Operational Certainty in Poultry Processing

How Mt Barker Chicken and Multisteps built a strategic packaging partnership focused on tray performance, supply reliability and evolving protein packaging requirements.

Western Australian poultry producer Mt Barker Chicken operates in a fast-moving processing environment where packaging must support operational efficiency, product presentation and supply chain certainty. Its evolving partnership with Multisteps highlights how flexibility in materials, tray formats and supply planning can strengthen processing operations.

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Packaging That Performs Under Processing Pressure

For Mt Barker Chicken, packaging must perform under continuous operational pressure. The company processes fresh free-range chicken daily, delivering product to retailers the same night or the following day.

In this environment, packaging performance is inseparable from operational reality. Trays must support sealing, cooling, logistics, food safety and product presentation without introducing uncertainty into the production line.

“Packaging has to stand up to the process —
we simply can’t introduce operational uncertainty into the production line.”

— Darrin Finlayson, Mt Barker Chicken

From Supply Challenge to Strategic Partnership

Mt Barker Chicken Tray Labelling Production Line

Mt Barker’s relationship with Multisteps began during a period of supply disruption, when its previous supplier was unable to manufacture the trays required for several weeks. With fresh chicken mince products still needing to move through production, Mt Barker reached out to Multisteps for support.

Multisteps responded quickly, supplying the required trays within tight timelines. What began as a supply solution soon evolved into a broader operational partnership as Mt Barker expanded tray formats and material platforms across its product lines.

“Once Multisteps delivered on the first product requirement, the partnership expanded into additional tray formats and applications.”

Packaging Designed for Processing Reality

Today, Mt Barker’s packaging requirements span multiple tray formats and material platforms. Approximately 70% of the company’s packaging uses Modified Atmosphere Packaging trays, with the balance across Vacuum Skin Packaging formats for selected product lines.

However, packaging decisions begin with operational performance rather than materials alone. For Mt Barker, packaging needs to be fit-for-purpose across sealing, food safety, cooling, logistics and retail presentation.

MAP Tray Formats

For high-volume poultry applications where sealing consistency, product protection and shelf presentation are critical.

VSP Pack Formats

For selected protein applications requiring strong pack integrity, product presentation and format flexibility.

Material Flexibility

Supporting Mono PET, PET/PE and Mono PP tray formats, depending on the operational requirements of each application.

Mt Barker Chicken Clear MAP Tray Retail Pack

“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.”

— Darrin Finlayson, Mt Barker Chicken

From Processing Line to Retail Shelf

Mt Barker Chicken Packaged Poultry Products Production Line

For retail-facing poultry products, packaging performance continues beyond the production line. Tray clarity, seal integrity and pack presentation all influence how the product arrives, displays and performs in store.

For Mt Barker, this means packaging needs to be structured to support both processing efficiency and the finished retail presentation. The tray must move reliably through sealing, cooling and logistics, while still presenting the product clearly when it reaches the shelf.

This is particularly important for free-range and specialty protein products, where the quality of the product inside the pack is central to the brand promise.