Case Study: Reducing Waste and Cost in a UK Bakery Through Bespoke Silicone-Coated Release Paper

Executive Summary

A leading UK bakery manufacturer partnered with Linwood Raker to address escalating production waste and rising liner costs associated with its high-volume baking operations. By introducing a bespoke die cut silicone-coated release paper we achieved measurable operational efficiencies, including an 8 % reduction in waste, a 5 % cost saving, and 100 % recyclability within the client’s waste stream. The project exemplifies how precise material engineering and responsive collaboration can deliver both economic and environmental benefits in food manufacturing.

Background & Challenge

The client operates multiple bakery production lines, supplying large-scale retail and food-service customers. Their existing liner material, a heavier weight imported paper, was causing excessive waste through inconsistent release performance, unnecessary over-specification and the need to cut by hand.

The company’s objectives were clear:

• Reduce material waste without compromising product quality or food-safety compliance
• Design a bespoke precut liner eliminating the need to cut by hand
• Lower liner costs in a challenging cost-inflation environment
• Enhance sustainability through improved recyclability and domestic sourcing

Traditional release papers were either too heavy for efficient use or lacked the release uniformity necessary for consistent baking results. We were engaged to engineer a technically suitable, lighter-weight paper solution tailored to the client’s exact process parameters.

Solution

Our technical team undertook a comprehensive review of the client’s production setup, including oven profiles, tray geometry, and temperature variation. From this assessment, a bespoke die cut silicone-coated release paper was developed — designed to provide optimal release performance while maintaining structural integrity at high temperatures.

Key attributes of the chosen paper included:

• Precision-applied silicone coating to deliver consistent release without surface tearing or adhesion
• Lighter grammage (die cut design bespoke to the customers tray) to reduce material use while preserving tensile strength
• Full food-contact compliance under UK and EU standards
• Domestic sourcing and full recyclability, reinforcing the client’s sustainability objectives

Implementation

A controlled two-week production trial was undertaken across two baking lines. Our engineers worked closely with the client’s quality and operations teams to monitor release performance, bake consistency, and liner endurance under repeated use.

The trial data confirmed that:

• The paper maintained consistent release force across all test batches
• Product surface quality improved, with reduced sticking and damage
• Line speed was unaffected, and handling characteristics remained stable

Following the successful evaluation, the client converted to full production use across all relevant SKUs.

Results & Measurable Outcomes

The collaboration delivered significant operational and environmental improvements:

The outcome demonstrated that precision-engineered coated papers can achieve both cost efficiency and sustainability without operational compromise.

Client Testimonial

“Linwood Raker’s paper exceeded our expectations. The team’s technical support and attention to process detail ensured a seamless transition to a lighter, more efficient material. We’ve seen measurable reductions in waste and a smoother production flow.”
— David Garner, Operations Manager

Key Takeaways

• Tailored engineering delivers tangible savings and performance gains in bakery operations
• Material optimisation (lighter grammage) can reduce cost and environmental impact simultaneously
• Collaborative testing ensures confidence in transition and compliance with food-safety standards
• Domestic supply and recyclability strengthen sustainability credentials across the value chain

Conclusion

This project underscores our capability to design and implement bespoke paper-based solutions that align with both operational and sustainability objectives. By integrating technical understanding, responsive service, and precision coating technology, we continue to support UK food manufacturers in achieving higher efficiency and environmental performance.

To learn more about our coated paper technologies for the food sector, visit our Food Manufacturing page.