Let’s be clear from the outset, all packaging has an impact on the environment to varying degrees and it’s our job to help clients find the best solutions to mitigate carbon, waste, cost, social and negative impacts whilst finding ways of making packaging work harder.
We measure and consider numerous factors before making recommendations much like a doctor reaches a diagnosis. So the more we can understand your products, processes and routes to market, the better our diagnosis will be. A great design is often limited by the brief and application of knowledge and resources. At Lesspack, it starts with questions to understand the challenge and how we might be able to help.
So what are we? Consultants, agents, manufacturers or what? We are often asked this question and we typically reply that we’re ‘hybrid manufacturers’. We provide consultative services for some clients and we also act as agents – sourcing and supplying packaging. We also invent and develop new materials, coatings and products then license the manufacturing and distribution to third parties. We are creative pragmatists and we say it how we see it and try to be as informative and unbiased as possible. We don’t pretend to know everything, but we do have a great network of contacts and trusted partners who provide the collaborative support and resources to make things happen efficiently.
We don’t sell products; we guide companies to make better choices
For example, Pots & Co use to only source flexo printed corrugated transit/display packaging for their luxury desserts. They were experiencing inconsistencies from one delivery to another so we suggested switching to litholaminated corrugated, powered by food waste bioenergy. This had two positive impacts; it reduced their carbon footprint and eliminated the print defects. This was also achieved with zero increase in cost, partly because the set-up costs of litho compared to flexo are nearly half.
Possibly the most efficient drink carrier in the world
In 2005, I was asked by a client to develop a 4-pint carrier to improve speed-of-service at bars. They were using moulded pulp fibre trays, which are bulky and potentially dangerous if frisbee’d into the crowd! I invented PortaDrink – a brandable carrier, which took-up about 1/4 of the space/handling/distribution and could be sponsored by advertising. This was then used by Costa, Coca Cola, Carlsberg and many other iconic brands. By 2010 we were delivering about 10 million carriers a year. I then sold the company.
PortaDrink has just had a makeover, reducing its footprint and cost by about 1/3 and is being exclusively marketed and distributed by Just Peel. The carrier is slightly smaller and can be printed and die-cut 6-up instead of 4-up on a sheet of board. At a time when board is so expensive, this makes a huge difference and once again this carrier is a compelling alternative to other cup carriers.
Are we running out of trees to make paper and cardboard?
No. Sustainably harvested wood-pulp ensures that 5-6 trees are planted for every one cut so there is no shortage. However, the increasing demand for plastic-free and e-commerce transit packaging is placing stress on the supply chain and in turn this is driving costs higher. We have witnessed increases on some grades of paper and board over 40% in the past 18 months and with rising energy costs and market instability, this will only get worse.
So what are the alternatives? We already make packaging from other cellulose fibres from plants such as bamboo and bagasse, but they’re not grown at scale in the UK or Europe to make these materials sustainable. However, we are working on an exciting and ambitious plan to change this…
Fibrepac – miscanthus (‘elephant grass’) pulp moulded fibre packaging
In 2023 we will launch Fibrepac in partnership with ESG Natural Capital – the largest growers and processors of miscanthus in Europe. Initially, this will be UK-grown miscanthus, thermoformed in a new food-hygiene manufacturing facility, located in Lincolnshire, powered by bioenergy produced from agriwaste. This means that this product will be carbon-neutral. We will initially have about 20,000 tonnes of miscanthus to make packaging, which is currently being delivered into power stations as biomass to generate energy.
Miscanthus is an important non-food perennial crop, which can be grown on marginal land without the need of pesticides or fertiliser. The roots (rhizomes) are non-invasive and remain in the soil for up to 30 years making this a viable crop for any farmer or land owner looking for a stable, viable crop with minimal maintenance providing other biodiversity benefits. It’s the second fastest growing plant on the planet and absorbs over three times more carbon than trees.
Fibepac looks, feels and performs like bagasse (waste from sugarcane) and will therefore provide a viable and sustainable alternative to imported products, plastic and woodpulp.
If you would like our help or more information, just send us a message and we will aim to come back to you within 24 hours.
Ian Bates
Bates Blog - Light Bulb Changer 