, giving us control over a key raw material and ensuring continuity of resources even in times of disruption. With UK-wide sites, we provide built-in resilience and flexibility – enabling us to adapt to short-term needs, deliver limited packaging runs, and maintain the stability required for long-term supply. This approach ensures customers benefit from a packaging partner who can safeguard their supply chain against international market pressures while keeping frozen food moving securely and efficiently.

Your Exclusive BFFF Invitation:

Packaging security extends beyond using the right materials; it’s about having a reliable packaging partner to overcome challenges and provide stability. If you would like support with navigating sustainability legislation, supply chain optimisation and innovative packaging solutions – or if you would like to book a site visit to Smurfit Westrock’s newly invested facility in Mold – connect with Fiona MacDougall directly at fiona.macdougall@smurfitwestrock.co.uk

Or take the next step with a complimentary Smurfit Westrock Better Planet Packaging Audit – giving you clear, expert insight to ensure your packaging is sustainable, compliant, and ready for the future of frozen food.

“We’re here to make packaging simple, effective, and ready for the future for BFFF members. From navigating EPR and optimising supply chains to securing sustainable materials and reviewing packaging with innovation in mind, our focus is on giving members the clarity and confidence they need,” Fiona MacDougall, Business Development Manager at Smurfit Westrock Mold.