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.
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.
we simply can’t introduce operational uncertainty into the production line.”— Darrin Finlayson, Mt Barker Chicken
From Supply Challenge to Strategic Partnership
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.
“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
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.
Managing Material Complexity in Protein Packaging
Like many protein processors, Mt Barker is balancing operational requirements with evolving sustainability expectations. While there is a preference to move toward more recyclable materials where possible, not every application allows that operationally.
Certain processing environments require materials capable of withstanding specialized conditions, including pasteurization-in-pack or high-temperature cooking. As a result, Mt Barker has adopted a product-by-product approach to packaging selection.
Today, this includes Mono PET, PET/PE and Mono PP tray formats, allowing the processor to transition materials where feasible while maintaining operational certainty.
Mono PET
For applications where recyclability and operational performance can align.
PET/PE
For selected applications requiring specific sealing or processing performance.
Mono PP
For applications requiring higher temperature performance or specialized processing conditions.
“First it has to work operationally. Then the question becomes: what is the most recyclable option we can use for that application?”
— Darrin Finlayson, Mt Barker Chicken
Local warehousing. Regular deliveries. Better inventory visibility.
A supply model designed to support processors without forcing excessive onsite stockholding.
Strengthening Supply Chain Certainty
For Mt Barker, supply reliability is just as important as packaging performance. The company processes poultry seven days a week and distributes products across Western Australia and interstate markets, with delivery timelines ranging from same-day local supply to several days for eastern states shipments.
To support operational continuity, Mt Barker worked with Multisteps to establish a supply structure that includes local warehousing in Perth and regular tray deliveries aligned with production demand. Collaboration around forecasting and supply planning has also improved inventory visibility.
Building Long-Term Packaging Partnerships
Mt Barker’s approach to supplier relationships reflects its long-term operational philosophy. The company does not change suppliers frequently, instead prioritising partners willing to invest alongside the business.
For growing processors, packaging partnerships need to support current production requirements while remaining flexible enough to adapt as product ranges, formats and material expectations evolve.
Supporting the Future of Protein Packaging
As consumer expectations evolve, protein packaging requirements will continue to change. Recyclability remains a growing focus, while convenience products and ready-to-cook formats are increasing demand for packaging solutions that deliver greater functionality.
For processors like Mt Barker, collaboration with packaging partners will remain essential.
“Ultimately it comes down to flexibility. We invest heavily in product development, so we need partners who are willing to work with us and explore new solutions.”
Processor Insight: Packaging Is an Operational Decision
For Mt Barker, the key lesson is that packaging decisions should always be viewed through an operational lens.
Packaging often gets treated as a procurement decision, but in processing it has a direct impact on production flow, product presentation and supply continuity.
Working with suppliers who understand the realities of processing — and who can support multiple formats and materials — makes it much easier to adapt as product ranges evolve.
Looking for Protein Packaging That Supports Your Processing Operation?
Whether you need MAP trays, VSP trays, Mono PET, PET/PE or PP tray formats, Multisteps works with protein processors to develop packaging solutions that support operational performance, product presentation and supply continuity.
