WHERE IT BEGAN

This partnership was kickstarted at Packaging Innovations in 2019, where Pret approached Colpac about developing sustainably sourced, paperboard platters to package their delivery range. After understanding Pret’s key challenges and goals, Colpac designed a visually striking new platter with a double walled picture frame construction that was strong enough to hold a variety of food contents for takeaway and delivery. The team also supported with training on assembly to ensure that the platters were quick to construct in busy Pret kitchens, supporting efficiency targets.

With a significant reduction in plastic content from the previous options, the paperboard platters were made with a PEFC-certified board and provided improved functionality and visual appeal. They also featured a lightweight laminate to guard from grease marks during prep and filling. Following testing and in-store trials, this product was launched globally in early 2020, which set the precedent for a partnership driven by sustainability and based on trust.

“Pret prioritises sustainability, and so do we, which is one of the reasons why our partnership works,” said Jonathan Morton, director of business development at Colpac. 

PLATTERS TO SALAD BOWLS

On the back of this innovative work, the team moved into another area of packaging development together, to create a new pack for Pret’s salads. Aiming to showcase the quality, freshness and nutrition, paperboard bowls were proposed with a wide top out to maximise visibility. Along with benefits around grease resistance, stability, nesting and ease of consumption for the end consumer, these bowls are made from FSC® certified paperboard. Custom-designed with Pret artwork to maximise the brand, the bowls are now in use at all stores worldwide. 

Part of this partnership was to bring production of the Pret bowls from overseas to the UK. Colpac invested in new machinery and three sizes of bowls are now manufactured for Pret at Colpac’s site in Bedfordshire. This facilitates tighter quality control, reduced environmental impact, much shorter lead times and a secure supply chain – particularly beneficial as global distribution networks become more difficult to navigate. Colpac’s agile UK factory is also the manufacturing location of Pret platters, as well as many custom food packaging projects and off-the-shelf ranges. This helps to provide market driven support and supply to many UK and European customers that look to reduce risk through local production.

“We are always looking at ways to improve products further – and our expert team gives us this ability to innovate and provide even better solutions to do Pret’s freshly made and delicious food justice,” continued Morton. 

AWARD WINNING

Fast forward to 2024 and the teams wanted to reduce plastic content further and make Pret platter bases even simpler to recycle. Following a thorough development process and exhaustive testing, Colpac and Pret launched its latest platter bases with no plastic laminate. This was achieved by replacing the plastic coating with direct food contact inks, incorporated with Colpac’s long-standing supplier – Sun Chemical.

Its Direct Food Contact (DFC) offering combines SunPak® DirectFood Plus inks with SunStar® DFC water-based varnishes to enable safe, compliant printing on the inside of fibre-based packaging. The inks are vegetable-based, mineral oil-free, low odour and certified for direct food contact. They deliver intense colour, covering over 75% of the Pantone colour range, enabling foodservice brands to bring vibrant, safe colour to the inside of the packaging and enhance consumer experience.

When paired with Sun Chemical’s SunStar® DFC functional varnishes, they offer vital protection against grease, moisture and abrasion, improving product quality. This means that foodservice brands can avoid using laminated plastic filmic layers on board, improving recyclability and helping to meet sustainability goals. Additionally, this simplified approach that facilitates a mono-material structure helps reduce packaging Extended Producer Responsibility (pEPR) costs. By replacing fibreboard composite materials with uncoated paperboard and direct food contact inks, the latest Pret platters are recyclable through any paper re-pulping process.

Colpac also identified and used new, lighter paperboard to further reduce the environmental impact of the platter bases. These changes are projected to achieve 9407kg* of packaging material savings/year and reduce projected pEPR unit cost by an impressive 55%.

This was the first project of its kind in foodservice, bringing this incredibly exciting technology to the marketplace in 2024. The success of this launch was marked through the winning of the New Packaging Award at the Sammies in 2025.

Both packaging solutions are thriving in Pret stores due to effective design that showcases fabulously fresh food to consumers, while also meeting operational and ESG challenges. Colpac proactively develops the products and provides consistent management of stock levels and service support. 

*Weights are calculated based on Pret’s annual usage.