Van Gils Sweet Creations and SFA Packaging have been working together for over twenty years. Based on this long-term collaboration, SFA became involved in the further development of an existing ice cream cup. The aim was to technically redesign the product and make it future-proof for long-term use in production.
Van Gils was already using a similar ice cream cup and wanted to further develop this product with a view to continuity and future use. The request to SFA was clear: develop a new product and create a technically reliable cup that could be used in the production environment for years to come without any problems.
The total project lead time was approximately one and a half years. During this period, SFA worked closely with Van Gils to optimize every detail of the design. The focus was consistently on quality and reliability, rather than speed. This approach resulted in a solution that not only works today, but can also be used reliably in the long term.
The biggest challenge was integrating the new cup into the customer’s existing filling line. Due to minimal deviations from the old model, the line did not run optimally right away. SFA adjusted the mold several times and tested each change again in production. Technical specialists visited the site several times to carefully fine-tune the process. Ultimately, the packaging ran smoothly within the existing production environment.
An important advantage of the new design is its suitability for IML (In-Mould Labeling). This technique was not possible with the previous cup. Thanks to IML, Van Gils now has extra space for branding and communication on the packaging, without compromising on functionality or processability.
The ice cream cup is designed as a single-material solution. The cup and the IML label are made from the same material, making the packaging fully recyclable. In addition, the design is prepared for future use of recycled material or bioplastic. This means that the packaging complies with future legislation and market developments, including the upcoming European Packaging and Packaging Waste Regulation (PPWR).
The collaboration between Van Gils and SFA was characterized by short lines of communication and continuous coordination. By making decisions together and remaining critical of details, a result was achieved that both parties fully support.
“This project confirms that we made the right choice. SFA’s commitment and expertise, combined with our shared focus on quality, clearly contributed to a wonderful end result. Once again, SFA has proven that it goes the extra mile for its customers, allowing us to focus on creating high-quality ice cream creations,” said the project manager responsible on behalf of van Gils, Ivan van Boxel.
In addition to developing the packaging, SFA also made clear agreements about stock management. A fixed safety stock is maintained for Van Gils, so that extra stock is always available and production can continue. This project underlines the role of SFA Packaging as a partner that looks beyond packaging alone and actively contributes to continuity in the chain.
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