An Italian producer of desserts and delicacies was looking for packaging with a stronger appearance and better protection of the product. The existing thermoform packaging did not offer enough possibilities for branding and no longer matched the desired positioning on the shelf. SFA Packaging therefore developed a new customised barrier cup. The result is a lightweight injection-moulded packaging with full-colour IML and strong oxygen barrier that protects the product for longer while giving it a distinctive look.
From thermoform to premium barrier cup
The original packaging consisted of a thermoform PP cup with barrier layer. That solution adequately protected the product, but limited the brand's appearance. Thermoform packaging requires printing on film, which keeps the packaging flat and simple in appearance. SFA Packaging's new barrier cup uses injection moulding technology combined with In-Mold Labelling. This gave the packaging sleek corners, a high-quality finish and a full-colour design that immediately stands out on the shelf.
The packaging was also completely rebuilt around the brand experience of the product. The IML label runs tightly over the side of the cup and connects neatly to the bottom. This immediately makes the packaging look more neat and professional. The hard edge of the injection-moulded cup also gives consumers a firm feeling when picking up the product.
Rapid development thanks to existing infrastructure
The project was realised in about two to three months. This short lead time was possible because SFA Packaging already had experience with barrier packaging within previous R&D projects. For an earlier pilot, SFA had already developed a small barrier cup, so the technical knowledge and test results were directly applicable within this project.
In addition, SFA made use of an existing mould frame. Instead of building a completely new mould, the team developed a new insert within the existing infrastructure. This kept the investment manageable and allowed production to start up faster. The robotisation and hotrunner system were also already in place within the production line. This allowed the development team to fully focus on optimising the cup and the labelling process.
Packaging with strong barrier properties
The biggest technical challenge was not in the cup itself, but in correctly positioning the barrier label. The label contains an EVOH barrier that blocks oxygen. This requires extremely precise positioning during the production process. As soon as small gaps appear between label and packaging, the protective layer immediately loses its effect.
SFA Packaging therefore developed a solution in which the label completely encloses the side as well as the bottom of the packaging. This creates a closed protective layer around the product. The packaging therefore combines the low weight of plastic with barrier properties comparable to glass or cans.
This difference is important for products that are sensitive to oxygen. Plastic naturally allows small amounts of oxygen to pass through. With thin-walled packaging, this happens faster than with thicker materials. With a clever combination of lightweight polypropylene and an integrated barrier film, the product retains its quality for longer without heavy packaging.
Exclusive design with full-colour IML
Besides protection, appearance played a major role in the project. The brand wanted packaging that better reflects the exclusive positioning of the product. That is why SFA Packaging opted for full-colour IML technology. The label is directly merged with the packaging during the injection moulding process, producing a scratch-proof result with high print quality.
The new packaging gives the product more visibility on the shelf. The colours remain clean, details remain sharply visible and the cup retains a well-kept appearance for a long time during transport and use. At the same time, the shape of the packaging creates a modern and recognisable design developed exclusively for this client.
Technically, the design also received extra attention. SFA Packaging placed the stacking lugs on the outside of the cup. This keeps the inside tightly finished and the containers stack stably during production and transport.
PPWR-ready and fully recyclable
The new barrier cup meets future requirements within the European packaging market. The packaging is designed as a PPWR-ready solution with recyclable components and a lightweight design. The limited use of materials reduces raw material consumption without compromising product protection.
SFA developed the packaging entirely with circular thinking in mind. The combination of mono-material polypropylene and recyclable IML makes the packaging suitable for existing recycling streams. The result is packaging that not only looks distinctive, but is also prepared for future regulations.
Further development of barrier packaging
This project marks the next step in the development of barrier packaging at SFA Packaging. The company has been investing in R&D around oxygen barriers, lightweight packaging and accurate label positioning for several years. Especially the combination of robotisation, injection moulding technology and barrier labelling requires specialist knowledge.
With this packaging, SFA Packaging shows that sustainable plastic packaging can be excellently combined with distinctive design and strong product protection. The new barrier cup for Sugo D'Uva proves that lightweight packaging can be future-proof, recyclable and distinctive at the same time.
Would you also like to develop packaging that combines sustainability, appearance and technical performance? Contact us and find out how we can future-proof your packaging.