Sam’s Club has moved to a fiber-based poultry packaging format at all U.S. locations, replacing expanded polystyrene and plastic-lined trays with a formed paper-based alternative. The change affects select fresh chicken items and aligns with growing interest across the food industry in recyclable, mono-material formats.
The new packaging eliminates several components typically found in poultry trays, including absorbent pads and multilayer plastic films. This shift emphasizes material reduction, waste stream compatibility, and operational efficiencies that could have downstream effects for foodservice buyers, commercial kitchens, and distributors.
Packaging Format: From Multi-Component To Single-Stream
The updated packaging consists of a thermoformed fiber base with a thin barrier layer designed for product protection. Unlike conventional trays that require multiple materials and components to function including foam bases, pads, film seals, and overwrap. The fiber-based solution consolidates these into a single, recyclable format.
Key differences in the material structure include:
Tray composition: Molded fiber with a light barrier coating
Sealing system: Applied adhesive layer replaces multilayer film
No added pads or film linings
Designed for recyclability, depending on local systems
This format draws on material developments already in use in other international markets, where fiber-based packaging has been trialed in meat and poultry categories.
Relevance For Foodservice Distribution & Storage
Foodservice operators and distributors may experience improvements in secondary packaging durability and space efficiency. The fiber trays are designed to better resist cracking and puncture during cold chain handling, potentially reducing leakage and repacking needs.
For distributors and large-scale buyers, the switch could offer operational advantages such as:
Less risk of contamination from damaged trays
Reduced secondary packaging needs during transport
Compatibility with sustainability reporting protocols
Streamlined waste sorting where single-material recycling is supported
The molded fiber design may also better align with emerging composting and recycling programs in institutional kitchens, depending on coating composition and local recovery capabilities.
Industry Momentum Toward Material Simplification
This rollout reflects a broader trend in protein packaging to simplify materials and design with recyclability in mind. Reducing the number of materials and layers in contact with raw poultry addresses long-standing barriers to recycling and creates more predictable end-of-life outcomes.
The elimination of multilayer films, plastic trays, and pads also supports material sourcing strategies that prioritize renewables and limit fossil-based content. While commercial compostability is not confirmed for this format, its simplified profile could make it more adaptable to evolving disposal infrastructure.
Looking Ahead
Though currently limited to select chicken products, the transition represents a step toward scalable packaging formats that meet retailer, distributor, and operator expectations for both performance and sustainability.
For professional buyers and foodservice groups sourcing fresh proteins through retail channels, the change may prompt reevaluation of storage, prep, and disposal procedures. As fiber-based materials gain traction in fresh food applications, operators should monitor developments in barrier technologies and recycling capabilities to stay aligned with supply chain shifts.
This packaging transition is less about branding and more about material design with operational and environmental impacts. As the protein sector explores alternatives to plastic-heavy trays, fiber-based formats offer a pathway to reduce material complexity and improve recovery rates across the foodservice supply chain.
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