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Poplast is a flexible packaging company supplying high-quality and sustainable solutions to the food and industrial sectors. Sales Manager Andrea Ghu discussed the company\u2019s investments into technology and sustainability, in conversation with Antonia Cole.<\/p>\n
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Founded in 1975, Poplast will be celebrating its 50th anniversary next year. The company has grown significantly since its establishment. In the year 2000, turnover was \u20ac7 million and there were 48 employees. Now, Poplast generates a turnover of over \u20ac110 million and employs 229 people.<\/p>\n
\u201cIt has been great to see the progress of Poplast in my time here,\u201d said Sales Manager Andrea Ghu. \u201cThrough our active R&D department and continuous investments in technology, we have developed innovative and sustainable solutions for the industry.\u201d<\/p>\n
The company operates over two plants in Italy, the first in Piacenza, Emilia-Romagna, and the second in Pistoia, Tuscany. With more than 30,000m2 of space, Poplast manufactures 16 million kilos of packaging a year, which is distributed across Europe and the US.
From a specialised R&D department to a dedicated customer care team, Poplast has the structure to develop and deliver innovative solutions to the flexible packaging market. Services include flexographic and rotogravure printing, plus lamination, laser cutting and more.<\/p>\n
Investing in service<\/strong> \u201cThe last two of these four machines have been installed this year, which is very exciting. This will not only improve our production capacity, but also our efficiency and design capabilities.\u201d With a fleet of seven Flexographic and three Rotogravure printers, Poplast offers state-of-the-art services to clients. All machines are equipped with modern control systems for print defects to ensure that every product meets the company\u2019s high-quality standards.<\/p>\n \u201cOur facilities are particularly advanced, but what really distinguishes us as a company is our attentiveness to the needs of customers and the speed at which we can resolve difficulties,\u201d added Mr Ghu. \u201cWe have our own raw materials warehouse, which not only accounts for around nine % of our turnover, but also enables us to respond quickly to our clients. Bio-based packaging<\/strong> Additionally, Poplast uses renewable energy from PV installations (as required by Italian regulations) at its site in Castel San Giovanni, Piacenza. This limits the company\u2019s reliance on fossil fuels, reducing its carbon footprint and contribution of harmful emissions. \u201cIn comparison to the year 2000, our polyolefin structures now allow a minimum energy saving of 30 per cent, as well as a reduction in thickness by 45 per cent,\u201d continued Mr Ghu. \u201cWe have achieved a remarkable amount of progress in making our packaging environmentally friendly. Our solutions allow our customers to operate as sustainably as possible, whilst still maintaining quality and effectiveness.\u201d Connecting people<\/strong> \u201cParticipation in trade fairs abroad is essential to consolidating the image of our company internationally,\u201d added Mr Ghu. \u201cOver the last 10 years, our percentage of foreign market trade has increased from five per cent to 30 per cent. Our goal is to reach 50 per cent within the next four years. To achieve this, we will continue to make connections around the world and demonstrate the quality of our services.\u201d Additionally, the company plans to continue investing in employees, as well as encouraging more young people and women to enter the industry. By creating more diversity within the company, Poplast will benefit from different perspectives and secure success into the future.<\/p>\n \u201cI love my work, collaborating with people and being a part of Poplast,\u201d added Mr Ghu, in conclusion. \u201cHere I have the opportunity to be innovative and create real solutions that are also sustainable.\u201d<\/em><\/p>\n [\/et_pb_text][et_pb_code _builder_version=”4.24.3″ _module_preset=”default” global_colors_info=”{}”]Share:
Poplast is constantly reinvesting into both technology and people within the company. Since 2015, Poplast has introduced new R&D and sales managers, as well as a new CFO. This leadership team has helped to drive the success of the company into the future.
\u201cIn the early 2000s, we began investing into new machinery with our first lamination and rotogravure machines,\u201d commented Mr Ghu. \u201cFrom 2019, we have invested heavily into our machinery. We have added two new Rotogravure machines, as well as two new Flexographic machines to our fleet.<\/p>\n
In addition to printing machines, Poplast has also upgraded its laminating and cutting machines. The company has a total of nine laminating machines, two of which also include laser die cutting. There are also 13 slitter rewinders able to cut panels of up to 1,620mm. A defect control system is equipped to two of the slitters to guarantee a high-quality result.<\/p>\n
\u201cFurthermore, our graphics office expands upon the quality of our service as it prepares design files internally. This means that we can efficiently create specific designs for each customer and adjust them as necessary. We act quickly and provide tailored solutions to guarantee that individual customer needs are being met.\u201d<\/p>\n
The company also positions itself at the forefront of the market in terms of sustainability. With its own solvent recovery plant, Poplast takes back over 450,000 litres of ethyl acetate a year. Carbon beads absorb pollutants from the printing process and then, the solvent retained by the carbon is recovered through a regeneration cycle.
\u201cSolvent is regenerated to a high degree of purity through a distillation column, meaning it can then be reused in production lines,\u201d explained Mr Ghu. \u201cWe also utilise regenerative thermal oxidisers to reduce emissions released into the atmosphere. The thermal energy from the operation of the recovery plant is used to heat the production department throughout winter months, saving a lot of energy.\u201d<\/p>\n
Not only does Poplast strive to improve the sustainability of its own operation, but it also works to facilitate clients\u2019 environmentally friendly practices. For more than 10 years, the company has been collaborating with customers to develop the most sustainable solutions that reduce energy and resource consumption.<\/p>\n
Poplast is encouraging clients to utilise PP- or PE-based polyolefin structures, as these have a reduced carbon footprint and are recyclable. All of the company\u2019s materials are certified for recyclability. Cyclos is used to certify polyolefins or OPA\/PE, Aticelca for paper and TUV for compostables.<\/p>\n
Through collaborative relationships with suppliers, Poplast is able to offer sustainable materials to clients. The company works with the supply chain to develop energy efficient processes and materials, implementing them into customer goods.
\u201cIt is vital for us to maintain our relationships with suppliers,\u201d said Mr Ghu. \u201cNot only can we facilitate the exchange of ideas, but it allows us to deliver a better service to our clients. We trust our suppliers and their products, meaning we can be confident in our own services.\u201d
To consolidate these relationships and create new partnerships, Poplast participated in FACHPACH, a European trade fair for packaging, technology and processes. This allowed the company to confront itself with innovations in the sector, as well as present its own.<\/p>\n
Poplast will continue to expand internationally into the future, as well as constructing a new plant in Castel San Giovanni, Piacenza (close to the existing one) to increase capacity. The new site has been designed to be sustainable, with advanced production flow, as well as reduced energy consumption and emissions.<\/p>\n