MCIU - Development of a line of ready meals in sustainable barrier packaging resistant to the retort process (VULCANO Project)

Objective

The general objective of the VULCANO Project is to develop and adjust a line of ready meals that will be packaged in biodegradable barrier packaging capable of being subjected to heat treatments.

This general objective will be achieved through the attainment of the following

specific objectives

Technical Objectives

Adjustment of the formulations/recipes followed for the preparation of ready meals -including the adjustment of water content, % oils, pH, as well as cooking and/or heat treatment parameters- to adapt them to the characteristics of biodegradable materials to be developed within the framework of VULCANO.
Adjustment of the grades of available biomaterials (e.g. PHBVs, PLA…) so that they can be subjected to extrusion processes in order to develop multilayer material that is biodegradable and resistant to high temperatures.
Packaging tests of the new ready meals in the finalist packaging. Validation against.
Chemical modification of particles (e.g. microcelluloses) for their compatibilisation with the film materials and improvement of barrier properties.
Manufacture of multilayer films incorporating functional additives. Validation against heat treatments and study of barrier properties.
Validation of recipes with biodegradable materials.

Economic Objectives

Both in Spain and internationally, consumers are increasingly aware of environmental aspects. Current lifestyles, together with growing environmental awareness, mean that consumers are increasingly demanding ready meals that are easy to consume but packaged in more sustainable packaging.

In this context, IAN and INTERAL, which market their products in plastic packaging, are aware that there is a clear threat of reduced sales of their meals due to the use of this type of material. It is therefore necessary to find alternative packaging in order to continue the growth of this product family.

The development of the VULCANO Project therefore aims to improve the market shares of both IAN and INTERAL thanks to differentiation and a commitment to sustainability.

For example, in a first phase, IAN could launch 1 million packages on the national market as a test and learning phase. The following year, it could then be launched on a mass scale nationally and internationally, with the corrections and measures deemed appropriate during the test phase. The objective is to substantially increase sales of Carretilla products, from forecast sales for 2023 of 1,000,000 units to sales of 10,000,000 units by 2025.

In the case of the products manufactured by INTERAL, the company’s objective is to move from forecast sales of 250,000 units in 2023 to 5,000,000 units in 2025. This objective is established based on Interal’s current market share internationally, where sustainability aspects take precedence over price when consumers purchase a product from the shelf.

Environmental Objectives

Development of a set of compostable packaging, obtained from renewable sources in a high percentage (80-100).
Obtaining a material (packaging) that is biodegradable in the marine environment, using a base material such as PHBV.
Reduction in the amount of plastic material placed on the market by companies
Support in meeting circular economy objectives for plastic materials.
Reduction of the environmental impact of the packaging waste generated. As shown in the following table, biodegradable materials (in green) usually have a lower carbon footprint.