FROM GLASS TO rPET
AND INTO GROWTH
A European antipasti producer supplying the retail market had traditionally packed its products in glass.
The customer wanted to explore whether plastic packaging could offer an attractive alternative while maintaining the premium appearance of the product and incorporating recycled material.
The challenge
Moving away from an established glass format was a significant packaging decision.
The customer needed confidence that a plastic alternative could deliver the transparency and presentation expected in retail while also providing the necessary stability during filling, transport and handling.
There were also broader commercial considerations. How would consumers respond to the material change? Could the packaging perform reliably throughout the supply chain? And would the new solution provide a strong platform for future packaging requirements?
The challenge was therefore not simply to find a plastic tray. It was to develop a packaging solution that could make the transition from glass commercially and operationally viable.
The solution
Together with the customer, Plus Pack identified Cubus™ in rPET40 as the right starting point.
The clear rPET material provides an appearance comparable to virgin PET while containing at least 40% recycled material, including a minimum of 25% post-consumer material.
The square Cubus™ design also offered practical advantages compared with the previous packaging format, supporting efficient use of space during transport and in refrigerated retail displays.
To meet the customer’s specific requirements, Plus Pack further adapted the tray-and-lid solution:
· Reinforced tray design provided the required strength and stability.
· New forming components improved material distribution.
· An optimised lid supported transport stability, easy application and reclosing.
· Clear rPET40 material combined product visibility with recycled content.
· Square packaging format supported efficient use of space in transport and retail.
The result was a tailored packaging solution designed not only around the product, but around the customer’s wider operational and commercial requirements.
The results
The move from glass to Cubus™ rPET40 has developed into a strong commercial success for the customer.
Volumes have increased significantly year to date, and demand is expected to result in 2026 volumes more than doubling compared with 2025.
The growth has also led the customer to invest further in the concept. Additional sealing capacity has been introduced to accommodate demand, while the success of the original format has supported an expansion of the range with an additional Cubus™ size.
What began as a strategic material change has therefore developed into a growing packaging platform.
The project demonstrates how the right packaging solution can create value beyond the material itself — helping customers:
· Make a significant material transition with confidence
· Maintain strong product visibility and retail presentation
· Incorporate recycled material
· Improve space utilisation in transport and retail
· Scale the solution as commercial demand grows
PACKAGING DEVELOPMENT WITH PPWR IN VIEW
PPWR is increasing the focus on recyclability, recycled content and how packaging is designed for future requirements.
For this Cubus™ solution, Plus Pack provides relevant supplier information, technical data sheets and food-contact declarations for both tray and lid.
The clear mono-material structure and documented recycled content also provide the customer with a clear basis for reviewing the packaging as further PPWR requirements are phased in.
The project shows how future packaging considerations can be incorporated into a commercial packaging decision without losing sight of performance, presentation and market acceptance.
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