Revolutionising Gummy Packaging: TCI Culinary’s Sustainable Tray Design That Does Double Duty

Overview

Client: Confidential Gummy Tablet Manufacturer

Service: Custom Eco-Friendly Packaging Tray Design

Sector: Health, Wellness, FMCG

Timeline: 5 Weeks

In the evolving world of health and wellness, sustainable packaging is no longer optional; it’s a competitive edge. A leading gummy tablet manufacturer turned to TCI Culinary to overhaul their packaging process with an innovative, recyclable tray that functions as both the mould and final product packaging. The result? Reduced waste, faster production, and a major leap forward in sustainable manufacturing.

The Challenge

The client needed a smart solution that could:

• Mould and package gummy tablets in a single step

• Use fully recyclable materials that met eco-standards

• Work within their existing production infrastructure

• Scale to millions of units without sacrificing quality or cost-efficiency

Traditional packaging approaches weren’t cutting it. This called for a bold redesign, one that fused manufacturing, sustainability, and scalability into a single innovation.

Our Solution

TCI Culinary engineered a custom recyclable tray that transformed how the client manufactures, packages, and delivers their products.

1. Innovative Tray Design

We created a dual-function tray that serves as both the moulding platform and consumer-ready packaging. This removed unnecessary handling, slashed contamination risk, and created a seamless production flow.

2. Sustainable Material Strategy

The trays were crafted from recyclable polymers, specifically selected for:

• Strength and structure retention

• Lightweight shipping performance

• Compatibility with UK and EU recycling systems
  

The design aligned directly with the client’s environmental commitments and ESG targets.

3. Plug-and-Play Integration

Our team designed the trays to integrate directly into the client’s production line, with:

• Quick-fill compatibility

• Rapid-cooling performance

• Smooth sealing and dispatch processes
  

The result? A streamlined, production-ready solution that didn’t require major retooling.

4. Mass Production-Ready

Using high-precision tooling, we scaled up manufacturing to millions of trays per month — meeting demand while maintaining tight quality tolerances.

The Results

Streamlined Manufacturing

By combining moulding and packaging, the client:

• Cut labour and handling time

• Increased daily throughput

• Reduced operational complexity

Tangible Sustainability Wins

The use of fully recyclable trays helped reduce single-use plastics and boosted consumer confidence in the brand’s green credentials.

Operational Cost Reductions

Eliminating the need for separate moulding equipment and reducing overall material use led to major logistics and cost savings.

Scalable Growth

The new tray format is now supporting mass-scale monthly production, ready to flex with demand without compromising sustainability or performance.

Conclusion

This project showcases how TCI Culinary is redefining what packaging can do. By building trays that act as both mould and package, we helped the client unlock:

• Greater speed and efficiency

• Lower environmental impact

• Stronger market differentiation
  

If your operation is ready to rethink how products are made and moved, we’re ready to help.

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