Overview
A leading UK bakery manufacturer sought a reliable, food-safe packaging material that would withstand high-fat, high-moisture environments without compromising recyclability or operational efficiency. Their existing laminate-based solution had been causing inconsistent barrier performance and avoidable product spoilage during distribution.
Client Background
The client produces a broad range of baked goods supplied into major supermarkets, convenience retailers, and food-service operators. Their packaging materials must deliver consistent grease-barrier performance, remain compliant with UK/EU food-contact regulations, and integrate seamlessly into high-speed packing lines.
The Challenge
Their incumbent packaging supplier had been experiencing several recurring issues:
The manufacturer required a fibre-based solution that maintained barrier robustness while supporting wider sustainability goals across its product portfolio.
Our Approach
Our technical team collaborated closely with the client’s operations, quality, and packaging development departments. The joint focus was placed on identifying a substrate with stable barrier properties, food-safe chemistry, and strong mechanical performance under typical FMCG conditions.
A tailored grease-resistant paper was selected, incorporating an optimised coating layer that provided:
Detailed trials were run on the customer’s lines, allowing real-world performance to be assessed and verified before full adoption.
The Outcome
The transition delivered measurable improvements across multiple operational and commercial areas:
The project is now used as a model for future packaging developments within the client’s broader FMCG portfolio.
Summary
This collaboration demonstrates how fibre-based coated papers can deliver robust performance in demanding food-contact settings while offering clear sustainability and operational advantages. By pairing technical expertise with close customer engagement, a long-term, high-value packaging solution has been established.
