Smurfit Westrock’s recyclable seafood box replaces Expanded Polystyrene (EPS) for Keltic Seafare

UK – Smurfit Westrock has produced a fully recyclable, moisture-resistant seafood packaging solution for Keltic Seafare, replacing Expanded Polystyrene (EPS) with a dual inner box system featuring corrugated insulation and gel packs to maintain low temperatures for live langoustines, lobsters, and scallops during transport from Dingwall to London.

The outer case features a moisture-resistant coating that repels seawater, allowing boxes and printed branding to remain unaffected during shipping.

Inside, corrugated insulation and gel packs create a fully insulated chamber maintaining the required low temperatures for live shellfish.

Why EPS Replacement Matters

Expanded polystyrene has long been the default for seafood shipping due to its lightweight insulation and moisture resistance.

However, EPS is rarely accepted in curbside recycling programs, takes hundreds of years to decompose, and breaks down into microplastics that contaminate marine environments.

Smurfit Westrock’s paper-based alternative offers comparable thermal performance without the environmental persistence of plastic foam.

Dual Inner Box System

The solution features a dual inner box system with divisions to keep shellfish secure and separated during transit.

Inner boxes are wrapped with T-piece liners and gel packs to create an insulated chamber inside the outer case.

By integrating insulation into a recyclable, moisture-resistant design, Keltic Seafare gains improved protection and packaging that aligns with its eco-conscious ethos.

Meeting Michelin-Starred Expectations

Keltic Seafare had previously switched from EPS to solid board with foam liner, but those boxes lacked branding and were not optimized for sustainable disposal.

With many Michelin-starred clients based in Central London, the ability to easily separate and dispose of packaging in standard municipal recycling bins was a key requirement.

Robert MacKinnon, procurement manager at Keltic Seafare, explained that the team created packaging that perfectly balanced eco-consciousness with ease of assembly, branding, and customer satisfaction.

Aishling Bradford, business development manager at Smurfit Westrock, added that moisture resistance and temperature control do not have to come at the cost of branding, speed, and sustainability.

She noted that while the project was challenging, it enabled the team to put design skills to the test without compromising on key features.

When Shellfish Ship Sustainably

Live langoustines, lobsters, and scallops do not care about packaging sustainability. They care about arriving alive.

Smurfit Westrock’s solution keeps them cold, dry, and secure, without EPS. For Keltic Seafare’s Michelin-starred customers, that means less waste and better branding.

For the ocean, it means one less source of persistent plastic pollution that would otherwise linger for centuries.

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