Hay & Brecon, a long-established farmers’ cooperative founded in 1902, has built its reputation on quality and reliability throughout its extensive history. As part of their acclaimed Castle range, introduced in 2001, they have relied on high-volume packaging solutions to ensure their products reach market efficiently. However, a growing need to address environmental concerns and escalating costs associated with plastic packaging prompted the cooperative to re‐evaluate their packaging strategy.

The Challenge: Reducing Plastic Usage and Cutting Costs

Hay & Brecon’s existing packaging system was predominantly based on plastic, which presented several challenges:

  • Environmental Impact: With increasing awareness of sustainability, the cooperative recognised that reducing plastic use was crucial. The environmental burden of plastic waste was no longer acceptable for a business committed to responsible practices.
  • Financial Pressures: The introduction of the plastic packaging tax significantly increased their operating costs. Additionally, paper sacks offered a more competitively priced alternative, providing a clear economic incentive for change.
  • Packaging Performance Issues: Attempts to utilise recycled plastic containing 30% recycled content led to difficulties with sealing and durability. This compromised the efficiency of the packaging process, impacting production flow and product protection.

Faced with these challenges, Hay & Brecon needed a packaging solution that was not only environmentally sound but also economically viable. That’s where Peter Marsh Group stepped in.

The Solution: A Seamless Transition to Paper Packaging

Peter Marsh Group worked closely with Hay & Brecon to facilitate a smooth transition from plastic to paper packaging. Our approach was tailored to ensure that the cooperative could maintain operational efficiency while reaping significant environmental and financial benefits.

1.⁠ ⁠Simple Setup and Integration

A common concern when switching packaging materials is whether existing machinery can handle the new material. In Hay & Brecon’s case, the transition was straightforward. Most modern packing machines are designed to handle both plastic and paper, although they perform best when optimised for one material.

After a brief period of trials to fine-tune the settings, Hay & Brecon successfully reconfigured their equipment to run paper sacks. This minimal adjustment ensured that production continued without any significant disruption, demonstrating that the changeover could be achieved quickly and efficiently.

2.⁠ ⁠Immediate Cost Savings

One of the most compelling benefits of moving to paper packaging was the immediate reduction in costs. By eliminating the need for plastic, Hay & Brecon were able to avoid the plastic packaging tax—a considerable financial saving. Additionally, paper sacks are generally more competitively priced than their plastic counterparts, further enhancing cost efficiency.

3.⁠ ⁠Enhanced Environmental Credentials

Switching to paper packaging allowed Hay & Brecon to significantly bolster their environmental credentials. With sustainability at the heart of modern business strategy, this change not only reduced their reliance on plastic but also provided a strong marketing narrative. Customers and partners now recognise Hay & Brecon as a forward-thinking, eco-conscious organisation, a reputation that adds tangible value to their brand.

4.⁠ ⁠Improved Packaging Performance

The performance of the new paper sacks proved to be consistently reliable, overcoming the issues encountered with recycled plastic. The improved sealing and durability of the paper packaging ensured that production flowed smoothly and that products were well-protected during transit. This enhancement in packaging performance further contributed to overall operational efficiency.

The Results: A More Sustainable and Profitable Business Model

Since the transition to paper packaging, Hay & Brecon has realised a host of benefits:

  • Elimination of the Plastic Tax: Direct cost savings were achieved by removing the additional financial burden associated with plastic packaging.
  • Competitive Pricing: The move to paper has resulted in lower packaging costs, enhancing the cooperative’s profit margins.
  • Boosted Environmental Image: Hay & Brecon’s commitment to sustainability has been firmly established, improving their market position as an environmentally responsible business.
  • Operational Efficiency: The superior performance of paper sacks has streamlined the production process, ensuring consistent and reliable packaging.
  • Future-Proofing: Building on the success of this change, Hay & Brecon plans to convert additional product lines within the Castle range to paper. This continued commitment is set to deliver further cost savings and environmental benefits.

Peter Marsh Group: Your Partner for Smarter Packaging Solutions

At Peter Marsh Group, we pride ourselves on helping businesses like Hay & Brecon make pivotal changes to enhance their operational efficiency and sustainability. Our expertise in packaging solutions enables us to provide tailored strategies that meet the specific needs of our clients.

If your business is facing similar challenges—be it reducing costs, eliminating unnecessary taxes, or improving your environmental impact—we are here to help. Our dedicated team works around the clock to offer expert advice and seamless integration, ensuring that you benefit from a packaging solution that is both cost-effective and environmentally responsible.

Get in touch with our Business Development Team today and discover how we can help you transition to smarter, greener packaging solutions.

For more information, please email us or contact our team directly to discuss how we can optimise your packaging strategy.