Global Green USA, Mountaire Farms, and Interstate Container have converted the largest poultry plant in the US to use recyclable, wax-alternative boxes. The change reduces the plants’ greenhouse gas emissions by more than 100,000 tons*, water consumption by millions of gallons annually and assists restaurants in achieving their environmental goals. This change has the potential to influence the design of transfer packaging for all types of poultry, meat, produce and seafood delivered to grocers and restaurants throughout the world.
In March 2009, Interstate Containers and Mountaire Farms announced their plans to conduct trials of recyclable modified atmosphere packaging through Hunt’s Point, the world’s largest food distribution center. The move is part of Global Green’s Coalition for Resource Recovery’s initiative to achieve 100 per cent recyclable wholesale transfer packaging through the facility.
Upon successful completion of the pilot in September 2009, Mountaire announced its plan to not only convert its existing modified atmosphere packaging to recyclable boxes but also to convert its ice packed product to modified atmosphere packaging to allow for a full transition of its entire product line to recyclable boxes. The full conversion of Mountaire’s first facility and the largest poultry plant in the US, located in Lumber Bridge, NC, was completed in January.
According to Annie White, Director of Global Green USA’s Coalition for Resource Recovery, “Converting to transfer packaging certified as recyclable by the Fibre Box Association (FBA) is a readily achievable step that industry and businesses can take to improve their environmental performance, enhance their service to customers, and improve their bottom line. Through dedication and perseverance, Interstate Container and Mountaire developed a cost-effective, high-performing offering that enhances service to its customers. Global Green calls on others in the poultry, meat, produce, and seafood industries, to develop solutions for all food and packaging types, rapidly accelerating their use.”
The switch to FBA-certified recyclable packaging is only one component of the sustainable packaging transition. The switch in packaging methods from ice packed poultry to modified atmosphere packaging will result in significant water and energy savings as well. In addition, the box size was reduced, and all wax was eliminated from the box, reducing the use of corrugated and petroleum products. Combined, these innovations also improve efficiency, streamline operations, and provide a safer work environment.
According to Interstate Container’s National Account Manager, Pete Bugas, “This is a first truly significant step towards replacing high-performance wax boxes throughout the difficult fresh food distribution channels. These boxes must withstand an extremely wet and challenging environment. Meeting the protocol criteria set forth by the FBA is a crucial step, and satisfying the rigors of the distribution channel in New York City is equally as tough. Ultimately, this fiber can now be recaptured instead of heading to a landfill where wax boxes are discarded. Interstate’s continuous environmental stewardship efforts remain a key part of our corporation’s DNA.”It is estimated that 1.5 million tons of un-recyclable wax-coated corrugated boxes are discarded in the US each year. If coated corrugated boxes were designed for recycling and recycled, a greenhouse gas savings of 5 million mtCO2e, equivalent to removing one million passenger vehicles from the road, would be realized, and US grocers and restaurateurs could save $63M annually in avoided disposal fees.**
For more information, please contact: Annie White, Director, Coalition for Resource Recovery at This e-mail address is being protected from spambots. You need JavaScript enabled to view it or 347-271-0243.
* Greenhouse gas savings calculated using EPA’s WARM tool. Saving assumes 100% of the boxes generated are recycled.
**According to the U.S. EPA 2007 MSW Facts and Figures, 31 million tons of OCC is discarded each year. The Fibre Box Association estimates that 5% of OCC is wax coated. EPA WARM Tool and Greenhouse Gas Equivalencies Calculator were used to calculate potential greenhouse gas savings. National restaurateur and grocers savings are based on a national average tipping fee of $42.08 based on the 2006 data in BioCycle’s State of Garbage report.
