ALASKA® BARRIER GREASE for Tesco
How Tesco, Samworth Brothers and Paranova replaced PE-lined cartonboard trays with ALASKA® BARRIER GREASE from MM Board & Paper
For food brands, retailers and converters, packaging optimisation is increasingly shaped by regulatory requirements, EPR considerations and the need to reduce plastic content – without compromising product protection, shelf appeal or operational performance.
Together, Tesco, Samworth Brothers Manton Wood and Paranova Print & Packaging have demonstrated how this can be achieved at commercial scale.
Across 20 chilled-food SKUs, the partners replaced PE-coated cartonboard trays with ALASKA® BARRIER GREASE from MM Board & Paper.
The result: the packaging moved from an amber to a green EPR classification, while replacing approximately 320 tonnes of PE-lined cartonboard per year.
Reducing plastic in chilled-food trays without compromising performance
Chilled-food packaging must meet demanding requirements. Trays need to manage grease and moisture, retain their stability at low temperatures and maintain a clean, premium appearance throughout filling, distribution and retail display.
The partners selected ALASKA® BARRIER GREASE, a virgin fibre cartonboard produced at MM Kotkamills. Instead of a separately applied PE lining, ALASKA® BARRIER GREASE uses a water-based dispersion barrier to provide grease resistance and moisture protection. The cartonboard is suitable for direct food contact and supports the printability, cutting, creasing and runnability required for branded retail packaging.
Although the trays remain flow-wrapped in plastic film, the two materials are easy to separate after use. This allows the cartonboard tray and film to be directed towards their appropriate waste and recycling routes.
From trial to shelf: a measurable improvement across 20 SKUs
Moving from a material trial to a 20-SKU rollout required close collaboration across the full value chain.
Paranova Print & Packaging converted the cartonboard into the finished trays. Samworth Brothers Manton Wood packed the chilled-food products. Tesco introduced the updated packaging to the retail shelf. Together, the reduced plastic content and improved material recovery supported the move from amber to green EPR classification.
The project shows how material innovation can support regulatory and sustainability goals while maintaining the performance required in demanding chilled-food applications.
It has also been named a finalist in the New Packaging Award at the 2026 Sandwich & Food to Go Industry Awards, known as the Sammies, and at the Green Packaging Star Award 2026.
Collaboration across the value chain
Will Mercer R&D Director at Paranova Print & Packaging, said: “Rolling out a material change across 20 SKUs required close collaboration and a high level of confidence in how the board would perform during converting and in the finished pack. ALASKA® BARRIER GREASE enabled us to replace the PE-coated tray material while retaining the grease resistance, stability and presentation required for chilled food. The move from amber to green EPR classification shows the commercial value that material innovation can deliver at scale.”
Looking to reduce reliance on PE-lined board in chilled-food packaging? Download the ALASKA® BARRIER GREASE technical datasheet or order samples through the MM Board & Paper product catalogue.
FAQs
The previous PE-coated cartonboard was replaced with ALASKA® BARRIER GREASE, a virgin-fibre cartonboard with a water-based dispersion barrier that provides grease resistance and moisture protection.
Reducing the plastic content and improving the cartonboard tray’s compatibility with the paper recycling stream supported a change from amber to green under the UK EPR Recyclability Assessment Methodology across all 20 SKUs.
ALASKA® BARRIER GREASE is designed to be recyclable through established paper and board streams, subject to local collection, sorting and recycling infrastructure. Testing according to the CEPI/4evergreen method recorded a recycling yield of around 99%, comparable to that of the non-barrier GC2 cartonboard reference.
The rollout across 20 chilled-food SKUs replaces approximately 320 tonnes of PE-lined cartonboard per year.
ALASKA® BARRIER GREASE is designed for food packaging applications that require grease resistance and moisture protection, including cartonboard trays for chilled foods.
