SFA Packaging, a Dutch expert in injection molding, is has unveilled a groundbreaking structural design at the PLMA’s World of Private Label 2026 trade exhibition at the RAI Amsterdam.
The company has developed a new lightweight rectangular yogurt container that offers a 33% enhancement in logistical and retail efficiencies, effectively addressing a significant manufacturing challenge within the dairy industry.
Historically, dairy producers have preferred round cups, as the angles of rectangular containers necessitate heavier materials and thicker walls to maintain stability, making them less sustainable and bulkier.
In collaboration with Bieze Food Group and retail association Superunie, SFA Packaging tackled this industrial issue, creating a 1,100ml rectangular format that preserves the lightweight qualities and strength typical of standard round dairy cups.
Optimizing Space Utilization
Transitioning from round to rectangular containers provides a crucial competitive edge through improved spatial efficiency. Round containers often leave gaps when packed together, which diminishes space efficiency throughout the food supply chain.
By addressing this challenge, SFA’s redesigned rectangular pots deliver several critical benefits for food manufacturers, logistics companies, and retail partners:
- Increased pallet density: The new shape allows for up to 33% more containers on a standard shipping pallet, significantly lowering both transportation costs and environmental impact associated with excess air.
- Optimized cold storage: Warehouses and distribution centers can accommodate the same product volumes in reduced cubic space, subsequently decreasing energy expenses related to cold-chain storage.
- Enhanced retail presence: Supermarkets are able to display a greater number of product units per shelf meter, which boosts overall category performance.
- Improved consumer experience: The rectangular pots are designed to fit better into standard refrigerator doors, making them more convenient for consumers.
Commitment to Circularity and Supply Chain Transparency
To enhance the overall life cycle assessment (LCA) of the product, SFA Packaging has coupled spatial efficiency with a localized, circular material approach. The containers are produced in the Netherlands using locally sourced polypropylene (PP), which significantly minimizes transportation distances during the initial manufacturing phase.
The mono-material PP structure guarantees that the containers are fully recyclable through standard municipal systems. To meet the growing environmental standards of European retailers and private label brands, SFA also provides options for incorporating bio-circular resins or advanced NextCycle IML labels, which dissolve easily during recycling to avoid resin contamination.
