ACA Ltd is renowned within the packaging industry for its highquality finishes and wide service offering. Having worked hard to diversify its portfolio over the years, the company is now offering end-to-end services. Carole McGregor, Customer Service Manager, explained more, in an exclusive interview with Inside Sustainability. Report written by Imogen Ward.
Initially focused on print finishing, the company diverted its focus to carton making when the company was acquired by Executive Chairman Dara Changizi in 2016. Today, ACA offers a wide range of services – each one just as pivotal as the next.
“Every service we offer has its own importance, and they all complement each other well,” Carole McGregor, Customer Service Manager, explained.
“A lot of what we do here is multi-process, and to be able to offer that is really one of our major unique selling points.”
Based out of a 40,000sqft facility in Inchinnan, Scotland, ACA provides customers with top-quality print finishing services. 5,000sqft of this area is entirely dedicated to factory space, which is managed by its sister company PAC Scotland (PAC).
Breaking into a new market
In 2018, the factory was granted BRCGS AA certification, which allowed for the processing of sheet foil work for the food packaging industry. Once successful in gaining accreditation, two nesting machines were ordered for the factory, to allow for the manufacture of opentopped takeaway cartons.
Since then, the factory has been subject to another BRCGS audit with outstanding results.
“Our most recent scoring came from an unannounced audit,” said Ms McGregor. “We were really happy with the results of that because we were awarded the AA+ level certification, which is the highest level achievable.”
Working in such close proximity to its sister company PAC, ACA witnesses the company’s achievements first-hand. PAC is a one-stop shop for environmentally friendly packaging targeting the takeaway food industry, and with the roaring success of its food cartons, the company plans to further develop its presence within this market.
“With a major focus on events, PAC has just begun production on non-plastic boxes for burgers and takeaway trays in different sizes,” Ms McGregor added. “We are also working closely with a company to perfect the barrier coating on these packages. Often companies will claim to offer heat and grease proofing in one
barrier. However, this does not seem to be the case.
“We have now found the first barrier that genuinely does both. This has been developed over the last six months and has been successful during the trial period. We expect this to be with our customers in the coming months.”
The A to Z of services
When it comes to packaging, ACA offers a diverse range of services, going the extra mile to ensure every customer receives a high-quality finish that they are happy with. Having everything under one roof ensures customers receive a simple and stress-free production process.
“A lot of the cartons that we manufacture are for the whisky industry, these often require lamination, foiling and die cutting before being glued together,” said Ms McGregor. “Having all that under one roof is a huge advantage.”
For those in the market for pre-packaging solutions, ACA is the only finishing company in the UK to manufacture both blocking dies and laser formes. With more than two decades worth of knowledge when it comes to die production, ACA offers multiple options. For a long-lasting and durable foil-block, ACA uses brass. The company also specialises in a magnesium alternative that can be made at a quicker pace and a cheaper price but does not hold the same longevity as its counterpart, making it best for shortterm projects.
“Having both blocking dies and laser formes in-house makes everything a lot more efficient,” Ms McGregor explained.
“We can have everything ready for when the customers need it. Also, if they require any tweaks, we can do that quickly, rather than having to send it out for adjustments. This avoids a lot of unnecessary delay.”
With more than 70 different processes available, ACA also offers foiling, die cutting , UV varnishing, embossing, Wire-O binding and logistics.
Becoming a more prominent part of the business in recent years, ACA’s logistics consists of four vans and a 17-tonne lorry. With the desire to make the finishing process as efficient as possible, these vehicles are regularly put to use transporting customers’ products nationwide.
Maintaining a green status
ACA has also expanded its offering to incorporate more sustainable materials and components. When it came to its choice of foils, the company was determined to keep it green.
“Our foil suppliers are the very best in the UK, and they offer options that are completely recyclable,” said Ms McGregor. “It is definitely an important factor for us, because we are heavily focused on sustainability.”
Also, on offer as part of ACA’s bid to be more sustainable are plastic alternative components, including biodegradable films.
Through its Wire-O binding service, clients can also customise their products with an added eco-friendly touch. At customer
request, ACA will incorporate biodegradabl e coils during the binding process.
“The biodegradable coils are a new product from our coil supplier,” Ms McGregor continued. “This option has been available s ince the start of 2023.”
The company’s commitment to sustainability is not limited to its supply chain, it has also partnered with a waste management company that sorts and recycles all the waste from the ACA facility.
ACA also has an entire fleet of electric cars, which it intends to expand this within the coming months.
New developments
With the desire to work more closely with end users, ACA has recently expanded its service portfolio. Having previously focused on print finishing and carton making, the company wanted to provide customers with a comprehensive service from start to finish.
“We have never dealt with this element of print before,” Ms McGregor explained. “That’s something that we are now diversifying into, and we are really excited about the potential of this new venture.”
To kick-start this, ACA has taken on a new customer in the local area. Since May 2023, the company has managed the print, diecutting and production for over one million of this customer’s cartons.
“That will be our main focus going forward, as we really want to perfect printing before we move on to bigger and better things,” said Ms McGregor. “Our main goal is to make sure customers are happy, and that there are no issues. That’s why we want to be there throughout the whole process , so we can ensure they are receiving a product they are happy with.”
“There’s a great pride that comes with bringing a customer’s idea to life,” Ms McGregor concluded. “It is such a collaborative process, and being able to achieve their vision is really special.” n
