Innovative Packaging Solutions, Crafted in the UK

Founded in 1998 by packaging engineer Martin Foster and supply-chain strategist Helen Davies, PackMaterialsUK started as a small corrugated-board converter in Surrey. Frustrated by lengthy lead times and limited material options, they set out to create a one-stop shop offering complete design, prototyping, and manufacturing under one roof. Over the past two decades, we’ve expanded to three state-of-the-art facilities in England, Scotland, and Wales—equipped with flexo-printers, extrusion lines, die-cutters, and compostable-film lamination units.
Our core strength lies in integration: an in-house design studio works side-by-side with production engineers to optimise structural integrity, material usage, and print quality. Every order undergoes rigorous quality-control checks—tensile tests, barrier-performance assays, and colour-accuracy scans—to ensure consistency and compliance with international standards such as ISO 9001 and BRC Packaging/Packaging Materials. We source raw materials from trusted UK and EU suppliers, prioritising FSC-certified paper and recycled polymers, while offering fully compostable PLA/PHA alternatives for clients pursuing circular-economy goals.
Sustainability is more than a buzzword here. Our factories run on 60% renewable energy, and we recycle 98% of production waste back into the supply chain. Continuous R&D collaborations with regional universities drive innovations in bio-coatings, barrier blends, and smart-pack technologies—like QR-linked labels for traceability. Whether you’re a boutique chocolatier or a global pharmaceutical group, PackMaterialsUK combines agility, technical expertise, and environmental stewardship to deliver packaging that performs and inspires.

Custom Corrugated & Rigid Boxes
Our corrugated-board production lines handle single, double, and triple-wall boards up to 12 mm thick—ideal for heavy-duty shipping and retail displays. Structural engineers use CAD and finite-element analysis to design boxes that optimise stacking strength while minimising material use. Flexible die-cutters deliver precision shapes and integrated handles, and inline flexo-printing in up to six colours ensures vibrant, brand-consistent graphics. Quality checks include burst-strength and edge-crush tests to verify performance under transit stresses. Prototyping is available within days, accelerating your go-to-market timeline. Eco-friendly options feature recycled and recyclable substrates certified by the FSC.

Flexible Film & Lamination Solutions
We produce high-barrier PE, PET, and PP films tailored for food, pharmaceuticals, and industrial products—offering oxygen, moisture, and aroma protection. Our extrusion-lamination lines bond films with compostable PLA for fully biodegradable pouches and sachets. Advanced metallisation and vacuum-coating techniques achieve foil-like barrier performance without heavy metals. Custom printing using gravure or flexo processes applies up to eight spot colours, with water-based, low-migration inks compliant with EU food-contact regulations. Reverse-printing and gloss/matte finishes add premium appeal. Roll lengths up to 10,000 m support large runs, while pilot-scale short runs enable rapid sampling.

Die-Cut Labels & Adhesive Solutions
From product labels to tamper-evident seals, our digitally-printed and flexo-printed labels adhere reliably across plastics, glass, and metal surfaces. We offer clear, white, and metallic films with permanent, removable, or high-tack adhesives for diverse applications. Laser die-cutting ensures crisp edges and fine detail in complex shapes, while in-line varnishes and laminates enhance durability. Our variable-data printing capabilities allow batch numbers, barcodes, and QR codes to be applied on the fly—streamlining traceability and batch management. Certification to ISO 22000 supports food and beverage industries requiring stringent hygiene controls.

Rigid & Semi-Rigid Packaging
For premium-grade presentation boxes, blister packs, and clamshells, our thermoforming and injection-moulding facilities craft durable, transparent or opaque packaging in PET, PVC, and PP. Tooling design considers material flow, wall thickness, and ejection mechanisms to minimise defects and cycle times. In-house finishing—hot-stamping, pad-printing, and PVC lamination—adds brand accents and tactile textures. We prototype with 3D-printed patterns to perfect geometry before investing in high-cost tooling. Suitable for electronics, cosmetics, and food service trays, our rigid packaging ensures product visibility and protection.

Kitting, Fulfillment & Assembly
Beyond manufacturing, we manage pick-and-pack operations for direct-to-consumer and B2B distribution. Our warehousing facilities use barcode scanning and warehouse-management systems to maintain real-time inventory visibility. We assemble multi-component kits, insert marketing collateral, and apply tamper-evident seals as configured. Cross-dock and drop-ship solutions integrate with your ERP or e-commerce platforms, streamlining order fulfilment and reducing lead times. Our quality-control team audits package completeness and label accuracy before dispatch via carriers across the UK and Europe.

Technical & Sustainability Consulting
Leverage our packaging experts to optimise your designs for cost, performance, and environmental impact. We conduct life-cycle assessments (LCAs) to compare material options, advise on circular-economy uptake, and calculate carbon footprints. Barrier-performance trials, shelf-life testing, and compliance audits ensure your packaging meets regulatory and retail requirements. Our innovation workshops—covering smart-pack integrations, bio-resin trials, and material substitutions—help you stay ahead of market trends. This strategic guidance elevates your packaging from functional to future-ready.

Fully Integrated Design-to-Delivery
In-house capabilities span concept, prototyping, production, finishing, and fulfilment—eliminating multi-vendor delays and ensuring clear lines of communication. A single project manager coordinates every stage, providing timeline and budget transparency from start to finish.

Advanced Material Expertise
Our R&D team continually tests new substrate blends—recycled fibres, compostable polymers, and nano-coated barriers—to expand your packaging possibilities. Material scientists guide substrate selection based on mechanical requirements, barrier performance, and end-of-life pathways.

Sustainability-Driven Operations
With 60% of our energy sourced from on-site solar and biomass, and 98% of production waste recycled, we set industry benchmarks for eco-responsibility. Our compostable-film and recycled-paper offerings meet EU and UK Government sustainability roadmaps, helping you achieve your green targets.

Unwavering Quality & Compliance
Certified to ISO 9001, BRC Packaging, and ISO 14001, we maintain rigorous quality and environmental management systems. Routine audits, performance testing, and traceable production records ensure every batch meets exacting standards.

Nationwide Coverage & Local Support
With production sites in Surrey, Glasgow, and Cardiff, we combine rapid local response times with national-scale capacity. Regional account teams understand local logistics, compliance nuances, and market trends—delivering service tailored to your region.

Continuous Innovation & Customisation
From QR-linked smart labels to biodegradable barrier films, our collaborative innovation pipeline turns emerging technologies into market-ready solutions. We customise each project—whether it’s embossed finishes, integrated RFID tags, or anti-counterfeit features—delivering packaging that protects, promotes, and performs.