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Blue Farm Case Study

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Blue Farm Case Study
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Finding ways to reduce packaging waste and improve environmental impact is crucial, especially as consumer demand for sustainable products is rising. According to a recent survey conducted by IBM in February 2022, 51% of global consumers say that environmental sustainability is more important today than it was 12 months ago1. Blue Farm, a provider of oat drink powder, has already significantly impacted this area with its product. Because the customer mixes the powder with water, this reduces Blue Farm's packaging by 10x compared to regular oat drinks. However, they didn't stop there. Recently, Blue Farm has taken an additional step towards sustainability by switching to a more eco-friendly stand-up bag solution in partnership with Packmatic.

The issue Blue Farm faced was the lack of recyclability of their existing packaging solution. Originally, Blue Farm used a common multi-material composition for its former stand-up pouches. This packaging met all the requirements for product protection and food safety, but it was not recyclable as it consists of multiple materials glued together. Multi-material films can’t be separated from each other and therefore have to be burnt. Thus, a full-paper solution for this product is not possible without the use of additional plastic barriers, which would have strongly limited the recyclability of the material. Thus, Packmatic was tasked to find a sustainable packaging solution and source the right supplier for future production, meeting all constraints regarding regulation, product protection and recyclability.

How Blue Farm used Packmatic to switch to sustainable packaging and reduce its annual spend by 25%

Blue Farm was founded in Berlin with the goal of rethinking the concept of “milk” in a new, more sustainable and plant-based way. Thus, a delicious and colorful range of oat bases and oat lattes in powder form has been created, becoming a fresh, creamy and natural drink in just 10 seconds. The product reduces up to 90% of packaging waste, transport emissions, the impact of dairy consumption and avoids food waste, for a more sustainable tomorrow.

Industry
Food & Drinks
Location
Berlin, Germany
Business Model
D2C (Direct-to-Customer)

Finding ways to reduce packaging waste and improve environmental impact is crucial, especially as consumer demand for sustainable products is rising. According to a recent survey conducted by IBM in February 2022, 51% of global consumers say that environmental sustainability is more important today than it was 12 months ago1. Blue Farm, a provider of oat drink powder, has already significantly impacted this area with its product. Because the customer mixes the powder with water, this reduces Blue Farm's packaging by 10x compared to regular oat drinks. However, they didn't stop there. Recently, Blue Farm has taken an additional step towards sustainability by switching to a more eco-friendly stand-up bag solution in partnership with Packmatic.

The issue Blue Farm faced was the lack of recyclability of their existing packaging solution. Originally, Blue Farm used a common multi-material composition for its former stand-up pouches. This packaging met all the requirements for product protection and food safety, but it was not recyclable as it consists of multiple materials glued together. Multi-material films can’t be separated from each other and therefore have to be burnt. Thus, a full-paper solution for this product is not possible without the use of additional plastic barriers, which would have strongly limited the recyclability of the material. Thus, Packmatic was tasked to find a sustainable packaging solution and source the right supplier for future production, meeting all constraints regarding regulation, product protection and recyclability.

25%

cost reduction

4 tons

annually made recyclable

(& rising)

Objectives:

Sustainable Solution  

Cost Savings

Packaging Quality

Results:

Recyclable, mono-material

25% cost savings

Premium look & feel

As a solution, Packmatic identified a fitting material that meets the needs of both the filling good and the company. The new stand-up pouches are made from a recyclable mono-material structure. The switch makes the bags recyclable, the stability of the bags is maintained through the use of an MDOPE and also the special barrier requirements for the product are still met.

But that's not all. Blue Farm also introduced a switch from stickered to printed bags, which not only improves the product's appearance but also increases recyclability. Furthermore, the use of light color prints is additionally beneficial to the recycling process.

This is also a conscious choice against greenwashing, as many companies choose to go with non-recyclable alternatives that look sustainable. Examples for this are paper-foil combinations or home-compostable alternatives, which both end up being burnt in most cases.

"Thanks to Packmatic, we were finally able to switch our packaging to mono material and full print, improving not only the recyclability of our packaging, but also our brand image. We have long been searching for a partner who can flexibly ensure high quality and cost-effectiveness, and through Packmatic we have been able to make our packaging a real marketing asset for us and even save costs in the process. We are thrilled with how dedicated the team is: regardless of the requirement, they make it happen in the shortest possible time."

Marie-Louise Völkel, Head of Business Development at Blue Farm

Challenges of finding the ideal solution included ensuring stability and maintaining high quality with the mono-material structure. Due to the great collaboration, all of these challenges could be solved. Not only do the new bags generate 25% savings despite lower minimum order quantities per specification and improved sustainability, but the company also expects the recycling of approximately 4 tons of material annually. While Blue Farm has yet to obtain a recyclability certification, this might be a next step in its journey toward a circular economy, due to Packmatic's great relations to various certification partners.

Due to the collaboration with Packmatic, Blue Farm was able to develop and source the right packaging solution that met both their product needs and sustainability goals. As more and more companies like Blue Farm switch to sustainable packaging, it is only a matter of time until others follow the rush to implement recyclable design and think circularly, to drive positive impact on the environment.

In conclusion, Blue Farm's recent switch to more sustainable stand-up bag packaging in partnership with Packmatic is a shining example of how companies can positively impact the environment while also meeting internal constraints regarding economic feasibility and product requirements. By switching to a recyclable mono-material and exchanging labeled with printed bags, Blue Farm was able to not only improve recyclability but also increase the bag's stability and provide good barrier properties while reducing costs. In such fashion, any company might be able to help the environment by using circular design principles and applying recyclable design.

Material:

PE-based mono-material

Construction:

Standup Pouch K-Seal

Printing:

High-quality digital printing in CMYK.

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