The trays are produced after palm leaves and empty palm fruit bunches not needed for food, cosmetics and personal care item manufacture are collected and converted into packs using a food contact-approved biodegradable bonding agent and, subsequently, a pressure forming process.
Currently being manufactured at a pilot plant, they are the result of a joint-venture between Malvern-based biodegradable packaging specialist Biopac (UK) and Maybrit, which specialises in developing commercial relationships between the UK and Malaysia.
A "third party" has now commissioned a full-scale production plant expected to have a 40-50m tray annual capacity.
Sainsbury's began using the compostable trays two months ago, and Biopac's technical director Mark Brigden says the company is hoping it will undertake a wider rollout for other organic goods in coming months. He adds: "The trays, which currently cost a little more than comparable polymer packs, but whose price we expect to fall, are being sealed with a biodegradable UCB NatureFlex flowwrap and feature biodegradable labels in the Sainsbury's application. We are also talking to several other potential customers."
