Sustainability & Plastics

Whilst the media is dominated by headlines surrounding plastic packaging waste we must be careful not to demonise all plastic packaging.  Across the supply chain, businesses need to respond with acctions that do not shift the environmental and recycling problem from one type of packaging material, to other less reusable or less recyclable alternatives.

There is no doubt unrecyclable single-use plastics are a bad thing.  Everyone has a responsibility to actively seek out alternatives to these.

Why use Plastics?

  • Without doubt, plastics extend the shelf life of food products, and reduce food waste
  • Plastics offer the consumer convenience and support modern-day, busy lifestyles
  • Almost all Rigid Plastics containing food items on the supermarket shelves contain PCW* recyclate content and are reusable or recyclable (* post consumer waste)

Charpak welcomes new talent

Paul Smith, Managing Director announces dynamic talent joining the expanding Charpak team. "Dan joins the team at an exciting time with the business going from strength-to-strength. With Dan's sales management and consultancy expertise, his experience is crucial in securing new business, and we also welcome two highly skilled designers, Sam and Daniel, who are already delivering the highest quality designs to solve our clients’ packaging needs”.


Dan Savident, Sales Manager leads the team in the next stage of the company’s growth. With 25 years in sales, sales management and new product development Dan has Dan Savident, Sales Managerworked with both SMEs and 'Fortune 500' companies serving the grocery retail, automotive and sports apparel sectors with globally recognised brands including Tesco, M&S, Nike and adidas, managing teams across the world. Dan is dedicated to ensuring Charpak's customers elevate their products through innovative product design and ensuring Charpak clients differentiate themselves from their competition. Dan is also a keen historian and is currently in his third year of an Open University history degree.

Technical Design

Sam Eggins, Junior Design EngineerCharpak welcomes Sam Eggins as Junior Design Engineer. Sam’s experience in industrial and interaction design spans the full concept creation through to manufacturing new products for a plethora of global brands in the airline, travel and electronics industries.  Prior to achieving his BA in Industrial Design and Technology Sam had already gained dynamic experience working in Central London and Amsterdam product design studios.
Sam’s technical knowledge includes CAD modelling in Solidworks, Fusion 360, Keyshot and electronics coding in Arduino IDE. Sam says his inspiration comes “from anything and everything that surrounds me. I love working in a highly creative environment, generating new ideas and making aesthetics and functional products.” With a love of acoustic and mellow electronic music Sam’s musicality encompasses playing the drums, learning new instruments and is a proud Welshman.

Daniel Murray, Tooling Design EngineerDaniel Murray, Tooling Design Engineer, is the newest member to the Charpak Technical Department.  Daniel graduated from Sheffield with a BEng in Product Design Engineering relocating from Greater Manchester to join the expanding team. Daniel’s in-depth induction included 3 weeks shadowing Tool Prep Engineer Mark Harman to learn from Mark’s extensive 6  years’ experience with the company.  Daniel’s key role in the development and design of client’s end products is engineering the highest quality tooling for manufacture. Daniel adds further CNC machining, 3D modelling and CAD software expertise.  Just for fun Daniel has most recently designed and built a bespoke computer, and to keep active he’s transferred his Peak District hill walking into road cycling for the flatter lands of Cambridgeshire, when he’s not playing the drums.

Charpak invests in a cutting edge new milling machine

CNC Milling MachineThe ultra-modern CNC machine enables even more complex tooling to be milled at high precision and at high speed, custom-made to all shapes and sizes as required by Charpak's clients.

Sam Curtin, Tooling Manager, is thrilled with the new machine.  With over 14 years in setting up CNC milling machines, Sam intuitively knows how long it takes to programme each of Charpak's 6 machines for clients' bespoke formings.

Sam advised "Programming milling machines can take 30 mins to 2-3 hours depending upon the complexity of the client brief; and with the larger tooling and wireless capabilities on this machine milling the tooling is quicker and more efficient than ever before."

The investment adds further gravitas to Charpak's market-leading turnaround times and agility - supporting the company's vision to remain one of the few UK thermoforming manufacturers who provide the complete solution from design concepts to full production; including all prototypes and tooling manufactured in-house.

Award-winning designers join the Charpak team

Award-winning product designer Max Cubitt has an impressive MSC in Integrated Product Design from the University of Brunel.  Max has also been recognised by Marks & Spencer, Birds Eye and BT winning 3 design awards for his product innovation.  Max brings 6 years' product design experience from the events and team building industry' and constantly challenges his creative and technical boundaries.  Max's nirvana design moments are when he creates a truly interactive experience between the consumer and product.  Max designs packaging solutions for commercial market sectors using his technical 2D and 3D design skills in KeyShot, Solidworks, and CREO while incorporating physical prototyping.

James Martin brings energy and enthusiasm to the Technical Design team as our Junior Designer.  Graduating from Loughborough University with a BA in Industrial Design James is happiest when designing extremely technical and aesthetically stunning designs, new concepts and blue-sky ideas.  James likes to challenge the boundaries of engineering capabilities whilst at the same time ensuring every design is manufacturable.  James is happiest when he sees his conceptual packaging designs on sale in national retail for recognisable international and UK brands. Outside work James is an active sportsman, an avid sketcher and a keen freelance graphic designer.

Charpak expands production capacity further

Illig RD53In support of Charpak's growth a new Illig RD53d arrives in September 2017.  This additional investment augments Charpak's ability to provide its client industry-leading turnaround times from initial concept designs, prototypes, tooling and to production - within 29 days.

Charpak's thermoforming capabilities to produce increasingly complex and innovative rigid plastic packaging are sector leading.  Technical Director, Gary Smith is delighted with this new investment saying "A key differentiator for Charpak is that we meet clients' requirements of premium quality and replicable formings for short cycle NPD trials, line production trials, and consumer testing.  This investment re-inforces our commitment where we provide the extra level of service to our clients."


ChaKeifel KMD78rpak invests in two state-of-the-art Kiefel machines

As part of Charpak's expansion plans the company has invested in 2 further Kiefel KMD78 4-station machines.  From early June 2017 the company now produces up to an additional 100,000 units per day.  Managing director, Paul Smith confirms "These 2 purchases are part of our strategic plans to grow the business and increase our capacity re-affirming our position as the most innovative and responsive UK producer of bespoke packaging."

He adds "We know our clients appreciate Charpak's flexibility and agility to respond quickly to their packaging challenges; so adding an additional 100,000 units per day means we continue to strengthen our industry-leading service delivery claim."

Charpak will receive delivery of a second Kiefel KMD78 machine in September 2017.  This will add up to an additional 200,000 units per day.


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11 Setters have now started the NVQ Level 2 Polymer Processing – Thermoforming course which will enhance there skills in the process of machine setting, this in turn will enable the company to become a lot more efficient.

We held an inaugural training session in Level 1 Food Safety Training for 16 selected staff that proved to be very successful, this will now be rolled out to the rest of the company during 2011.

Congratulations go out to our First Aiders who all completed the First Aid at Work Training course with flying colours.

We also ran a Forklift Truck Refresher Training course this year as well as having 5 employees take the Forklift Truck Novice Training course.

David Hill, our Sales Administrator has just completed a refresher course in ‘Customer Relations’ to ensure we continue to support our customers at the highest level possible. Our aim as a supplier is to make your life easier as a customer!