In a market where sustainability, supply chain resilience and brand trust matter more than ever, one leading UK pulses and seed manufacturer has proven that smart packaging choices can make all the difference.

After years of sourcing packaging from overseas, this well-known bird food supplier decided it was time to rethink its approach. Rising transport costs, long lead times, and pressure from retailers to reduce plastic use pushed the company to search for a better, local alternative. That search led them to Peter Marsh Group, the Liverpool-based paper sack manufacturer with nearly two centuries of experience supplying high-quality, sustainable packaging across the UK.

The Challenge: From Plastic to Paper and From India to the UK

For many years, this manufacturer relied on plastic packaging supplied by a producer in India. Initially, the lower unit price made financial sense. However, as environmental regulations and consumer expectations shifted, plastic quickly became a liability. Retailers were demanding recyclable, paper-based packaging options and customers were making purchasing decisions based on sustainability credentials.The manufacturer made the first move by asking their Indian supplier to switch production from plastic to paper sacks. While this improved sustainability optics, it introduced new complications:

  • Lead times of 12-15 weeks made production scheduling difficult.
  • Shipping delays and customs checks caused frequent stock shortages.
  • Freight costs surged, narrowing the price gap between Indian and UK-sourced packaging.
  • Limited quality oversight meant that each batch varied slightly, affecting product presentation and consistency.

By mid-2024, the cost advantage of importing sacks from India had all but disappeared and with carbon emissions from overseas shipping becoming harder to justify, the company decided to look closer to home.

The Switch to Peter Marsh Group

After consulting with their distributors and sustainability team, the company reached out to Peter Marsh Group for a solution that could deliver the same performance with faster, greener results.

Peter Marsh’s team carried out a full packaging assessment, testing paper sack designs that would maintain product protection for the bird seed while meeting the retailer’s requirements for 100% recyclable materials. Within weeks, trial runs were completed and approved, allowing the company to fully transition production to UK-based paper sacks.

Results: Speed, Quality, and Sustainability Gains

The move to Peter Marsh Group’s UK-made paper sacks delivered immediate improvements across multiple areas:

1. Faster Lead Times

Orders that once took three months now arrive in under four weeks, giving the company flexibility to respond to changes in seasonal demand, which is critical in the bird food market.

2. Improved Quality Control

With production taking place in Liverpool, the company can now visit the site, inspect print proofs, and approve batches directly. Every sack is manufactured under BRC AA+ certified conditions. The highest standard in packaging quality and hygiene.

3. Sustainability Alignment

The sacks are fully recyclable, paper-based, and manufactured locally, significantly reducing transport emissions compared to imports from Asia. This aligns perfectly with both retailer CSR targets and the brand’s own “homegrown and responsible” message.

4. Competitive Total Cost

Once freight, customs, and storage costs were accounted for, the UK-made sacks proved to be cost-neutral and operationally superior. The company now benefits from predictable deliveries, stable pricing and reduced administrative overhead.

A Partnership Built on Shared Values

The collaboration has evolved beyond a supplier relationship. As a valued customer, the seed manufacturer was invited to Peter Marsh Group’s annual Race Day at Haydock Park, an event celebrating long-term partnerships and the company’s deep roots in UK manufacturing.

For the team, this wasn’t just a day at the races, it symbolised a new kind of partnership: homegrown packaging for a homegrown brand, built on shared commitments to quality, sustainability and reliability.

The Value of Staying Local

This case highlights the tangible benefits of working with a UK-based manufacturer:

  • Reduced risk from global disruptions
  • Transparent quality assurance
  • Lower carbon footprint
  • Faster, more flexible supply
  • A shared understanding of UK market needs and compliance

In short, switching from imported to UK-made paper sacks has helped this bird food producer future-proof its packaging strategy, ensuring reliability, sustainability and brand integrity.

Partner with Peter Marsh Group

If you’re a UK manufacturer considering a switch from imported or plastic packaging. Now’s the time to explore the advantages of sourcing locally.

Peter Marsh Group, based in Liverpool, produces custom, recyclable, and BRC AA+ certified paper sacks for food, feed, agriculture and construction sectors across the UK and beyond.

Contact our Business Development Team or visit www.petermarsh.co.uk to start your packaging transformation. See why “homegrown packaging for homegrown brands” is the smarter choice.