PKN examines how Western Australian poultry producer Mt Barker Chicken and packaging manufacturer MultiStep have built a long-term partnership around operational certainty, multi-material flexibility and reliable supply.
In poultry processing, there is little room for uncertainty. Fresh product moves through production every day, putting a premium on packaging reliability.
For Mt Barker Chicken, that reality has shaped the way the business approaches packaging decisions. Rather than focusing solely on materials or sustainability credentials, the company evaluates packaging first on its ability to perform reliably throughout the production process.
As Darrin Finlayson, GM – New Products, Processes & Purchasing at Mt Barker Chicken, explains: “Packaging has to stand up to the process – we simply can’t introduce operational uncertainty into the production line.
“We’re processing seven days a week and producing fresh product every day. Packaging has to work consistently across sealing, cooling and logistics. If something disrupts the line, it doesn’t work for us.”
From supply challenge to strategic partnership
The company’s relationship with Australian thermoformed packaging manufacturer Multisteps began when Mt Barker needed an alternative source of trays at short notice.
“Our previous supplier couldn’t manufacture the trays we needed for several weeks,” Finlayson recalls. “We still had to maintain supply of our fresh chicken mince products, so we reached out to Phil at Multisteps to see if they could help.”
Multisteps responded within the required timeframe, with Perth-based sales representative Phil Milosevich coordinating the transition. What began as an emergency supply solution evolved into a broader relationship, allowing Mt Barker to consolidate more of its tray requirements with one supplier across multiple formats and material platforms.
“Once we gave Multisteps the opportunity with that first product, they delivered,” Finlayson says. “They nailed it – and that opened the door to looking at other tray formats as well.”
Performance before materials
Today, Mt Barker’s packaging requirements span multiple tray formats and material platforms. Around 70 per cent of production uses Modified Atmosphere Packaging (MAP) trays, with the balance across Vacuum Skin Packaging (VSP) formats for selected product lines.
For Finlayson, packaging decisions begin with operational performance rather than material selection.
“The packaging has to be fit-for-purpose,” he says. “That includes sealing, food safety, cooling and how the product moves through the logistics chain.”
Presentation also matters for premium retail products.
“One of the biggest improvements we saw was tray clarity,” Finlayson explains. “Our 8×5 clear tray has been a standout. We believe we’ve got a very good product inside, so we want the packaging to show it off.”
Balancing sustainability with operational reality
Like many food manufacturers, Mt Barker is working towards more recyclable packaging, but only where operational requirements allow.
Certain applications require packaging capable of withstanding demanding production conditions, including pasteurisation-in-pack and high-temperature cooking.
“Sustainability is embedded in what we do,” Finlayson says. “We’d prefer to move toward the most recyclable materials available – particularly PET – but not every application allows that operationally.”
The result is a packaging portfolio that includes Mono PET, PET/PE and Mono PP tray formats.
“First it has to work operationally,” Finlayson explains. “Then the question becomes: what is the most recyclable option we can use for that application?”
“Having a supplier that can support multiple materials is very important,” Finlayson says. “It allows us to transition formats over time rather than constantly changing suppliers.”
Reliability beyond the production line
Supplying customers across Western Australia and interstate makes dependable tray supply essential.
“Knowing we have consistent supply is critical,” Finlayson says.
To support that objective, the two companies established a supply model incorporating local warehousing in Perth together with scheduled tray deliveries aligned to production requirements.
“The ability to receive trays regularly without having to carry excessive stock onsite has been valuable,” Finlayson explains.
“There’s a constant conversation around forward planning and supply timelines,” he says. “That provides assurance to our purchasing and operations teams.”
Mt Barker also favours long-term supplier relationships.
“We don’t change suppliers frequently,” Finlayson adds. “Our label supplier has been with us for more than 20 years, and our previous tray supplier was with us for over a decade.”
For Mt Barker, supplier investment also matters. Multisteps continues to invest in Australian manufacturing capability, local warehousing and supporting infrastructure.
“Knowing that a supplier is investing in manufacturing capability and local infrastructure is important,” he explains. “As we grow, we want to know our partners are growing with us.”
Looking ahead
Consumer expectations continue to influence packaging development, particularly around recyclability and convenience.
Finlayson expects both trends to accelerate as processors expand ready-to-cook, ready-meal and value-added product ranges.
“I think consumers expect the industry to keep improving recyclability,” he says. “We’re seeing more convenience lines, more product innovation and more packaging requirements to support that.”
Meeting those changing requirements will depend on suppliers evolving alongside processors.
“Ultimately it comes down to flexibility,” Finlayson says. “We invest heavily in product development, so we need partners who are willing to work with us and explore new solutions.”
For Mt Barker, the experience reinforces that packaging should not be viewed simply as a procurement decision; it directly affects production flow, product presentation and supply continuity. As Finlayson sees it, working with suppliers that understand processing realities and can support multiple formats and materials makes it much easier to adapt as product ranges evolve.
This article was first published in the Q3 September 2026 print issue of PKN Packaging News, p20.
