In the food packaging industry, choosing the right flexible packaging material is about much more than appearance or cost. Packaging must protect products, perform consistently during production, withstand distribution and meet the changing demands of manufacturers, retailers and consumers.
From VFFS packaging films used for fresh produce to peelable lidding films designed for alternative food trays, even small differences in material properties can significantly affect packaging performance.
At D&M Packaging, we combine industry experience, technical knowledge and specialist flexible packaging solutions to help customers overcome these challenges.
Here are two examples of how our team identified packaging problems, developed effective solutions and delivered outstanding results.
Case Study 1
Eliminating VFFS Bag Failures in Fresh Produce Packaging
The Challenge:
Packaging Film Splitting During Distribution
A food manufacturer supplying shredded lettuce to a major fast-food chain was experiencing a persistent problem with its vertical form fill seal (VFFS) packaging.
Despite using an established flexible packaging supplier, the customer was receiving approximately 60 complaints every month due to bags splitting during transportation and distribution.
These packaging failures created unnecessary product waste, increased operational costs and caused frustration throughout the supply chain.
The existing packaging supplier had suggested increasing the gauge, or thickness, of the plastic film to improve its strength.
However, increasing film thickness doesn't necessarily address the underlying cause of packaging failure.
The customer approached D&M Packaging for an independent technical assessment and advice on finding a more reliable VFFS packaging solution.
The Solution:
A More Resilient Flexible Packaging Film
Rather than simply recommending a thicker film, D&M's technical packaging team investigated the properties of the existing material and its suitability for the application.
Our assessment identified fundamental limitations in the material's ability to withstand the stresses experienced during handling, transportation and distribution.
Increasing the film gauge alone was unlikely to resolve the issue.
Instead, our team recommended an alternative flexible packaging material with improved shock resistance, designed to better withstand the physical demands placed on the finished VFFS bags.
Working closely with the customer, we conducted a series of packaging material trials to assess performance and establish the most suitable solution.
The result was a more robust VFFS packaging film that provided the protection the product required without relying solely on additional material thickness.
The Result
From 60 Monthly Complaints to Zero
Following the successful trials and introduction of the recommended material, the customer reported that packaging complaints had fallen from approximately 60 per month to zero.
The improvement was so successful that the end customer requested the same packaging solution be introduced across another supplier within its supply chain.
D&M Packaging subsequently supported this wider rollout, helping deliver more consistent packaging performance across multiple operations.
The key takeaway: Selecting the correct VFFS film structure and material properties can be far more effective than simply increasing film thickness.
By identifying the root cause of the problem, D&M provided a long-term solution that improved packaging reliability, reduced waste associated with damaged bags and restored customer confidence.
Case Study 2
Developing Peelable PET Lidding Film for Board Punnets
The Challenge
Moving from Plastic Trays to Board Packaging
As food manufacturers and retailers explore alternatives to conventional plastic trays, board punnets have become an increasingly attractive packaging option for applications such as fresh produce and chilled foods.
However, moving from plastic trays to board packaging presents technical challenges, particularly when it comes to achieving a consistent and reliable heat seal.
Traditional peelable lidding films designed for plastic trays are not necessarily suitable for sealing directly onto board substrates.
In some applications, this can create a need for an additional plastic lining within the board tray, increasing material complexity and potentially undermining the original objectives of changing the packaging format.
Several customers approached D&M Packaging looking for an effective peelable lidding film for board punnets that could deliver dependable sealing performance while supporting their evolving packaging requirements.
The Solution
Multiseal PET Lidding Film
D&M's technical team began investigating alternative lidding film materials that could provide the necessary sealing characteristics for board packaging applications.
We sourced and evaluated a variety of packaging films, conducting trials across different board punnet materials and tray specifications.
These trials identified our Multiseal PET lidding film as the strongest-performing solution for the applications tested.
The selected material offered reliable sealing performance on compatible board trays while providing the peelability required for convenient consumer opening.
The solution also incorporated recycled content, helping customers address material selection and cost considerations alongside their packaging performance requirements.
By carefully matching the lidding film to the board substrate, we were able to provide a practical alternative to conventional lidding arrangements that require additional plastic tray linings.
The Result
Over 100 Tonnes of Multiseal PET Supplied
The success of the trials led to the adoption of Multiseal PET film across a growing number of packaging applications.
To date, D&M Packaging has supplied over 100 tonnes of Multiseal PET lidding film, with demand continuing to grow as more businesses recognise its suitability for compatible board packaging formats.
The material has since become a preferred lidding solution for customers seeking reliable sealing performance on board punnets.
The applications extend across food packaging categories, demonstrating the versatility of a carefully selected PET lidding film.
The key takeaway: Moving towards alternative packaging formats requires more than changing the tray material. Successful board punnet packaging depends on selecting a compatible lidding film, conducting thorough trials and understanding how different materials interact.
Why Technical Expertise Matters in Flexible Food Packaging
These two case studies highlight a common principle: the right packaging solution starts with understanding the problem, not simply supplying a product.
Whether a manufacturer is experiencing VFFS bag failures, exploring more suitable food packaging materials or looking for peelable lidding films for alternative tray formats, technical knowledge is essential.
At D&M Packaging, we support customers through material selection, packaging trials and technical problem-solving, helping businesses identify solutions tailored to their products, processes and production requirements.
Our flexible packaging capabilities include:
VFFS & HFFS packaging films – material solutions designed for vertical and horizontal form fill seal applications.
Peelable lidding films – specialist films for compatible trays, punnets and food packaging formats.
Printed flexible packaging – high-quality flexographic printing for a wide range of food and non-food applications.
Flexible packaging conversion – specialist processes including lamination, slitting and perforation.
Technical support and material trials – helping customers overcome packaging challenges and improve production performance.
From finding solutions to existing packaging failures to developing materials for new packaging applications, our team is committed to delivering quality, reliability and practical innovation.
Looking for a Better Flexible Packaging Solution?
If you're experiencing packaging failures, considering a change in packaging materials or searching for a reliable UK flexible packaging supplier, D&M Packaging can help.
Our experienced technical team can assess your requirements, recommend suitable materials and work with you to develop a flexible packaging solution that delivers the performance your business needs.
Don't just change your packaging. Improve it.
Explore our Flexible Packaging Applications or contact the D&M Packaging team to discuss your requirements.
