R&G Fresh Herbs has been a trusted supplier of high-quality fresh cut herbs for over five decades, serving supermarkets, wholesalers, and the foodservice industry. From humble beginnings as a Covent Garden market stall to becoming a leading UK supplier for Waitrose, Ocado, and major restaurants, R&G has built its reputation on quality and innovation.
When R&G approached us, they had a clear objective: to reduce film usage in their packaging, which would not only cut costs but also enhance the appearance of their product bags. Through collaboration and innovative design, we delivered a solution that exceeded their expectations.
Understanding the Challenge
R&G’s goal was twofold: minimise film wastage and optimise the presentation of their fresh herbs in packaging. Achieving this required careful analysis of their existing processes and tailoring a solution that addressed their unique needs.
Our team began with a detailed evaluation of their packaging setup, focusing on the bag size, product orientation, and common issues such as bridging—where clumpy products like basil or coriander get stuck during the packaging process.
Tailored Solutions for Maximum Efficiency
Optimising Formers for Herb Packaging
To meet R&G’s requirements, we designed formers with thin-wall K Lite technology to maximise the internal diameter (ID) of the tube. This ensured smoother product flow into the bag while minimising film usage.
To further reduce bridging risks, we added a K Slip coating inside the tube. This slippery coating made it easier for herbs to flow without clogging. On the outside, we applied a K Flow coating to improve the movement of various film types over the former.
Low-Friction Enhancements
We developed a low-friction draw-down strip for the points where the draw-down belts contact the former. This strip eliminated the need for Teflon tape while incorporating spreaders to ensure the film maintained its shape and flow during the sealing process.
Improved End Seal Quality
To enhance the end seals, we introduced Dura Therm jaws—provided through our partnership with Greener Corporation. These jaws improved the thermal conductivity at the seal face, ensuring stronger seals and better bag aesthetics.
Delivering Results
Our tailored solutions resulted in significant benefits for R&G Fresh Herbs, including:
- Reduced Film Wastage: The optimised formers and coatings allowed for more efficient use of film.
- Improved Bag Appearance: The changes enhanced the presentation of the product in the bag, elevating its shelf appeal.
- Better Seal Quality: Stronger end seals ensured the freshness of the herbs while maintaining a professional look.
By addressing their specific challenges with innovative solutions, we helped R&G Fresh Herbs achieve their goals and deliver even greater value to their customers.
