Hilton Foods Australia – Delivering a Circular Protein Supply Chain with Reusable Packaging
Case Study
1 October 2026
Hilton Foods Australia – Delivering a Circular Protein Supply Chain with Reusable Packaging
The Challenge
Hilton Foods Australia is one of Australia’s largest protein processors, operating facilities across Western Australia, Victoria and Queensland, and supplying case-ready meat products to more than 1,000 Woolworths stores nationwide.As part of its commitment to improving operational efficiency and supporting Woolworths’ circular economy strategy, Hilton sought to replace single-use corrugated cartons throughout its Western Australian supply chain with a reusable packaging solution.
The existing corrugated packaging presented several challenges, including:
- High volumes of single-use packaging waste
- Product quality risks caused by moisture absorption and damaged cartons
- Limited visibility of packaging assets
- Ongoing packaging and waste disposal costs
- Increasing sustainability expectations from retailers and regulators
Hilton needed a solution that would improve supply chain performance while delivering measurable environmental outcomes without disrupting operations.
Heath Manix, Hilton Foods Australia – General Manager (Bunbury), explains:
“The reusable crate solution has delivered measurable operational and sustainability benefits, improving product protection, simplifying our operations and supporting our commitment to a more circular supply chain.”
The Results
The partnership has delivered significant operational and environmental benefits for Hilton Foods Australia.
4,000,000
Single-use cartons removed (Up To)
51%
CO₂ emissions reduction
Tonnes CO2 eq
44%
Waste reduction
kg PM2.5 eq
74%
Water reduction
L water eq
Corrugate Dust Reduction
The transition to reusable crates also reduced corrugate dust within the processing environment, improving housekeeping standards and removing a source of fibre-based packaging dust associated with carton handling, erection and disposal activities.
Load Stability and Product Protection
Reusable SBCs improved product protection and helped reduce collapsing pallet loads, supporting better load stability, fewer handling disruptions and improved reliability through the supply chain.
Operational Simplification
The reusable crate model also reduced reliance on corrugated carton erection equipment, simplifying packaging operations and supporting a cleaner, more efficient operating environment.
Operational Benefits
- Improved product protection throughout the supply chain
- Reduced collapsing loads on pallets and associated handling disruption
- Reduction of corrugate dust within the processing environment
- Reduced reliance on single-use corrugate packaging and carton erection equipment
- Greater visibility and control of reusable packaging assets through RFID technology
- Increased supply chain reliability
- Long-term commercial certainty
The successful Western Australian implementation has also strengthened Viscount’s position as Hilton Foods Australia’s exclusive supplier for East Coast Swing Bar Crate growth and replenishment.
Supporting a Circular Supply Chain
The Hilton Foods Australia partnership demonstrates how reusable packaging can deliver meaningful sustainability outcomes while improving operational performance.
By combining Australian manufacturing, reusable asset pooling, RFID tracking and national wash services, Viscount has helped create a scalable circular supply chain that supports both Hilton Foods’ operational goals and Woolworths’ long-term sustainability strategy.
The project also reinforces Viscount’s commitment to helping Australia’s food industry transition away from single-use packaging through practical, commercially viable reuse solutions.
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