Composite Packaging Specialists

Our ability to solve packaging problems with new thinking, technology and materials comes from our specialisation in composites. Our production techniques and expanded options allow us to replace more expensive plastic and metal components with paper to reduce cost and increase sustainability.
We have the ability to offer highly competitive prices on composite packaging solutions, in addition to reducing the cost of your packaging solutions. Competitive pricing, combined with genuine cost reductions come from our advanced technologies and production processes, and our focus on replacing more expensive and less sustainable materials, with paper board.

Explaining Composite Packs

Examples of composite materials feature everywhere in our daily lives from motor vehicles (carbon fibre) to houses (timber, steel reinforced concrete and synthetic laminates) and clothing (combinations of synthetic fibres and/or natural fibres).

"The principal of composite materials is based on combining materials to allow us to maximise their strengths and at the same time minimise their weaknesses. The end result, is a superior material for the job at hand, in our case, packaging.”

David Kilpatrick, Zipform Packaging Research & Quality Director

Zipform Packaging composite packs combine different materials to produce a set of outcomes that could not be achieved by using single materials. Those outcomes include the key benefits we deliver - environmental, functional and aesthetic.

Composite Pack Benefits

A composite pack is a cost effective, hermetic (if required), rigid, lightweight and environmentally intelligent alternative to folding cartons, metal cans, glass jars, plastic containers and ‘bag in a box’ packaging that uses mostly recycled paper. They can be used as either primary or secondary packaging.

A composite pack is mainly composed of a body, a top closure and a bottom closure.

The body is made from a series of (typically 3 - 4) plies with the flexibility to choose a range of materials and combinations. The specification best suited to any individual application will be based on the specific required outcome for customers in terms of light, moisture and oxygen barriers, aesthetic appeal, weight, strength and cost.

The Zipform Packaging Process - Linear Draw Packs

Zipform Packaging use the Linear Draw process because it gives us a superior product, with a simplified and more flexible process.

Linear Draw Packs are produced by drawing the materials through the gluing section and then through the tooling (body making) process before the tube is cut into individual packs using a photoelectric sensor to ‘read’ the label. The complete pack is made in a single process, length changes are controlled by artwork and most importantly, the shape of the pack is infinitely variable.


The alternative composite pack manufacturing processes in most cases will prove to be inferior to the Linear Draw process because they deliver a less-smooth finish, with more layering visible.

They will also most often involve a separate process for labelling, which adds significantly to the overall cost, while the Zipform Packaging process allows the consumer facing decoration to be an integral part of the pack.

The most common alternatives to the Linear Draw process are known as Convolute Wound and Spiral Wound Packaging.

For a more detailed explanation of the advantages Zipform Packaging offers, please contact us. We are always happy to help by explaining the options,and identifying the main benefits for your company.

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