Quorn is a UK-based food producer and a global leader in meat-free and plant-based protein products. With a well-known commitment to sustainability and innovation, the company has consistently sought to reduce its environmental impact across its entire supply chain.
As one of the first major food brands to recognise the limitations of black plastic packaging, Quorn approached Parkside to develop a more sustainability-focused alternative that would meet both environmental goals and consumer expectations for convenience and ease of use.
The challenge
Quorn’s existing packaging consisted of mixed polymer black plastic trays that offered excellent barrier performance and protection. However, they presented several significant challenges.
The most pressing was recyclability. Black plastic cannot be effectively sorted by optical systems used in UK recycling facilities, meaning it is rejected from recycling streams and destined for landfill or incineration. Beyond recyclability, Quorn wanted to enhance the consumer experience with packaging that helped reduce food waste by keeping products fresh between uses. Traditional lidding films offered limited functionality in this regard; once opened, they couldn’t be securely reclosed.
Importantly, any new solution had to run seamlessly on existing packing lines without reducing speed or requiring costly modifications, while barrier performance had to match or exceed the incumbent design. The pack also needed to meet WRAP’s plastic sustainability goals and align with On-Pack Recycling Label (OPRL) guidelines.
The Parkside solution
Parkside’s solution enabled the move from mixed polymer black plastic trays to a recyclable monopolymer system, featuring integral peel-and-reclose functionality made possible through ParkScribe™ laser technology.
The new design used a clear PET tray heat-sealed to a laminate lidding film. By using a single polymer throughout, the entire pack can be recycled as one unit through household collection systems. The clear material also means effective sorting by optical scanners at recycling facilities.
The reclose functionality required no additional components – no zippers, stickers, or separate labels that would add to the packing process. Everything is integrated into the film structure, keeping the specification simple and eliminating the need for consumers to separate the materials.
The new pack offered superior protection against oxygen and moisture compared with the original design, extending shelf life and maintaining product quality. The new packs ran at full speed on existing lines with no modifications, keeping transition costs and timescales to a minimum.
Adding to the success of the project, upon launch it was one of the first PET lidding films on the market to contain PCR content, an extra advantage outside of the original design brief.
The results
The transition removed 13 tonnes of mixed-material polymer from Quorn’s supply chain annually. The design aligns with OPRL guidance for recycling through standard UK household systems and, for consumers, disposal was straightforward – rinse and recycle the entire pack together, with no separation required.
The pack’s integral peel-and-reclose functionality helped shoppers to keep products fresh without transferring them to separate containers, supporting household food waste reduction. Enhanced barrier performance delivered benefits throughout the supply chain, as products maintained quality for longer, reducing retail waste and improving the consumer experience.
Operationally, the solution proved seamless. Production lines continued at full speed with no modifications, enabling rapid rollout without disrupting operations or requiring significant capital expenditure.
The last word
“Working with Parkside enabled us to develop a solution that didn’t just solve the recyclability challenge, it actually improved the consumer experience through built-in reclose functionality. The laser technology was key to achieving this without compromising recyclability or adding unnecessary components. This project demonstrates that with the right development partner and innovative technology, you don’t have to choose between sustainability, functionality, and operational efficiency.”
Spokesperson at Quorn
