PFF Group is a leading manufacturer of rigid plastic packaging. The family-owned business has a focus on the environment, producing recyclable and sustainable packaging solutions for a variety of sectors. Managing Director Rob Atkin discussed the company’s expansion and innovative technology, in conversation with Antonia Cole.
Over the past few years, PFF Group has achieved significant growth, Managing Director Rob Atkin said:
“In 2021, we acquired Sirap UK as part of our continued growth strategy. Bringing together two reputable packaging businesses has given us the capacity and floor space to grow all areas of our business. This includes investment in new technology, including an in-mould labelling thermoformer, the only one of its kind in the world. This innovation has the potential to revolutionise sustainable packaging.”
Established in 1993, PFF Group is the UK’s largest independent food packaging manufacturer. The company employs 220 people across two sites, the first in
Keighley, West Yorkshire, and the second in Sedgefield, Stockton-on-Tees. With a vertically integrated structure, PFF Group generates an annual turnover of £40 million.
When it was founded, the company originally manufactured plastic packaging for imported cosmetics, toiletries and gifts, before then entering the food packaging sector. This transition induced rapid growth for PFF Group, which now provides packaging solutions to leading supermarkets, multi-national food manufacturers, food service and fresh produce companies across the UK.
In 2020, the company’s ability to be flexible and meet individual customer
SHABRA RECYCLING
We congratulate Rob Atkin and PFF on installing their unique new packaging line, which shows their commitment to innovation, sustainability, and creativity while also leading the way in using recycled PET in their products.
As Ireland's leading RPET supplier, we value innovation and investment, i.e., our recently installed Irelands-only PET reprocessing hotwash line.
We wish PFF continued success and look forward to growing our relationship.
editorial mention
requirements led it to provide frontline NHS and social care staff with disposable aprons for the Department of Health and Social Care. Following on from PFF Group’s newly established health division, the company acquired Sirap UK less than a year later.
Sirap UK was part of the Italian Sirap Group, a leading provider of thermoformed rigid plastic food packaging. The combining of both companies gave PFF Group the space to grow and broaden its product portfolio and client-base to what it is today.
Leading the pack
PFF Group’s continuous success led to the significant investment in a new thermoforming machine, made in collaboration with ILLIG Gmbh. As part of a multi-million pound investment programme in new process technology, this development encompasses the company’s commitment to innovation, sustainability and creativity.
As the first of its kind in the world, this machine has enabled PFF Group to maintain its position as a leader of sustainable packaging. The company’s IMPAC-T packaging is produced in the machine, facilitating the transition from polypropylene to more recyclable materials. IMPAC-T is made from rPET, a plastic that contains up to 90% recycled material, over 50% of which is post-consumer waste.
The machine’s advanced technology creates a hybrid pot with a card wrap within a singular process. By streamlining packaging production and improving efficiency, carbon emissions are reduced significantly in comparison to the previous
two-stage manufacturing process. The end result is a fully recyclable composite pack that is suitable for a variety of food industries.
“It’s a really revolutionary piece of kit,” added Mr Atkin. “The product itself isn’t new to the marketplace, but the process that the machine allows, is. This not only sets us apart from our competitors, but also creates a new sustainable option for the industry. As well as being extremely efficient, this process reduces plastic usage by up to 25%, making it a brilliant alternative for brands hoping to lower their environmental impact.”
Through the implementation of this technology, PFF Group has secured large contracts, creating significant growth for the company. Some major brands that are now utilising this new environmentally friendly system are Onken, Tim’s Dairy, Rachel’s Organic and Graham’s Family Dairy.
Not only does this machine allow PFF Group to operate more sustainably, but it also extends this opportunity to customers. Many food companies are looking for innovative ways to limit their impact on the environment and this innovative packaging process fills a gap in the market for effective sustainable packaging solutions.
Sweeten the pot
In addition to implementing efficient machinery like the new Illig thermoformer, PFF Group has a variety of ways in which it is reducing the environmental impact of operations. With full granulation capability across both sites, the company heavily engages in the recycling of excess material.
Both PFF Group’s rPET and polypropylene contain approximately 30% post-process waste from the company. Excess material produced in operations is collected, before it is then transformed into new thermoformable PET and polypropylene sheets.
“Recycling our own waste has a substantial impact on our sustainability as a company,” explained Mr Atkin. “Although we try to make our processes as efficient as possible and minimise waste, it is
important to recycle any waste from our processes. As well as recycling our own waste, every year we convert 6,000 tonnes of post-consumer waste into PET Trays. This not only improves sustainability, but also reduces our use of virgin raw materials.”
Managing Director Rob Atkin
Where possible, PFF Group sources materials locally. This supports the UK supply chain and reduces the company’s carbon footprint as less transportation is required.
“In 2022, we invested in an energyefficient transformer for our site to significantly reduce energy wastage,” continued Mr Atkin. “This has resulted in a five per cent reduction in our carbon footprint. We are also converting our company cars to hybrid or electric vehicles to limit pollution.”
Wrapping up
PFF Group is working with a sustainable plastic consultancy company called Nextek. NEXTLOOPP is Nextek’s project aiming to create a more circular economy around plastics, closing the loop on food grade PP. Using unique marker technology, food-grade packaging can be separated at plastic recycling facilities to then be reused.
The packaging division at PFF Group has supported the implementation of this innovation by undertaking a production trial of the recycled polypropylene resin, PPristine. Once commercialised, this material has the potential to be used in injection moulded packaging, which is usually difficult to recycle.
“Collaborating with others who share our passion for sustainability is what’s allowing us to make real progress,” commented Mr Atkin. “We’ve built up relationships with partners and suppliers since the company was founded, so we work very closely with them. Not only does this allow us to ensure we are using high-quality recycled materials, but we work with them to improve processes together.”
PFF Group hopes to continue expanding over the coming years. The company will continue developing its existing processes, as well as actively looking for new technology that will allow it to
deliver high-quality products that drive sustainability.
“We have a lot of freedom at PFF Group,” Mr Atkin said, in conclusion. “As an independent business, we have the ability to adapt and act quickly, better fulfilling our customer’s needs. This is a key factor in what will drive our growth into the future.”
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