i2r Packaging Solutions has unveiled a new tray design that removes the need for absorbent pads in fresh meat and seafood packs — a shift that could simplify pack formats, cut waste and strengthen recyclability across protein categories.

The Dimple Base Tray uses an engineered base profile to capture and retain liquid within the tray itself. By integrating the function of a soakaway pad directly into the tray, producers can eliminate a component that has long complicated recycling streams and added cost to pack formats

Testing shows the tray can retain up to 16ml of liquid, matching the performance of a conventional absorbent pad while delivering 30% greater strength than a standard smoothwall tray.

What it means for seafood and meat processors

• Simplified pack formats — removing pads means fewer components to source, store and assemble. For high‑volume protein lines, this reduces changeovers, speeds up packing and lowers the risk of incorrect component use.
• Improved recyclability — pads are typically made from mixed materials that are difficult to recycle. A single‑material aluminium pack supports circularity and helps processors meet retailer and EPR-driven recyclability targets.
• Lower packaging waste — eliminating pads removes a non-recyclable element from billions of packs produced annually.
• Higher pack strength — the 30% strength increase improves handling robustness on chilled lines, reducing deformation and leakage risks.
• Operational efficiency — fewer SKUs, simpler procurement and reduced QC checks for pad performance.
• Shelf-life confidence — by retaining purge effectively, the tray maintains pack presentation and reduces the risk of free liquid affecting seals or MAP conditions.

Circularity built in

Manufactured from aluminium, the tray aligns with circular economy goals. i2r’s smoothwall trays currently contain 54% recycled content, with a target of 90% by end of 2026. Removing pads also eliminates a component that typically ends up in residual waste streams.

Scalable across protein categories

The first Dimple Base profile has proven the concept, with additional formats planned to extend the technology across a wider range of fresh food applications — from white fish and salmon to poultry and red meat.

Tom Cliffe, i2r’s sales director, said: “We challenged the assumption that pads are essential. The Dimple Base Tray delivers the same performance while removing an unnecessary packaging component.”