All systems go for sandwich pack production

The cardboard used in the sandwich packs is FSC certified and the transparent window is made from Polylactic acid (PLA), a corn-based polymer, and are imported from Finland and the USA respectively.

The new sandwich pack replaces the thermoformed PET wedge, hinged lid and sticker variety.

The packs were initially developed and manufactured by Nampak Cartons UK for British retailing giant, Marks & Spencer (M&S). Since Woolworths has a very close technical and working relationship with M&S, the company decided to replicate the pack locally as part of its “Good Business Journey”.

The pack “unzips” to form a handy, self-contained and disposable tray. The creation of the tear-strip required major structural development, as it's die-cut from both sides by the reverse score cut method, which demands high quality cutting and creasing facilities.

The packs are designed with a colour-break to identify the 21 sandwich variants, allowing for multiple schemes on one run. They're glued and delivered flat, then erected and sealed on a forming machine for an airtight pack that enhances product freshness and shelf life.

Nampak Cartons UK has a patent pending in respect of the packs.

Local production

For the purposes of local production, the Epping-based facility invested R2.2 million in a Heiber & Schröder window-patcher, which is modelled along similar lines as the one used by Nampak Cartons UK. Ian Vowles, national marketing manager of Nampak Cartons & Labels, says that this machine was the first choice of UK branch in terms of reliability, technology, speed and backup.

In addition, the local facility received full operator training, supported by the technical manager of Nampak Cartons UK. Nampak's research & development branch also supported the ramp up process by doing taint and shelf life tests of the new packs.

The facility was chosen as the manufacturing hub due to its close proximity to the Woolworths head office, design studio and related professional service infrastructure.

The packaging production company plans to use the Heiber & Schröder machine to grow its general carton window and microwave susceptor businesses. Possible areas for expansion include salad cartons, tortilla wraps, ready meals, desserts and snacks.

The South African sandwich market is valued at R9 million per annum and is expected to double by 2009/2010.