How to Choose Your Right Packaging Format with Sealpac UK?

In today’s competitive food industry, choosing the right packaging format is crucial—not only for product protection, but also for brand appeal, sustainability, shelf life, production efficiency, and ultimately consumer safety. Whether you're launching a new product or upgrading your line, the right format can boost both your operations and your consumer satisfaction.

At Sealpac UK & Partners, we guide food manufacturers across the UK and Ireland in selecting innovative and sustainable packaging solutions that meet market demands. From recyclable traysealing to vacuum packs and flow wraps and bagmakers, here's a breakdown to help you choose the right format for your product.

Sustainable Traysealing Formats That Perform

Traysealing remains one of the most adaptable, cost-effective, and environmentally responsible formats in food packaging. Sealpac's machines are designed to run a variety of sustainable packaging formats that help reduce environmental impact while maintaining visual appeal and protection.

Key tray formats include:

• Mono-Mono Trays: 100% recyclable packaging made from mono-material base trays and top films. Ideal for brands prioritising recyclable plastic reduction.
• Fibre Trays: Featuring a compostable fibre base with a removable liner, these trays are recyclable, oven and microwave safe, and available in custom colours and artwork.
• Foil Trays: Made from endlessly recyclable aluminium, suitable for oven and microwave use. Excellent for ready meals, meat, and baked goods.
• Cardboard Trays: FSC and BRC certified card trays with removable liners. Designed for fully recyclable, food-grade packaging.
• eTray®: These combine reduced plastic content with strong visual presentation. eTray® uses a cardboard base and liner system, cutting plastic by up to 40%.
• TraySkin®: With their 100% recyclable mono trays, and top film, they provide extended shelf life. This also helps reduce food wastage.
• FlatSkin® and FlatMAP®: Premium flatboard formats using recyclable materials for sliced products and enhanced merchandising.
• EasyLid®: Creates a seal and a lid in a single step, eliminating the need for additional lidding machinery and streamlining your line. Reclose feature included as well.
• Separate InsideCut: Offers MAP-sealed, individually separated compartments within a single tray — extending shelf life and enhancing product presentation. Ideal choice for snacks and lunch packs.

Thermoforming: Smart, Scalable, and Sustainable

For high-speed production environments, thermoforming offers unparalleled output, consistency, and material flexibility. Our advanced Sealpac Thermoformers support mono-structure films and enable film downgauging, helping reduce packaging weight without compromising on pack integrity.

Our innovations include:

• Mono-Mono packs: 100% recyclable packaging made from mono-material base and top films. Ideal for brands prioritising recyclable plastic reduction.
• Rapid Air Forming: A reliable process that maintains forming quality while enabling reduced material thickness.

• FibreStyle: Compostable paper-based thermoformed packs that support flexible shapes, ideal for premium, sustainable retail packaging.
• DaybyDay Format: Portion-controlled packs designed for daily consumption, extended shelf life, and improved convenience.

These systems work seamlessly with recyclable films including PE, PP, and mono PET structures.

Flexible Bagmaking with JASA

As demand grows for efficient, adaptable packaging, our VFFS (Vertical Form-Fill-Seal) machines — supplied in partnership with JASA — offer reliable, high-speed performance with a strong focus on sustainability.

Key benefits include:

• NXXT Bagmaker: Capable of producing multiple bag styles, using recyclable or compostable films. The system delivers fast changeovers and minimal downtime.
• Bag Material: Bagmaking technology integrates various sustainable materials including - mono, paper, netted or vented bags.
• Versatility: Suitable for packaging snacks, produce, dried goods, confectionery, and more.
• Operator-Friendly Interface: Designed with usability and efficiency in mind, reducing training time and boosting uptime.

Whether you're seeking compact VFFS machines or large-scale bagging systems, we deliver flexible packaging solutions tailored to your product and line speed.

Flow-Wrapping Solutions with Synchropack

Sealpac UK & Partners, in collaboration with Synchropack, offers high-performance horizontal flow-pack machines designed for precision and versatility. Ideal for both primary and multipack formats, our flow-wrappers handle a wide range of products—from snacks and bakery items to meat and produce.

Key features include:

• Custom automation for stacking, grouping, and feeding
• Compatible with sustainable films for eco-conscious packaging
• Reliable, space-saving design for consistent, efficient output

Enhance your packaging line with tailored flow-wrapping solutions that support productivity and sustainability.

Vacuum & Shrink with BMB

Through our partnership with BMB, we deliver advanced vacuum packaging machines built for high-volume, high-efficiency packaged food production requiring vacuum or MAP.

These robust systems ensure consistent sealing quality and are engineered for intensive, industrial use—supporting sustainability and productivity across your packaging line.

Let us help you find your accurate packaging format

There’s no one-size-fits-all in packaging. That’s why we invite you to our Innovation Centre at our HQ in Poole to experience our technology in person. With our Consulting, Delivering, Supporting mantra, we are confident we can help identify the best format for your product and brand.

Get in touch today to discover how our packaging and inspection solutions can transform your production line while embracing sustainability.

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