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A sustainable alternative to glass packaging

het-duurzame-alternatief-voor-glazen-verpakkingen
SFA Packaging

The customer demand

Marne Mosterd, producer of mustard and sauces, approached SFA Packaging with the desire to make their 1 kg jars more sustainable by switching from glass to plastic. Besides sustainability, brand image also played an important role. Moreover, glass is increasingly avoided in professional kitchens because of its fragility and associated safety risks.

The existing glass packaging presented several disadvantages. Glass has a relatively high CO₂ footprint due to its energy-intensive production process. It is also fragile, which increases the risk of breakage during transport and leads to higher costs. In addition, glass is not nestable, meaning it takes up more space and requires additional transport movements, further increasing its carbon footprint. The key question was therefore: how can we develop a lighter, more sustainable packaging solution that offers the same level of protection as glass?

Project approach

At SFA Packaging, we started with a thorough analysis of the customer's requirements and wishes. In doing so, we examined material selection, production techniques and logistical advantages. The aim was to determine the right wall thickness for the plastic pots, with an optimal balance between weight and protection.

To ensure product shelf life, extensive tests were carried out to make sure the jars effectively block light and oxygen. In addition, we developed a suitable sealing mechanism to ensure the jar remains tightly closed without the need for an additional seal. This process involved multiple rounds of testing and optimisation, during which we worked closely with Marne Mosterd to incorporate feedback directly.

We then moved on to the design phase. Within the technical constraints of the production process, the final model was defined. As a final step, in-mould labelling (IML) was selected, giving the jar a high-quality and consistent brand appearance.

Challenges and solutions

One of the biggest challenges was maintaining the quality and safety of the contents when switching from glass to plastic. Glass naturally offers excellent protection against oxygen, which is crucial for food shelf life. The challenge lay in achieving a similar barrier with a lighter material.

A second challenge was to develop a lid that was both sturdy and user-friendly. The closure had to offer sufficient protection without adding an extra seal. By testing different sealing mechanisms, a solution was developed that seals the jar tightly and protects the contents from air and moisture. This not only increases durability, but also enhances ease of use.

Marne Mosterd plastic packaging
Lid

Why glass is not a sustainable packaging material

Glass is often seen as a sustainable packaging material, but practice shows that its production is very energy-intensive. Glass factories run continuously at high temperatures, leading to high carbon emissions. Although glass is recyclable, the remelting process also requires substantial amounts of energy.

In addition, glass is heavy and not nestable, making storage and transport less efficient and contributing to a larger carbon footprint. This highlights the need to consider alternative packaging solutions that better support efficient and sustainable logistics.

The advantages of plastic
For this application, plastic offers clear advantages over glass:

  • Lower CO₂ emissions due to less energy-intensive production process
  • Lighter weight, resulting in more efficient transport and lower fuel consumption
  • Less fragile, reducing the risk of breakage and associated costs
  • More efficient stacking and storage thanks to nestability
  • 100% recyclable, extending the life cycle of the material

Cooperation as a success factor

With this transition, SFA Packaging, in close collaboration with Marne Mosterd, developed a plastic packaging solution that offers the same protective properties as glass, while delivering clear advantages in terms of sustainability, safety and logistics. The project demonstrates how technical expertise and close cooperation result in a packaging solution that is both functional and aligned with the brand..

"What stood out to us during this process was how SFA guided the entire project from start to finish. From material selection to the final design, a significant amount of work was taken off our hands. This resulted in a robust packaging solution with a look and feel that perfectly matches our brand," says Paul de Vries of Marne Mosterd.

Raise your packaging standards

Are you looking for a packaging solution that takes your products to the next level? SFA Packaging is happy to think along with you. We develop packaging that is not only functional, but also contribute to your sustainability goals. Feel free to contact us to discuss how we can optimise your packaging together.

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