The detail behind the headline numbers, real packaging challenges, what I did about them, and what changed as a result.
Packaging rationalisation · SKU reduction · value engineering
The challenge
Gü's dessert packaging portfolio had grown complex across international markets, too many formats, too much specification variation, and rising cost and operational complexity as a result.
The approach
I led a packaging redesign and rationalisation programme across the portfolio, working with a 30+ strong supplier network to simplify formats, optimise specifications and harmonise packaging across markets, without compromising the brand's premium positioning.
The results
• 22% reduction in packaging SKU complexity
• £800k in documented savings through specification optimisation and redesign
• 20+ packaging innovation projects launched across the portfolio
• Improved operational efficiency and supply chain flexibility
Gü Desserts:
International Packaging Rationalisation
Sustainable packaging · material transition · plastic reduction
Marks & Spencer:
Plastic Elimination Without the Capex
The challenge
M&S needed to hit ambitious plastic reduction targets across Ambient Grocery and Non Food, but a full retool of manufacturing lines wasn't a realistic budget or timeline.
The approach
I identified and delivered a move to paper based packaging for tissue, pasta and Christmas ranges that worked on M&S's existing manufacturing infrastructure, removing the need for capital investment entirely. I backed the transition with a structured post implementation review to apply learnings the following year.
The results
• 9 million plastic units removed from the packaging portfolio in 2021/22, with 24 million units on track for the following year
• 100% of plastic packaging and wrap removed from the Christmas cards and wrap range
• Zero capital expenditure required, delivered using existing production lines
• A repeatable packaging brief process introduced to reduce design revisions going forward
Sustainable materials · rPET · multi market rollout
Pepsi Lipton (Unilever):
100% rPET Across Europe
The challenge
Pepsi Lipton needed to hit ambitious European sustainability targets for its premium beverage brands while keeping shelf standout and production reliability intact across multiple markets.
The approach
I led the global packaging innovation and sustainability programme across Europe, Africa, the Middle East and Asia, building a five year innovation roadmap and managing the rollout of 100% recycled PET (rPET) bottles across European markets, including a standout new bottle design for the premium Pure Leaf range.
The results
• 100% rPET bottle programme delivered on time and in full across Europe
• 188 tonnes of packaging material removed annually
• 25+ packaging innovation and commercialisation projects delivered across international markets
• A five year packaging innovation roadmap embedded into the business
Packaging innovation · cost optimisation · luxury retail
Hotel Chocolat: Premium Innovation on a Tighter Spend
The challenge
As Packaging Manager, I was asked to keep innovating Hotel Chocolat's premium gifting and seasonal packaging, without letting packaging spend run away from the business.
The approach
I took category briefs and developed them into new, innovative formats while actively managing and reducing packaging spend, sourcing new supply channels and challenging suppliers to hit both creative and commercial targets.
The results
• £424k in documented savings through packaging optimisation and supplier collaboration
• New formats launched including the first Large Advent calendar and a branded fabric Christmas stocking
• Holographic ‘boxed selections’ and a resealable flap packaging format introduced via new machinery
• New sourcing channels developed in the Far East for better materials at better cost