Introduction

Aztec Fruits, part of the Troya Group, is one of eight specialist companies covering production, packing, distribution and promotion. Operating under Troya Alimentos, the company is a leading Mexican fresh produce supplier with over a decade of experience delivering premium fruit and vegetables to national and international markets. Their portfolio includes Hass avocados, tomatoes, citrus, mangos and a wide range of seasonal produce, supplying major supermarkets, foodservice and export markets.

Historically focused on loose fruit and vegetables in Mexico, the company sought new ways to modernise packaging and introduce multi-SKU for fresh produce packaging, while reducing plastic waste. Inspiration came from European retail, where they observed linerless labelling systems in supermarkets like Carrefour during their time in Belgium.

Rodolfo Meza, Director at Troya Group, said: “Whenever I went grocery shopping, the linerless system always caught my eye – especially the neatly packed lines of tomatoes.”

The Challenge

Traditionally, Mexican fresh produce has limited pre-packed options:

• Plastic bags for apples and grapes
• Clamshells for berries
• Nets for avocados and mandarins

Prior to the project, nets were the only packaging format used by Aztec Fruits for many products. There were no readily available carton trays, no linerless labelling infrastructure and minimal consumer familiarity with packed fresh produce.

“It was a big challenge to get trays in Mexico. There’s not one company that assembles small carton trays,” said Rodolfo.

Introducing linerless labelling therefore required not just new machinery, but a new market concept.

Why Linerless?

The decision to adopt linerless labelling was motivated by sustainability, operational efficiency and scalability, enabling Aztec Fruits to implement multi-SKU for fresh produce packaging for a variety of fruits and vegetables. With plastic regulations tightening in Mexico and consumer interest in sustainable packaging increasing, Aztec Foods saw an opportunity to modernise their product lines.

The company presented multiple repackaging options to Mexico’s second-largest supermarket, Chedraui, and Ravenwood’s linerless solution was the clear favourite.

“The cost isn’t high, and that’s crucial – otherwise, expanding on a larger scale would be impossible,” Rodolfo added.

After evaluating several repacking systems, Ravenwood was selected as the preferred partner.

The Solution

Azteca Foods implemented the Ravenwood Nobac linerless applicator, introducing:

• Linerless labels applied directly to carton trays
• 20 SKUs in the initial rollout
• One Nobac linerless applicator (with a second planned)

Linerless Applicator

The Ravenwood Nobac 5000L is a purpose-built linerless applicator for fresh produce trays, engineered to apply ‘fruit lid’ labels directly to carton/fibre-based trays at speeds up to ~70 packs per minute. Its modular design supports a range of tray formats and label styles, helping Azteca Foods scale multiple SKUs for fresh produce packaging with operational efficiency and sustainability at the core.

Linerless Labels

The linerless labels are printed by Reflex Labels’ North American operation in California, part of the globally expanding Reflex Group.

Fibre-Based Trays

TrayCycle™ trays from Paper, Pulp & Film paired with Ravenwood’s linerless labels form a complete, eco-friendly pack. The fibre-based trays combine sustainability, practicality and strong shelf appeal, working seamlessly with the linerless labels to deliver a modern, fully integrated packaging solution.

Performance

• Large trays (mandarins, tomatoes): 20–25 packs per minute
• Smaller trays (apples): up to 50 packs per minute

The Nobac system is easy to operate and fits seamlessly into existing workflows, even for staff new to Ravenwood’s linerless technology.

Market Rollout

The concept officially launched in January 2026, beginning with 30 stores. Expansion plans are ambitious:

• Month 1: 50,000 packs
• Month 2 (projected): 75,000 packs across 50 stores
• Month 3 goal: 200,000 packs across 150 stores

Distribution spans Mexico City and extends as far south as Tulum and as far north as Los Cabos. Azteca Foods is also preparing to supply Amazon Fresh in Mexico City following trials and protocol development.

Sustainability & Environmental Impact

Ravenwood’s linerless labelling system aligns with Troya Alimentos’ sustainability goals, reducing plastic and backing paper waste. Early results indicate significant environmental benefits and alignment with consumer expectations.

“Sustainability is really important to our brand and our customers.”

Retail & Consumer Response

Consumer curiosity has been high, with many experiencing linerless-labelled produce for the first time. Retail feedback has been positive, supporting further expansion.

“Customers are curious about the concept – most of them have never seen it before.”

Sales growth data is still being tracked, but early retailer adoption suggests strong market potential.

Partnership & Support

The collaboration with Ravenwood has been crucial for a smooth market entry.

“The support and guidance from Ravenwood’s team have been exceptional, making our market entry seamless.”

This international partnership has enabled Aztec Fruits to introduce a European packaging concept to a new market with confidence.

Future Plans

Expansion will continue as awareness grows in Mexico:

• More SKUs
• Broader geographic reach
• Additional Nobac 5000 linerless applicators

“First, we need time for people to get used to the concept, and then we can expand to more products and regions,” Rodolfo concluded.

Conclusion

With Ravenwood’s Nobac linerless system, Aztec Fruits / Troya Alimentos has successfully introduced a category-defining fresh produce solution in Mexico. Combining operational efficiency, consumer appeal and sustainability, the project sets a benchmark for modern packaging in the country’s growing fresh produce market.

Contact

Want to find out more? Reach out to our marketing team: +44(0)1284 749144 or send a message via our ENQUIRE NOW button.

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Meeting Production and Sustainability Challenges

Naturvega, which manufactures salads, sauces, dips and ready-to-eat meals for both its own brand and private-label lines across Europe, faced challenges with its previous labelling processes. The company relied on self-adhesive full-wrap plastic labels with backing liners, applied via a combination of manual and semi-automatic methods. This approach led to slow application speeds, high liner waste, frequent stoppages, and rising material costs, limiting the company’s ability to scale production. Environmental concerns, particularly around liner waste, also became a critical consideration for both corporate and retail sustainability commitments.

Choosing Linerless Technology for Eco Friendly Food Packaging

After evaluating alternatives, Naturvega decided to switch to Ravenwood linerless labelling solutions, supplied and configured by Ravenwood’s approved Spanish machinery distributor, iMarket. The Nobac 5000 applicator was selected for its high speed and adaptability, achieving labelling rates of 65–70 packs per minute – more than double the previous rate of 30 packs per minute. The linerless labels are printed by Ravenwood’s approved Spanish linerless label printer, Conver. A Digi H1-700 scale was also installed.

The decision to adopt Ravenwood’s linerless technology was driven by several key benefits:

• Significant speed improvements and line efficiency
• Elimination of backing liner waste
• Reduced material and disposal costs
• Enhanced sustainability credentials, including alignment with platforms such as Ecovadis (a leading global platform for assessing and rating corporate sustainability performance)
• Greater flexibility for print-on-demand labelling
• Compatibility with high-volume production
• Tangible Results and Benefits

Since installing the Nobac 5000, Naturvega has reported measurable operational improvements:

• Faster labelling speeds and higher throughput
• Reduced manual labour and downtime
• Enhanced print quality and improved brand presentation
• Quicker product changeovers and less storage space required for labels

The environmental impact has also been substantial:

• More than 50 million linerless labels applied to date
• Complete elimination of liner waste
• Lower waste disposal costs and extended maintenance intervals thanks to intermittent adhesive

Retailers and customers have responded positively, noting improved shelf appeal and consistent product presentation.

Future Expansion Plans

Building on the success of its initial installation, Naturvega is expanding its linerless operations. Plans include:

• Adding a second Nobac 500 unit to automate another production line
• Considering two additional Nobac 5000 units
• Moving towards linerless labelling as the standard format across its production facilities

Conclusion

Naturvega’s adoption of Ravenwood linerless labelling demonstrates how modern technology can simultaneously improve operational efficiency, enhance brand presentation and support corporate sustainability goals. With iMarket’s expert integration, the company is now well-positioned for continued growth, streamlined production and reduced environmental impact.

For further information, contact Marketing on +44(0)1284 749144.

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This latest linerless development marks a UK first in fresh produce: a 3×2 (six-pack) linerless apple format, following the earlier 2×2 Sassy™ pack also supplied by Mansfield, owners of the Kissabel® brand.

Innovative Linerless Packaging for an Innovative Fruit

Kissabel® Rouge, known for its vivid red skin, natural red flesh and berry-like flavour, made its UK retail debut on 2 December in a striking plastic-free linerless pack that reflects the fruit’s premium appeal. To meet the brief, the packaging solution needed to deliver:

• Strong on-shelf standout
• Fully recyclable materials
• High-speed, reliable application
• A bold design aligned with the Kissabel® identity

ProPrint Group collaborated with Worldwide Fruit, the Kissabel® design team and Smurfit Westrock to produce a robust linerless fruit lid and cartonboard tray format, evolving from the previously launched 4-pack to the new 6-pack configuration. All materials are kerbside recyclable to support retailer sustainability goals.

Nobac 5000L: High-Speed, Low-Waste Linerless Application

At the core of the project is Ravenwood’s Nobac 5000L fresh-produce linerless applicator, engineered for efficient, accurate application of linerless fruit lids. The success of this launch demonstrates the synergy between Ravenwood’s advanced machine technology coupled with Ravenwood’s linerless label printer, ProPrint Group.

Two clean trials were quickly conducted at Ravenwood, achieving optimal setup – essential for this seasonal product. Notably, the first production run was delivered just seven working days after artwork approval.

The Nobac 5000L delivered:

• Consistent, precise label placement
• High-speed performance
• Minimal waste due to the linerless format
• Fast, reliable setup for rapid turnaround

Jan Rees, UK Sales Manager, Ravenwood Packaging said: “The Kissabel® project is a perfect example of how linerless packaging technology can elevate premium fresh produce. The Nobac 5000L was developed to give packers both efficiency and flexibility and it’s great to see it helping our partners bring a UK-first format to market.”

Building on Success with Mansfield Fruit Brands

This launch builds on the success of the Sassy™ apples linerless 2×2 pack, also produced for Mansfield using Ravenwood machinery and linerless technology. Together, these projects highlight how linerless innovation enhances shelf presence while supporting retailers in reducing material waste.

Sustainable Packaging Moving Forward

The Kissabel® 3×2 pack reinforces the shift toward plastic-free, kerbside-recyclable packaging. With the high-performance Nobac 5000L and the print expertise of ProPrint Group, a Ravenwood approved linerless label printer, Kissabel® enters the UK market with a standout, sustainable solution.

Ravenwood Packaging continues to champion its linerless technology that delivers performance, efficiency and environmental benefits across the fresh-produce sector.

For further information, contact Marketing on +44(0)1284 749144.

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The new packs feature Linerless lids printed by Reflex Group, paired with TrayCycle™ trays supplied by Paper, Pulp & Film and printed by Superior Litho. These innovative window tray designs were featured during California Apricot season at major retailers across the USA and Canada.

A key driver of the project’s success is the Ravenwood Nobac 5000 applicator, which applies the linerless fruit lids at over 50 packs per minute. This high-speed automation has delivered substantial labour savings while ensuring consistent, precise application. Ravenwood’s linerless fruit lids offer a sustainable solution that reduces material waste, enhances shelf impact and eliminates the need for backing paper – streamlining both production and recycling.

The TrayCycle™ trays – developed by Paper, Pulp & Film, are a fibre-based alternative to plastic clamshells, designed specifically for produce, prepared foods and foodservice applications. The trays offer a compelling combination of sustainability, functionality and shelf appeal and are fully recyclable and PFAS-free.

“We’re proud to support Blossom Hill Packing with a linerless solution that delivers both speed and sustainability. The Nobac 5000 not only reduces labour costs with high-speed automation but also helps set a new benchmark for product visibility and presentation in fresh produce,” said Tal Cloud, President and Owner of PP&F.

Featuring a custom window design for maximum product visibility, the new linerless pack sets a new benchmark for sustainable retail presentation in the North American fresh produce market. Ravenwood’s linerless labelling technology offers a sustainable, waste-free solution by eliminating backing paper. It enables high-speed, efficient application with full-surface branding – perfect for modern, eco-conscious packaging.

For further information contact Ravenwood’s marketing team on +44 (0)1284 749144 or Tal Cloud at Paper, Pulp & Film on +1-559-233-1151.

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Available during the UK off-season, Sassy™ offers a premium New Zealand-grown option for shoppers looking for something a little different. With eye-catching colour and a graffiti-inspired brand identity, these apples are designed to stand out.

To match the brand’s punchy personality with real sustainability, Sassy™ is packed in a fully recyclable, plastic-free Linerless pack, developed in partnership with Mansfields Fruit Farming, Ravenwood Packaging, Smurfit Westrock, and ProPrint Group. The format uses only biodegradable paper and board, with no plastic wrap or backing waste, while still delivering strong shelf appeal.

One of the key challenges in packing Topfruit apples is achieving secure presentation and standout branding without relying on plastic, ”said a spokesperson from Mansfields”. This move is not only about functionality and sustainability, but also about offering consumers a pack that’s consistent with their values.

The packs are applied using Ravenwood’s high Nobac 5000L machine, ensuring efficiency and minimal waste across production. All materials used are kerbside recyclable and tested for optimal performance.

The impact of easily recyclable packs for Sassy™

We wanted to bring some excitement and differentiation to the apple category,” said Eleni Hogg, Head of Brand at Sassy™. “Sassy™ is about bold design, great eating quality, and doing things a little differently. Our packaging reflects that, it’s fun, functional, and plastic-free, giving UK consumers something they can feel good about picking up.”

The Sassy™ launch is part of a wider sustainability push from Mansfields Fruit Farming and the Sassy™ owners, who plan to roll out more Linerless solutions across their top fruit offerings. As UK retailers look to cut plastic while still delivering premium, high-visibility branding, this packaging format is gaining significant momentum.

Sassy™ apples are available in UK Retailers now, go give them a try you will not be disappointed.

To find out more about Linerless packaging options for Fresh Produce, contact Graham Bonus at ProPrint Group.

Case Study conducted and written by ProPrint Group.

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Dominique van Leendert and Lotte Bronckers

Premium Presentation

Vogely places strong emphasis on the premium presentation of its game products. To support this, the company has worked for many years with Espera—another family business that marked its 100th anniversary in 2024, and is also run by the third generation. Espera specialises in advanced weighing and labelling systems for the food industry. Lotte Bronckers, responsible for marketing, explains: “We don’t just supply the machines—we also provide service, maintenance, training and system integration. I look at how we can improve processes, both in-house and at our clients’.” Dominique adds: “We have direct lines of communication, and if something goes wrong or needs fixing, it’s resolved quickly. That’s crucial during our busy game season.”

Plans for Expansion

When Dominique and his colleagues began planning for capacity expansion and more sustainable packaging in 2024, returning to Espera was the logical step. They visited the EMPACK packaging fair to see a demonstration of the latest weighing and labelling systems, and came back to Kerkrade full of ideas. “They wanted to switch to a new type of skin packaging for retailers, which requires a sleeve containing up-to-date information and a high-end appearance,” explains Jan Zwaan, Managing Director at Espera, who oversaw the project. “Meeting that need called for a combination of speed, flexibility and digital integration. Vogely is the first company to have our latest weighing and labelling machines installed in-line with the Nobac machine,” Jan says. “A first we’re proud of!”

Dominique van Leendert and Jan Zwaan

They chose a set-up consisting of:

• Two ES-E1011 weighing and labelling machines, used to weigh pre-packaged products—both fixed and variable weight. The machines print up-to-date product information and apply labels to both the top and bottom of the packaging. They’re connected to Vogely’s ERP system for real-time data communication.
• One Nobac 5000 from Ravenwood, which applies so-called linerless C-/D-labels—labels without backing paper, reducing waste and providing more space for product information and branding. The Nobac is equipped with two printers that can print top and bottom simultaneously.
• Esprom software, which allows central management of labels and data for both new and existing machines, including the Nobac.

Precise Integration

The machines were installed in August 2024. “We had to fine-tune a few things at first, especially the ERP integration,” says Dominique. “But once everything was set up, it ran smoothly.” The new machines integrate seamlessly with the existing systems and are considered user-friendly by the team. “We now have more capacity, a more professional look, and less chance of errors. The machines are not only technically aligned with our needs—they also support our commitment to sustainability.”

Looking Back with Pride

Both companies look back on the project with pride. The collaboration was smooth and professional. “This truly was a joint effort,” says Lotte. “From concept to execution, everything was coordinated, tested, installed and delivered as a team—on time and within budget.” Dominique agrees: “The entire process went just as we envisioned it, and the end result is a real step forward. This is how three third generations head into the future together.”

www.vogely.nl
www.espera.com 

Photos: © Fotopersburo Bert Jansen

Case Study composed and supplied by: Espera

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PP&F’s TrayCycle boxes, already popular among suppliers of apple, stone fruit, and citrus, can now be paired with Ravenwood’s linerless fruit lids. This combination creates a complete, sustainable packaging solution that eliminates the need for traditional plastic packaging such as poly clamshells or plastic flow wrap.

Transatlantic Partnership Powers Eco Packaging Launch

The collaboration with UK-based packaging expert Ravenwood has empowered PP&F to offer its customers an alternative that is not only 100% kerbside recyclable but also cost-effective. To bring this solution to market, PP&F worked closely with Reflex Labels, a UK linerless printer, to supply a recyclable packaging alternative to an apple grower – launching the first project of its kind in the U.S. for 4-pack apple trays.

“Linerless labelling combined with our TrayCycle box is the perfect solution,” said Tal Cloud, President and Owner of PP&F. “We’ve been looking for ways to move away from plastic, and the paper-based linerless label paired with our recyclable tray creates a winning combination.”

The new packaging format delivers both strength and sustainability. The combined tray and lid offer robust protection for fresh produce, matching the durability of traditional plastic options while providing a sustainable alternative.

“Plastic is incredibly durable, and produce needs that protection,” said Cloud, “but now we can offer the same benefits with a greener footprint.”

In addition to its environmental advantages, the linerless lid offers increased surface area for branding, product information, QR codes, and UPCs, enhancing both shelf appeal and traceability.

Ravenwood has appointed Cloud as an approved distributor of its labelling machinery in North America. “It made sense,” Cloud explained, “to offer our customers a complete, 360-degree solution – from the packaging materials to fully automated packing lines.”

Following the successful apple project, PP&F is already expanding the concept to other fruit categories including apricots, oranges, and additional apple varieties. Conversations are also underway with avocado and kiwi producers.

Ravenwood’s linerless Fruit Lid is rapidly becoming the preferred choice among retailers, brand owners, and packers thanks to its zero waste-to-landfill design and low environmental impact. Unlike traditional labels, linerless labels require no backing paper, reducing waste and production costs.

Linerless Key USPs

• Fewer Roll Changes
  Since there’s no backing paper, linerless label rolls contain more labels per roll, resulting in fewer roll changes and less downtime on packaging lines.
• Space-Saving & Lightweight
  Cartonboard trays and linerless labels are usually more compact and lighter than bulky plastic clamshells, improving transport efficiency and reducing storage needs.
• Retailer Preference
  Many large retailers are pushing suppliers to reduce plastic packaging and adopt sustainable alternatives.
• Regulatory Trends
  Cartonboard and linerless labels are helping companies stay ahead of upcoming regulations banning or limiting single-use plastics.

Founded in 1986, Paper, Pulp & Film operates out of a 115,000-square-foot facility on seven acres in Fresno, complete with a BNSF railroad siding and 14 truck doors. The company supplies a wide range of paper grades tailored for industrial, printing, and agricultural applications.

For more information on Ravenwood’s sustainable linerless labelling, contact the marketing team at +44 (0)1284 749144.

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The award-winning bacon producer has successfully installed two state-of-the-art Ravenwood Nobac 5000 linerless applicators. The company has also partnered with UK-based linerless printer, ProPrint Group, to produce the new linerless sleeves.

“We’re absolutely thrilled with how seamlessly the linerless applicators and our new linerless sleeves have integrated into our production process. The machines have transformed our labelling operations, making it faster and more efficient, while the sleeves provide a premium, high-quality solution that perfectly complements Denhay’s brand,” said Jim Loescher, MD of Denhay Farms.

The switch to linerless comes as part of Denhay’s efforts to reduce manpower on the packaging line, improve staff welfare and add value by smarter spending. The transition from labour-intensive hand sleeving to fully automated labelling has been implemented across all Denhay’s own-label sliced bacon including the Spoilt Pig brand, and wholesale catering packs.

Denhay’s investment in two Ravenwood Nobac 5000 linerless applicators has fully optimised their production lines. These flexible applicators can sleeve a variety of fixed-weight pack formats and tray sizes, linking seamlessly to weigh scales for variable weight packs as well as check weighing. However, Denhay does not connect the Nobacs to scales in this application. The transition to linerless has not only improved packaging efficiency but also reduced storage and shipping space due to the compact nature of linerless reels compared to traditional manual sleeves.

Prior to linerless, employees spent long hours performing repetitive manual sleeving tasks. With the switch to linerless, staff now have more time to focus on other areas of production, leading to improved operations and a significant boost in morale.

“The wellbeing of our staff is at the heart of our operations. This transition has been a true ‘win-win’ – not only have we enhanced our labelling processes, but our team is also much happier with the new system. We’re so impressed with the results that we plan to expand the use of linerless technology across other products in our bacon range,” said Jim Loescher.

Throughout the transition, Denhay sought to retain the premium look and feel of their original cardboard sleeves. Ravenwood’s linerless sleeves, supplied on a roll and cut to size by the applicator, are designed to meet these aesthetic standards. These pressure-sensitive board reels are available in slideable or non-slideable versions, offering a high-quality, seamless finish. With no backing paper, linerless offers an eco-friendly and sustainable solution.

During initial trials, Denhay raised concerns over the visible white lines in the plate repeat pattern on the linerless sleeve. To resolve this, ProPrint introduced an innovative solution by filling the join with the same Pantone colour as the sleeve border during the artwork stage, referred to as an ‘infill’. This solution, which has since become a standard offering by ProPrint Group, ensures the sleeves maintain a flawless, premium appearance at no additional cost to the customer.

Founded in 1952, Denhay Farms has been producing award-winning bacon for almost 30 years. Their products are available through Tier 1 and Tier 2 retailers, as well as online platforms like Ocado and Amazon Fresh.

For further information, please contact Ravenwood’s marketing team at +44 (0)1284 749144.

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THE CHALLENGE

The primary focus was to transition away from plastic flow wrap, paving the way for a packaging overhaul that would meet the criteria for the high-profile marketing campaign.

• Zespri and Tesco collaborated for revamping the kiwi packaging with the aim of introducing a more practical and attractive design that would be both sustainable and fully recyclable.
• The packaging re-design needed to be fresh and vibrant for enhancing the appeal of the kiwi fruit.

THE SOLUTION

Marketing

• As part of the campaign, several trade marketing activities were approved to promote the newly branded packs. Initiatives such as online banners, radio advertising, and consumer sampling were launched to enhance visibility for the new kiwi packs.
• All initiatives implemented to raise consumer awareness and drive engagement for increasing sales.

Packaging

A linerless Fruit Lid and carton board tray has been approved for use in individual kiwi packs. When combined, the Fruit Lid and tray create a fully integrated packaging solution, that UK linerless printer, ProPrint Group, refer to as ‘ProProduce’. This food-grade solution eliminates the need for the plastic flow wrap that was previously used for the kiwis.

For the first time, Tesco is showcasing a branded kiwi product in-store, moving away from their traditional private label branding.

Fruit Lid and Carton Board Tray Packs

• Printed carton board tray supplied by: ProPrint Group.
• Printed wholesale box supplied by: Smurfit Kappa.
• Linerless label technology: Ravenwood Packaging.
• UK linerless label printer: ProPrint Group.

Label and Carton Board Tray Design

• The design and branding has been applied to both the linerless Fruit Lid and carton board tray.
• The graphic design features vibrant shades of orange and yellow, capturing the delicious taste and ripeness of the fruit.
• Speciality tooling is used to die cut sections of the Fruit Lid to resemble ‘sun rays’ that feature to Zespri’s logo.
• This tooling is necessary for die-cutting and removing waste at high speeds, making the product commercially viable for larger volume runs.

Linerless Technology

Unlike traditional labels, linerless labels do not require backing paper on the reel. Instead, they stick to themselves with corresponding strips of adhesive and silicone applied to the label’s underside and surface. This design greatly minimises material usage and waste. By removing the liner, which is typically sent to landfill, linerless labels significantly lower CO2 emissions, offering a more sustainable and recyclable solution.

Linerless Applicator

A Ravenwood Nobac 5000L linerless applicator was procured for applying linerless Fruit Lids to the carton board trays. With a speed capacity of 70 packs per minute, the applicator plays a key role in meeting order fulfilment lead times.

In addition to sleeving fixed-weight, the Nobac 5000L can link to weigh-scales from a range of manufacturers for variable-weight products, as well as check weighing.

THE SUCCESS STORY

The linerless Fruit Lid and carton board tray pack has proved to be a winning formula for both Zespri and Tesco in terms of the criteria set out in ‘The Challenge’.

• Practical and Vibrant Packaging Design = Enhanced on-shelf appeal.
• Kerbside Recyclable Packaging = Consumer convenience and approval for a reduced carbon footprint that supports a wider circular economy.
• 2024 Summer Marketing Campaign = The new packaging, along with the range of promotional initiatives has assisted in raising consumer awareness and driving engagement.
• Sales Boosted = All initiatives and activities launched as part of the Summer marketing campaign have increased sales, surpassing forecasts.

For further information on this case study, then please contact Marketing on +44(0)1284 749144. Visit Zespri’s website.

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Salsicciamo, a multi-award-winning artisan sausage producer, has made significant advancements in their production by switching to linerless labelling. This transition has streamlined business operations, offering increased flexibility, cost savings, faster labelling application speeds, and enhanced sustainability.

Giuseppe Roberti, Salsicciamo’s Founder said: “We have seen numerous improvements, the most significant being our transition from manual label application to fully automated labelling lines.”

“Since moving to linerless, we are now experiencing faster labelling speeds, enabling us to pack and label a wider range of products more time efficiently.”

Application speeds have increased by 133%, enabling retailers to benefit from quicker order turnarounds. Previously, sausage packs were labelled by hand at a rate of about 15 packs per minute. Since fully automating with linerless, production has now reached 35 packs per minute.

Giuseppe added: “Linerless labels are extremely cost-effective and we are seeing a 50% saving on material costs when compared to the self-adhesive labels we were using previously.”

Linerless materials go directly from the mill to the printer, eliminating the need for costly conversion processes associated with self-adhesive labels. Siliconised liner paper is both energy-intensive and expensive. By eliminating the liner and silicone, no waste is sent to landfill. Consequently, linerless labelling results in less transportation, fewer journeys and lower CO2 emissions.

When comparing self-adhesive to linerless labelling, the label dimensions of the self-adhesive labels were entered into Ravenwood’s CO2 calculator. The results show that for each reel of 3,000 labels, 13kg of CO2 emissions are prevented from entering the atmosphere. Additionally, this also means that each reel saves 83 square meters of liner from being sent to landfill.

On considering the full spectrum of benefits, Salsicciamo purchased a Nobac 5000 linerless applicator with a 53mm coder.

Giuseppe said: “The Nobac 5000 can reach speeds of 100 packs per minute and has future proofed our production line.”

Salsicciamo challenged Ravenwood to develop a single flexible labelling format that could accommodate multiple tray sizes. Their sausage products were packaged in four different trays, all with the same width and length but varying heights. Giuseppe also wanted the labels applied along the narrow edge to maximise shelf space in retail stores. Ravenwood’s Keyline Designer created a c-wrap linerless label design that perfectly satisfy these requirements.

Giuseppe said: “Using the same label size for all of our sausage products has made things so much easier. We no longer have to adjust the label applicator’s settings which has really streamlined the labelling application process and enabled us to work much faster.”

Salsicciamo’s labels are printed by UK linerless printer, Coveris. Coveris is a leading European packaging and labelling company.

Before adopting linerless labels, Salsicciamo used a self-adhesive desktop printer to print the self-adhesive labels, which were then manually applied. With the installation of the new Nobac 5000 linerless applicator, labelling processes have been completely transformed, resulting in happier factory staff. Previously, the staff found the manual application process to be slow and repetitive, requiring them to spend a significant amount of time in a cold environment. With more time freed up, staff are able to assist in other areas of the production line.

Founded in 2014 by Giuseppe Roberti, Salsicciamo operates under Carnevale and is headquartered in London, with a nationwide distribution. Products are sold into Costco through Carnevale Wholesale and smaller independent retailers. Their authentic Italian sausages are crafted from UK-reared pigs and are proudly ‘made by Italians in the traditional Italian way.’ The sausages feature select flavours, organic Sicilian sea salt, natural casings, and reduced fat content. They are also gluten-free and additive-free.

For further information, contact Ravenwood’s marketing team on +44(0)1284 749144.

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