GOING GREEN:
flexible packaging reimagined
InterFlex Group has developed a solid portfolio of packaging solutions for the US, UK and European markets. With 50 years’ experience, the group is now gearing up for growth following several key acquisitions. Commercial Director Alex O’Connor and Marketing Director Dan Richards explained more, during an in-depth interview with Inside Sustainability. Report by Imogen Ward.
Originally established in 1975, InterFlex Group provided flexible packaging to an array of food-based sectors. With two sites based in the UK and two in the US, the group developed significant demand in core markets, such as bakery, snacks and confectionery.
Since then, InterFlex has developed strong partnerships with many Fortune 1000 companies across North America, the UK and Europe – making it a highly appealing asset when it came up for sale in 2022.
“Two years ago, we were acquired by TOPPAN,” said Commercial Director Alex O’Connor. “Being a huge global packaging business, TOPPAN was interested in InterFlex’s prime locations, which aligned perfectly with its desire to establish a flexible packaging
production network in America and Europe (two key markets it had yet to penetrate).”
Alongside Toppan, Interflex has continued to strengthen its position within the marketplace, reinforcing its reputation for innovation and excellence. Vertical integration swiftly became a top priority as part of the inter-company amalgamation, which is something that both businesses are still collectively working towards today.
Coming together
From designing and laminating right down to the regranulation of its own waste, InterFlex has worked hard to bring every element of its production process in-house. This has better-solidified lead times, improved efficiency and guaranteed quality.
Although InterFlex had done a fantastic job of becoming a vertically integrated business, there was still one area of the process that remained evasive: extrusion. In order to bridge that gap, InterFlex went in search of a company suitable for acquisition.
Being an expert in cast and blown extrusion (alongside printing, laminating, bag conversion and line slitting) Scunthorpe-based company Skymark was deemed an ideal addition to the InterFlex brand, and the sale was completed in Q3 of 2023.
Not only did this sales agreement bring extrusion in-house, but it also provided InterFlex with an additional manufacturing facility, further bolstering its presence within the UK market.
“The addition of the Scunthorpe site has been instrumental to InterFlex’s integration goals,” explained Marketing Director Dan Richards. “The facility’s casting capabilities,
in particular, have become a distinctive advantage for our customers.”
The acquisition of Skymark also fits in well with the overarching goals of parent company TOPPAN. As a global packaging business, TOPPAN prides itself on having an excellent synergy across all its businesses, and Skymark has slotted perfectly into that model of collaboration – enhancing the parent company’s capabilities while also supporting InterFlex’s other UK facilities.
To ensure Skymark is as efficient as possible, the site has seen significant investment post-acquisition. These improvements have helped maintain the site’s operations and upgrade its bagging capabilities, with the inclusion of two new lines, new slitters and new ways to further enhance its extrusion capabilities.
“The first slitter was ordered during the crossover from Skymark to InterFlex, and
has been installed as of the start of 2024,” revealed Mr Richards. “We now have an additional machine ordered for installation further down the line.”
A greener vision
Another key area of synergy within the organisation is the shared dedication to sustainability. Following TOPPAN’s formulation of Vision 2050 – a framework of ambitious goals designed to accelerate its green agenda – the company directed its focus to three key areas: People, Environment and Communities as detailed within the TOPPAN Sustainable Transformation (Sx) agenda.
Inspired by these commitments, InterFlex is channelling that same green ethos through its own core product lines.
“Our Sustainable Transformation agenda is really driven from the top, with aspirations to reduce carbon emissions, minimise water intake and give back to the community,” said Mr Richards. “What InterFlex has done is funnel all those ambitions through our lines RECYFLEX, PUREFLEX and PAPRFLEX, whilst maximising our vertical integration.”
All three lines are thoughtfully designed to add sustainability to customers’ needs, while also improving recyclability rates across InterFlex’s entire portfolio – a statistic that now sits at 86%, proving the effectiveness of this model.
RECYFLEX, InterFlex’s innovative solution for reducing virgin polymer consumption, integrates recycled content into a diverse array of packaging applications. Whereas PUREPLEX seeks to introduce fully recyclable mono-materials to the portfolio, which are ideal for flow wraps and pouches.
The third sustainable solution, PAPRFLEX, features kerbside recyclable paper twist wrap, heat seal paper overwrap and barrier paper solutions.
Mr Richards added: “Building on this momentum, we are excited to announce that we will be exhibiting at Packaging Innovations at the NEC in February 2025, where we will showcase these innovative sustainable solutions and more.”
In order to ensure an increased recyclability rate, InterFlex fully utilises its in-house process of regranulation. Not only does this ensure its
waste production is minimal, but it also helps cut down the company’s reliance on virgin materials. Already utilised in products such as dry tissue overwrap, this exciting development has also extended to wet wipe packaging for the personal care sector, for both PE and PP solutions with 30% recycled content.
“We have focused a lot of our R&D towards integrating our recycled content into laminate structures for non-food applications,” explained Mr Richards. “However, as the supply chain continues to strengthen and new legislation changes come into effect, we will be able to reassess the food contact side of the business.”
The next steps
As the company focuses on the future, it intends to continue pouring its energy into improving brand sustainability. To support
Commercial Director, Alex O’Connor
this effort, TOPPAN has recently relocated a Senior Packaging Specialist to InterFlex’s Dalkeith site. In doing so, the companies work collaboratively to ensure seamless communication and enhance the production of their packaging solutions.
“The specialist is expected to work across all three sites for a minimum of two years, where she will contribute valuable feedback and expertise, fostering collaboration and sharing insights with TOPPAN in Tokyo,” explained Mr O’Connor. “This is an important step in our development, and we look forward to seeing where it will take us over the next five years.”
At the same time, InterFlex remains dedicated to product development and aims to continue its market penetration through a collaborative approach, working seamlessly across
the group alongside trusted, long-standing suppliers. “Our supply chain is our life blood; without them we would not be able to function,” said Mr Richards. “We pride ourselves on having long-established partnerships with suppliers that are innovative, resourceful and always up for a challenge.
“Being on the marketing side of the business, I am incredibly passionate about creating these partnerships and supporting our team to success.”
“These companies will play a key role in helping shape InterFlex into a sustainably driven globalised business,” added Mr O’Connor, in conclusion. “We are on a journey that is going to take time and effort, but it is one that I know we can achieve thanks to the continued support that surrounds us.” n
Marketing Director, Dan Richards
