Case Studies

Sustainable Product Packaging Conversion

FOOD

#Potato Tray – Microwavable

Problem
Solution

Customer tried with several vendors to develop a fibre tray that was microwaveable/ovenable and sealable with a lidding film. However, the laminating films would always peel away with the lidding film.

We provided the customer with a tray that not only holds the laminating film when the lidding film is peeled but then allows the customer to remove the film after cooking.The tray is run through an auto denester, tray sealer and a tray sleever.

The customer was looking for a sustainable fibre alternative to their exiting ovenable tray, a fibre solution with high heat resistance capability.

The solution we provided is a peelable tray that can withstand 200C for an extended period of time in the oven.

#Salad Bowl – Shelf Life

Problem
Solution

The customer wanted a sustainable alternative to their plastic bowl but couldn’t achieve the barrier required for their target shelf-life.

We provided a custom film that achieved the shelf-life barrier requirements and fitted to the customer bowl shape, taking into account the required insert trays and indentations of the mould.

INDUSTRIAL

#Lock parts packaging

Problem
Solution

The customer was struggling with packs missing parts upon delivery. Parts were packed into a carton with kraft paper and tissue. There was no way of verifying if a part was missing.

We provided two trays with specific layouts for each type of part. Once the trays are packed and barcoded, they are scanned by machine vision for any missing parts or discrepancies.

#Mini Jam Advent Calendar

Problem
Solution

The customer was using die cut corrugate inserts and because the volume of orders was high, it was causing repetitive strain injuries to staff due to constant assembly of the inserts.

We provided a moulded tray into which they could directly place their jars into. It simplified and sped up the packing process.

MEDICAL

#Surgical Instrument Tray

Problem
Solution

The customer was looking for a sustainable medical procedure tray with the following characteristics: Laser etched with instructional messaging / Two wells to hold disinfectant fluids / Snap fits to hold swabs used for the disinfectant fluid / Sterilisable / Extremely low lint, dust, foreign matter content that would lower the chance for the spread of infection and lower their carbon footprint.

We provided a unique alternative with a high definition printing option using food safe inks. The tray has the capability to create a low draft interference fit allowing secure retention of the swabs. Our patented Safetex coating, was used for the wells that needed to hold the disinfectant fluid. This proprietary compound is impervious to fluids and will not allow the liquid to leak through. Our unique formulation allows the tray to be sterilised by Gamma irradiation, EtO and Autoclave and offers a safe high hygiene alternative to plastic which has an extremely low lint and dusting offering a level of protection that is equal to plastic and suitable for clinical and surgical environments.

#Endoscopy Tray

Problem
Solution

The customer wanted to switch their current packaging from plastic to a moulded fibre The primary requirement was to reverse engineer the existing packaging in terms of depth, ridges and curves while ensuring ensure the end product could be compostable.

We designed a fibre counterpart that still protected the item from damage during shipping and most importantly, the end-of-life cycle for the insert was compostable and recyclable. With our cure-in-mould manufacturing, the end product was smooth and aesthetically pleasing.