Replacement of rigid black-plastic packaging in the packaged meals industry is of critical importance in order to meet sustainability targets. Our client, a major packaging supplier, wanted to rapidly commercialise a natural and compostable product, but could not apply the grease- and water-resistant coating in an economic manner.

Our team of scientists and engineers evaluated the options for the coating, scoping solutions across pure mechanical iteration, chemistry adjustments and pre-treatment options. We ranked and filtered options based on commercial criteria and technical feasibility to provide our client with a practical set of options to test on their pilot line.

By improving coating consistency and reducing pinhole-creation, our best performing solution reduced the required total coating weight by 75%, making the new product profitable at the desired price point.