There were a number of factors that had to be considered to ensure the packaging would meet the requirements of the product and maintain the brands integrity. Firstly, the pouches needed to be 100% recyclable utilising existing waste streams within the UK. They also needed to provide suitable barrier properties to provide a shelf life of at least 9 months and as the packs would contain multiple portions, Whitworths were keen to incorporate a reclose function for consumer convenience. Branding and print quality were also key. Stand up pouches merchandise well on shelf, providing optimal exposure for branding, allowing Whitworths to create eye-catching, vibrant designs in line with their existing product packaging. The solution therefore had to be fully printable with outstanding print quality. Finally the pouches would need to run efficiently on existing packing lines with no requirement for capital investment.
FFP offered a pre-made, stand-up, doy pouch made of a mono material all PE laminate called ‘FFPE’ that met all of Whitworth’s packaging requirements. It is 100% recyclable as it can be recycled with carrier bags at larger stores, as classified by OPRL.
The pouches were supplied with an EVOH layer to provide oxygen and moisture barrier for product freshness and shelf-life. To address the reclose requirements, FFP provided the pouches with an all PE zip that would maintain the packs recyclable credentials. A tear notch was also incorporated for ease of opening.
The pouches needed to run efficiently on automated filling lines which can be challenging with all PE materials as they have a tendency to stretch and not hold register. FFP however, after a great deal of Research & Development, were able to offer an all PE solution that runs efficiently on pouch machines as well as automated filling machines due to the heat differential between the two layers.