Transforming waste into value

Our own packaging lines for REAL Turmat and REAL Field Meal have seen significant improvements due to skilled operators and strong internal collaboration. Over the past year, we’ve managed to reduce the number of discarded or ‘wrecked’ bags by 34%.

Reducing waste through enhanced quality assurance

Our previous challenges with food waste were largely linked to quality assurance processes during bag preparation for distribution and sale. Bags that were categorized as wrecked would previously be discarded straight into a container as packaged food waste. Recognizing the potential for improvement, we initiated the “From Wreck to Surplus Goods” project across much of the company.

From aesthetic flaws to valuable assets

We’ve found innovative ways to utilize goods that do not meet the market standards for aesthetic reasons but are still safe and consumable. What we formerly considered as wrecked goods due to aesthetic flaws are now treated as ‘plus products’:

• B-grade products are consistently used for free lunches and dinners in our cafeterias.
• B-grade products are used as samples at domestic and international fairs.
• B-grade products are supplied to our brand ambassadors both domestically and internationally.
• B-grade products are donated to charitable causes.

Continuous improvement and data insights

Although we have not yet reached our goal, the data collected throughout the project provides valuable insights into our future direction. Ensuring safe food remains a non-negotiable requirement, and there is still much work to be done before we can claim zero waste in our finished meal pouch production.

Examples of product categorization

• Pulled pork incorrectly weighed, classified as B-grade.
• Pasta Bolognese, not suitable for hanging in retail settings, categorized as B-grade.
• Bags without labels are considered B-grade.
• Game stew examples of D-grade due to improper vacuum sealing or punctured bags.

Toward zero waste and enhanced sustainability

Through the “From Wreck to Surplus Goods” initiative, we are making substantial strides towards reducing waste and enhancing sustainability in our operations. This journey not only improves our environmental footprint but also adds value to our products and benefits the community.