The EU-backed Redysign project has reported major research advancements in the quest to eliminate non-recyclable plastics from fresh meat packaging, focusing specifically on a notoriously difficult component: the internal absorbent pad.

While traditional absorbent pads efficiently manage meat exudates to preserve shelf life, they typically rely on synthetic materials and adhesives that contaminate paper waste streams, rendering entire packaging units unrecyclable.

The Redysign consortium — bringing together material researchers and industrial partners including Tecnalia, RISE PFI, and McAirlaid’s  —is tackling this challenge by engineering fully bio-based, circular alternatives derived entirely from wood-based cellulose.

Toward a circular meat tray

The initiative addresses the core performance and system integration hurdles required for commercial meat packaging:

• Adhesive-free Airlaid technology: one development stream explores advanced airlaid bonding techniques that completely eliminate the need for petrochemically derived binders.
• Ice-templating porous structures: researchers are also harnessing an ice-templating process to craft binder-free, highly porous structures made exclusively from cellulose fibres.
• Ultra-thin profile & roll stock integration: to meet industrial requirements, the newly developed core materials and associated films are engineered to remain thin — ideally under 1 mm combined — minimising production, storage, and transport costs while maintaining compatibility with high-speed roll stock lines.

Overcoming the contamination hurdle

A primary barrier to recycling food-contact paper packaging has always been organic contamination from meat juices. Beyond developing the absorbent pads themselves, the Redysign project is simultaneously pioneering specialised recycling and sanitation processes — such as advanced oxidation treatments — capable of cleaning contaminated fibres so they can be successfully upcycled into new packaging.

As part of a broader framework that also incorporates wood-derived moulded pulp trays, bio-based barrier coatings, and smart anti-food spoilage sensors, these advancements bring the fresh food sector closer to fully recyclable, plastic-free packaging that aligns with upcoming European environmental regulations.