Eliminate poly entrapment and reduce plastic in 60lb or 27.2kg frozen beef trim cartons

The project addressed the ongoing issue of poly entrapment in frozen beef trim cartons within the Australian red meat processing sector, a problem that contributes to customer complaints, product rework, and excess plastic use. It evaluated thermoforming as an alternative packaging system for 27.2 kg trim cartons, aiming to eliminate poly entrapment while preserving product integrity, maintaining export compliance, and ensuring the method was operationally viable.

A staged methodology was applied, beginning with proof‑of‑concept trials on a small‑scale thermoformer, followed by equipment modification, commissioning, and controlled production runs. Custom thermoforming templates and spacers were engineered to support the full weight of trim cartons and to prevent pack deformation and air entrapment during sealing. After progressive integration into the boning room with supporting conveyors, the system demonstrated the ability to eliminate poly entrapment, reduce plastic usage, and produce stable packs suitable for freezing and downstream handling. The project provides a practical framework for wider industry implementation and forms a foundation for future automation, enhancing product quality, sustainability, and process control.