Quick Guide to Sustainable Frozen Food Packaging

Sustainability is a growing priority across the food industry, and frozen food packaging is no exception. However, making meaningful changes isn’t as simple as switching to the newest “eco-friendly” material. Many options that look promising on paper present real challenges when put into practice—whether due to cost, availability, durability, or compatibility with existing equipment.

 

Frozen food manufacturers must balance sustainability goals with operational efficiency and retailer expectations. That’s why the focus needs to be on solutions that align with today’s business realities—materials that support sustainability efforts while maintaining performance and efficiency in the supply chain.

 

The Challenges of Sustainable Packaging in Frozen Food Applications

Frozen food packaging has distinct requirements compared to fresh, shelf-stable, or refrigerated food packaging. Unlike products that require oxygen barriers to extend shelf life, frozen foods rely on the freezing process itself for preservation. This means that barrier protection against oxygen or moisture absorption is generally not a primary concern.

 

However, barrier properties do play a role for specific frozen food applications, particularly steamable packaging that is designed to be cooked in the microwave. These packages must regulate steam pressure while maintaining integrity during cooking.

 

Key Challenges for Frozen Food Packaging

• Cold-Temperature Durability: Packaging must remain flexible and resist brittleness and cracking at freezer temperatures. Some sustainable materials become brittle at low temperatures, leading to breakage or compromised seals.
• Structural Integrity: Packaging needs to withstand handling, stacking, and transport in frozen distribution without puncturing or failing. 
• Seal Strength: Even without strict barrier requirements, strong seals prevent leaks or freezer burn.
• Microwave Venting (for Steamable Products): Steamable frozen packaging requires controlled venting capabilities to prevent package rupture during heating.
• Sustainability & Compliance: Packaging must align with retailer sustainability goals (such as Walmart’s requirement for 20% PCR content) while maintaining operational efficiency.

 

For sustainability to work in frozen food, solutions must be practical, scalable, and aligned with both business and environmental goals.

 

Evaluating Sustainable Packaging Solutions for Frozen Foods

With many sustainable materials entering the market, it’s important to separate what’s available from what’s viable for frozen food applications. Below, we assess key packaging options through the lens of performance, sustainability impact, and business feasibility.

 

1. Recyclable Films

Recyclable films offer a realistic and scalable option for frozen food manufacturers looking to reduce environmental impact while maintaining packaging performance. Unlike compostable materials, they integrate into existing recycling systems, making them a more straightforward step toward sustainability.

Why Recyclable Films Make Sense for Frozen Food:

• Retains flexibility at low temperatures, preventing brittleness and cracking.
• Works with existing packaging equipment, reducing the need for operational adjustments.

 

2. Compostable & Degradable Packaging

Compostable and degradable packaging continues to gain interest, but in frozen food, its practicality is limited. While these materials work well in some applications, they present specific challenges in frozen storage.

 

Key Considerations for Compostable Packaging in Frozen Foods:

• Cold-Temperature Performance: Some compostable materials become brittle in freezing temperatures, leading to breakage or seal integrity issues.
• Moisture Resistance: Condensation can weaken some biodegradable films, impacting performance.
• Limited Infrastructure: Compostable packaging must be processed at an industrial composting facility, and only 15% of U.S. composting facilities currently accept it.

 

3. PCR (Post-Consumer Recycled) Packaging

For many frozen food manufacturers, PCR (Post-Consumer Recycled) plastic is the most practical way to balance sustainability with packaging performance. PCR materials reduce reliance on virgin plastics while maintaining the necessary strength and flexibility for cold storage applications.

Why PCR Works for Frozen Packaging:

• Readily available material that meets 2025 retailer requirements (20% PCR content, 15% virgin plastic reduction).
• Performs well in cold temperatures, retaining flexibility without becoming brittle.
• Integrates into existing packaging systems, allowing for an easier transition.

 

Strategies for Compliance Without Overhauling Your Packaging Process

Sustainable packaging in the frozen food industry must be both environmentally responsible and operationally viable. While new materials continue to emerge, the focus should remain on solutions that integrate seamlessly into existing supply chains and meet business objectives.

 

• Choose materials that meet compliance while maintaining efficiency.
• Work with packaging partners who can navigate sustainability regulations.
• Ensure your packaging choices align with retailer expectations to maintain competitive positioning.

 

Key 2025 Retailer Requirements to Consider

• Current Industry Standard: 20% PCR content and 15% reduction in virgin plastic.
• Looking ahead: Some retailers (such as Walmart) have committed to 100% recyclable, reusable, or industrially compostable packaging by 2025.

 

To learn more about how sustainability requirements are developing and viable packaging options, download our The 2025 Sustainable Food Packaging Guide for U.S. Packers.