Case Studies
The British Crisp Company
The First Commercial Adoption of Ryvon High Barrier™
Awfully Posh Nuts
Delivering High-Performance Sustainable Packaging
The Challenge → The Partnership → The Solution → The Commercial Result.
Tesco Chocolate Bars
Validating Ryvon Standard at National Retail Scale
Tesco worked with Ryvon to introduce Ryvon Standard material across its own-brand 150g chocolate bar range, beginning with a single product as part of a controlled commercial validation programme.
The project objective was to pack the bar at existing production-line speeds while assessing Ryvon’s performance throughout the full supply chain, from packing and distribution through to store presentation and customer response.
Following successful production trials and supply chain evaluation, the product was rolled out across Tesco stores throughout the UK.
This project demonstrated that Ryvon Standard could deliver the required production efficiency, pack quality and retail performance within a major national supermarket environment.
Ryvon and Tesco are now working together to assess further applications across additional product categories where recyclable paper packaging can support Tesco’s sustainability objectives without compromising performance.
Jimmy's Shortbread & Reid's of Caithness
One Technology. Two Brands. Different Objectives. Shared Success.
Ryvon partnered with Jimmy's Shortbread and Reid's of Caithness to develop a complete range of premium shortbread products using Ryvon High Barrier recyclable paper packaging.
Jimmy's objective was to launch a new single-serve range that would support expansion into the hospitality, travel and foodservice sectors, enabling customers to reduce flexible plastic waste and move towards more paper-based packaging solutions without compromising product quality.
For Reid's of Caithness, the focus was different. The goal was to create a clear point of differentiation within the highly competitive UK retail market by introducing a premium, sustainably packaged product that would strengthen its appeal to major supermarket customers.
Working together, Ryvon, Jimmy's and Reid's successfully achieved both objectives. The result was a portfolio of high-performance recyclable paper packs delivering outstanding shelf life, excellent moisture and fat barrier performance, and reliable high-speed operation on existing automated packing lines.
The collaboration demonstrates how Ryvon can create commercial value through sustainable packaging—helping brands grow, differentiate and meet the evolving expectations of retailers and consumers alike.
Ryvon partnered with The British Crisp Company and Europe Snacks to develop the packaging solution for the launch of Air Heads—a new range of popped rice snacks aimed at the growing lunchbox and healthier snacking market.
The project presented two key challenges. First, the packaging had to achieve reliable production speeds of up to 120 packs per minute on existing packing lines. Second, the material needed to deliver the required barrier performance while remaining commercially competitive in a highly price-sensitive market.
Working collaboratively, the development team engineered a bespoke Ryvon High Barrier material specifically for this application, optimising performance, machine efficiency and cost without compromising sustainability.
The result is a recyclable paper packaging solution that delivers excellent product protection, dependable high-speed production and a distinctive sustainability advantage, providing both companies with a market-leading offering in one of the fastest-growing snack categories.
For many years, Fisherman's Friend products have been packed using a complex paper, aluminium foil and plastic laminate to deliver the high barrier performance required for premium confectionery products.
With increasing environmental legislation and Extended Producer Responsibility (EPR) requirements, these multi-material structures are becoming increasingly difficult and expensive to manage at end of life.
Ryvon partnered with Fisherman's Friend, Kenray and Perfect Seal to develop a complete packaging solution based on Ryvon High Barrier technology. Working together, the team optimised the material, packaging system and automatic cartoning process to deliver reliable high-speed production while maintaining the product's demanding barrier requirements.
The new solution replaces the traditional multi-layer laminate with a lightweight, recyclable paper-based structure that is designed to be recycled through existing paper recycling streams. In addition, the project achieved significant material down-gauging, reducing both packaging weight and material consumption while maintaining excellent pack performance and shelf life.
This collaboration demonstrates how Ryvon can help established global brands transition from complex, difficult-to-recycle packaging to practical, high-performance solutions that support both commercial and sustainability objectives.
From Multi-Material Waste to Paper Recycling
Gnaw Chocolate
Sustainable Innovation for a Seasonal Product Launch
Gnaw Chocolate partnered with Ryvon to launch its popular chocolate button range in recyclable paper packaging for the Christmas season, creating a clear point of difference during one of the busiest retail periods of the year.
The objective was to replace conventional packaging with Ryvon Standard while maintaining the premium shelf appeal, vibrant graphics and production efficiency expected of a leading confectionery brand.
Working closely with Gnaw and its contract packing partner, Ryvon optimised both the material and packing process to deliver exceptional print quality, reliable pack integrity and consistent high-speed production—all within an ambitious development timescale.
The result was a successful Christmas product launch that combined premium presentation with genuine sustainability, helping Gnaw differentiate its brand while demonstrating that recyclable paper packaging can deliver both commercial performance and consumer appeal.
Helping Brands Stand Out When It Matters Most.
Caroboo
Sustainability Inside. Sustainability Outside.
"When sustainable products are paired with sustainable packaging, innovation becomes impossible to ignore."
Eurostar set out to replace conventional plastic packaging for its single-serve cookies with a solution that could be fully recycled within its closed-loop paper waste stream. With the majority of products consumed on board or within stations, simplifying waste separation and increasing recycling efficiency were key project objectives.
Working together with Eurostar and its food supply partners, Ryvon delivered the only packaging solution capable of meeting every technical, operational and environmental requirement. Ryvon provided the barrier performance and machineability needed for commercial production while enabling the packaging to be recovered through the paper recycling stream.
The project demonstrated that sustainable packaging can do more than reduce plastic—it can simplify waste management, lower whole-life operational costs and support ambitious circular economy objectives across high-volume transport networks, aligning with Eurostar's wider focus on increasing circularity and reducing waste
One Waste Stream. One Smarter Solution.
Fox's Glacier Mints
Refreshing an Iconic Brand Through Sustainable Innovation
Fox's Glacier Mints is one of Britain's most recognised confectionery brands, with a heritage built around purity, freshness and the iconic polar bear standing proudly on Arctic ice.
As consumer expectations evolve and competition from challenger brands and retailer own-label products increases, Valeo Foods recognised the opportunity to refresh the brand through genuinely sustainable packaging.
Working with Ryvon, the objective was to replace conventional flexible packaging with Ryvon High Barrier recyclable paper packaging, creating a solution that delivers the barrier performance and shelf life the product demands while significantly improving its environmental credentials.
The partnership creates a compelling new brand story. The iconic polar bear has long symbolised the Glacier Mints brand; paired with Ryvon's fully recyclable paper packaging, it now also represents a commitment to protecting the environment and reducing packaging waste.
Together, Fox's Glacier Mints and Ryvon demonstrate how packaging innovation can strengthen an established brand, creating a powerful point of differentiation while supporting the transition towards a more sustainable future.
An Icon brand Protecting More Than Freshness. with Ryvon
Traditional butter wrappers are typically manufactured from a complex laminate of paper, aluminium foil and plastic, making them extremely difficult to recycle through conventional household recycling systems.
Working in partnership, Ryvon and Mastellone Hermanos set out to develop a genuinely recyclable butter wrap that delivers the performance of traditional materials while enabling disposal through the paper recycling stream.
Butter packaging presents unique technical challenges. The material must resist high levels of moisture, fat and oil migration while maintaining excellent dead-fold characteristics, seal integrity and long product shelf life.
To meet these requirements, Ryvon developed two specialist material platforms: a standard high-barrier construction with the barrier layer positioned inside the wrap, and a metallised version that delivers the familiar premium appearance of traditional butter packaging while retaining Ryvon's high-performance barrier technology.
Shelf-life validation and food-contact migration testing have now been successfully completed, demonstrating the material's suitability for demanding dairy applications. The project now moves into full-speed commercial production trials.
This collaboration highlights how technical partnerships transform complex packaging challenges into commercially viable, recyclable solutions for the food industry.
From Complex Laminates to Circular Solutions.
Clifton Packaging and Ryvon partnered to develop Evo-Seal™, a patented resealable paper packaging system that delivers the convenience consumers expect without the need for plastic zippers or additional components.
The project required extensive collaboration across material science, print technology and packaging conversion. Together, Ryvon and Clifton developed the optimum method of accurately applying the Evo-Seal™ system during the printing and converting process, ensuring consistent performance at commercial production speeds.
A major technical challenge was engineering a reseal system that remained easy to open while providing up to 20 secure open-and-close cycles without compromising package integrity. Equally important was ensuring the system operated reliably on high-speed VFFS packaging lines, where product dust contamination can reduce the effectiveness of conventional resealable solutions.
Through joint development, testing and optimisation, Ryvon and Clifton created a robust, commercially proven resealable paper packaging technology that combines consumer convenience, manufacturing efficiency and genuine recyclability within the paper waste stream.
The result is a unique innovation that demonstrates how strong technical partnerships can transform ambitious ideas into commercially successful packaging solutions.
Orkla Foods is one of Europe's leading manufacturers of soups, seasonings and dry food mixes, producing high volumes across multiple manufacturing facilities throughout Europe.
To support the project across the region, Ryvon partnered with Optipack, combining materials expertise with local converting capability to deliver a complete technical solution tailored to Orkla's production requirements.
One of the most demanding aspects of the project was the need to run high-speed sachet lines incorporating compression rollers that remove excess air from each pack before sealing. Products containing dried pasta, herbs and other sharp ingredients create a significant risk of puncturing during this process, placing exceptional demands on both the packaging material and machine performance.
Working together, Ryvon and Optipack developed a high-performance paper structure and process that combines excellent puncture resistance with outstanding barrier performance, allowing the material to withstand these demanding production conditions while maintaining consistent seal integrity and reliable machine speeds.
The project demonstrates how close collaboration between brand owner, converter and material developer can overcome complex technical challenges to deliver commercially viable, recyclable paper packaging without compromising production performance.
Technical Challenges. Collaborative Solutions.
Herbalife is one of the world's leading health and nutrition companies, supplying a comprehensive range of nutritional products to customers across the globe.
As part of its ongoing sustainability strategy, Herbalife is exploring alternatives to traditional rigid HDPE containers. While these containers provide excellent product protection, they also represent a significant proportion of packaging weight, increasing transport costs, storage requirements and environmental impact throughout the supply chain.
Working closely with Herbalife's Asian packaging team, Ryvon is developing a new generation of high-barrier paper stand-up pouches designed to replace conventional rigid plastic containers while maintaining the product protection and shelf life demanded by premium nutritional products.
The project is evaluating multiple manufacturing formats, including both single-web and two-web pouch constructions, to determine the optimum balance of durability, functionality, consumer convenience and commercial performance.
By combining Ryvon's high-barrier paper technology with Herbalife's global packaging expertise, the partnership aims to create a genuinely recyclable alternative that reduces packaging weight, improves logistics efficiency and supports Herbalife's long-term commitment to more sustainable packaging solutions.
This ongoing collaboration demonstrates how technical partnerships can unlock the next generation of high-performance paper packaging for global consumer brands.
Transforming Rigid Plastic Into Circular Paper Solutions.
MadeGood Foods is one of Canada's leading healthy snack manufacturers, producing a wide range of better-for-you cereal bars and snack products for consumers around the world.
The company challenged Ryvon with two demanding packaging applications: developing a recyclable high-barrier pillow pack capable of running at 120 packs per minute, and a high-speed flow-wrap solution for muesli bars operating at 600 packs per minute on existing production lines.
Working alongside MadeGood's engineering and production teams in Canada, Ryvon carried out extensive machine trials, material optimisation and sealing development to achieve the required production speeds while maintaining exceptional pack presentation, seal integrity and product protection.
The collaboration successfully demonstrated that Ryvon High Barrier can deliver the performance demanded by modern, high-speed food manufacturing without compromising sustainability objectives. The resulting packaging is now undergoing extended shelf-life validation, with early stability data demonstrating excellent barrier performance and outstanding product protection.
This project highlights how close collaboration between brand owners and technical partners can accelerate the transition from conventional plastic packaging to commercially viable, recyclable paper solutions.
Pladis, one of the world’s leading snacking companies, is working with Ryvon to launch its Verkade 150g chocolate bars in Ryvon High Barrier recyclable paper packaging.
The project required the material to deliver validated shelf-life performance while also meeting demanding production requirements on high-speed flow-wrap lines. Shelf-life testing has been completed and accepted as fit for purpose, confirming Ryvon’s ability to protect the product throughout its commercial life cycle.
On the engineering side, the packaging had to run at a minimum of 200 packs per minute and support automatic reel splicing without compromising pack quality or line efficiency.
To achieve this, Ryvon developed a dedicated forming box designed to deliver perfect pack presentation while preventing tearing when the flow-wrap line accelerates instantly from a dead stop to full production speed.
Current trials with the Pladis manufacturing team have exceeded expectations, delivering consistent high-speed running over extended periods. The project is now progressing towards full production, demonstrating Ryvon’s ability t
Walkers Chocolates was one of Ryvon's earliest development partners, recognising the potential of recyclable high-barrier paper packaging long before it became a mainstream industry priority.
From the earliest stages of development, Walkers worked alongside the Ryvon team to validate, refine and optimise the material across a diverse range of chocolate products and packaging formats. Their willingness to innovate and collaborate played a significant role in transforming Ryvon from a promising concept into a commercially proven packaging platform.
In an increasingly competitive contract manufacturing market, Walkers recognised that Ryvon offered far more than sustainable packaging—it created a genuine point of differentiation. By offering customers high-performance recyclable paper packaging,
Walkers gained a unique competitive advantage that helped open new commercial opportunities and strengthen relationships with existing and prospective brand owners.
Today, the partnership continues to demonstrate how close collaboration between material developers and manufacturers can accelerate innovation, create new business opportunities and bring market-leading sustainable packaging solutions to life.
Primal Nutrition has worked in close partnership with Ryvon over the past 18 months to develop a new generation of healthy snacking products that combine premium nutrition with world-leading sustainable packaging.
Together, the teams have developed a complete range of high-protein vegetarian snack bars and bite-sized products while simultaneously engineering packaging capable of delivering the shelf life, barrier performance and manufacturing reliability required for commercial launch.
Rather than treating packaging as an afterthought, Primal has built its entire brand around sustainability. Every element—from product formulation and packaging technology to brand identity and consumer messaging—has been developed to create a genuinely differentiated offering in an increasingly competitive health and wellness market.
Wrapped in Ryvon's high-barrier recyclable paper packaging, Primal products offer consumers a healthier snack inside packaging that is designed to reduce environmental impact without compromising performance.
Supporting the launch is an ambitious digital-first marketing strategy spanning TikTok, Instagram, Facebook and other social media platforms, using a distinctive brand story to engage consumers and accelerate market awareness.
With product development complete, packaging fully validated and a compelling brand identity established, Primal Nutrition is now positioned to launch with a powerful competitive advantage built on innovation, sustainability and consumer appeal.
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Every successful project begins with a challenge. Our case studies showcase how customers have partnered with Ryvon Technologies to develop innovative, high-performance sustainable packaging solutions that stand out in the marketplace. Explore the journey from concept and material selection through validation and commercial launch, and discover how Ryvon's unique technology has helped brands strengthen their market position, demonstrate innovation, enhance consumer perception and unlock new opportunities for growth.
Ryvon isn't just replacing plastic—it is helping brands win business.
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Every project begins with a challenge. Every partnership creates an opportunity. If you'd like to explore how Ryvon can help transform your packaging, we'd love to start the conversation.
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Air Heads Rice Snacks
Engineering Performance for a New Market Launch
Innovation in Partnership. Growing Business Together
Fisherman's Friend
Replacing Complex Laminates with Truly Recyclable Paper Packaging
Caroboo set out to create a genuinely different confectionery brand—combining an ethical chocolate alternative with a strong commitment to sustainability. To complete that vision, they partnered with Ryvon to replace conventional plastic packaging with high-performance recyclable paper packaging.
Working closely together, Caroboo and Ryvon successfully transitioned their product range to Ryvon Standard, delivering the shelf life, print quality and machine performance required for commercial retail while significantly improving the environmental credentials of the finished product.
The combination of an innovative product and innovative packaging helped strengthen Caroboo's retail proposition, supporting successful listings with Holland & Barrett and other high street retailers looking for brands that demonstrate genuine sustainability rather than simply making environmental claims.
Today, Caroboo demonstrates how product innovation and packaging innovation can work together to create stronger brands, greater consumer appeal and a clear competitive advantage.
Eurostar
Simplifying Sustainability Through Closed-Loop Recycling
Mastellone Hermanos – Butter Packaging
Reinventing One of Packaging's Most Challenging Applications
Clifton & Ryvon
Engineering the World's First Paper-Based Resealable Packaging System
"Innovation in Partnership. Convenience Without Compromise."
Orkla Foods Solving Complex Packaging Challenges Through Technical Partnership
Awfully Posh partnered with Ryvon to transition its premium nut range—including Honey Chilli, Simply Salted and Dry Roasted—from conventional packaging to Ryvon High Barrier paper while continuing to use its existing contract packing operation.
The combination of small pack formats, high packing speeds and the demanding fat and moisture barrier requirements of roasted nuts presented significant technical challenges.
Working collaboratively with Awfully Posh, the contract packer and Ryvon, we developed a solution that delivered excellent machine performance, outstanding barrier protection and consistent pack quality without compromising production efficiency.
Today, Awfully Posh nuts are supplied in Waitrose Meal Deals, leading pub groups, hotels and rail catering, giving customers a distinctive sustainability advantage through fully recyclable paper packaging while supporting continued brand growth and market expansion.
The British Crisp Company became the first brand to adopt Ryvon High Barrier™ for the commercial packaging of crisps, establishing a partnership that would help shape the future of sustainable snack packaging.
Working collaboratively, our teams developed a high-performance paper packaging solution capable of delivering the oxygen and moisture barrier required to achieve shelf lives of up to 12 months, while maintaining the freshness, flavour and crispness consumers expect.
Our collaboration extended well beyond the material itself. Together, we engineered complete packaging solutions by optimising forming shoulders, sealing jaw profiles and machine settings to ensure Ryvon materials could operate at commercial production speeds on the industry's leading automated packaging systems, including TNA and Ishida equipment.
The result was a fully integrated packaging platform that matched the speed, consistency and reliability of conventional plastic packaging while providing genuine paper recyclability and exceptional environmental performance.
Today, this pioneering project stands as a landmark achievement in sustainable flexible packaging, demonstrating how close collaboration between an innovative brand and a technology partner can deliver commercially viable solutions without compromising performance.
Project Highlights
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First commercial adoption of Ryvon High Barrier™ for crisps
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Up to 12-month validated shelf life
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High-speed production on industry-standard packaging equipment
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Joint development of proprietary forming shoulders and sealing technologies
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Proven compatibility with TNA and Ishida packaging systems
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High barrier performance with genuine paper recyclability
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A partnership that transformed innovation into commercial reality
Together, we proved that sustainable packaging can match the performance of plastic—and create a powerful competitive advantage for forward-thinking brands.
Herbalife & Ryvon Reimagining Global Supplement Packaging
MadeGood Foods Engineering High-Speed Sustainable Packaging
High Speed. High Performance. High Confidence.
Pladis / McVitie’s – Verkade Chocolate Bars High-Speed Paper Packaging for a Global Brand
Walkers Chocolates & Ryvon A Partnership That Helped Shape Ryvon
Global Brand. High-Speed Performance. Recyclable Paper Packaging.
The Partnership That Turned Innovation into Opportunity
Primal Nutrition & Ryvon
Building a Brand Around Health and Sustainability
Healthy Inside. Revolutionary Outside.
The case studies featured on this website represent just a selection of Ryvon's development projects.
Across the UK, Europe, North America and Asia, we are actively collaborating with global brands, retailers, packaging converters,
machinery manufacturers and technical partners to develop the next generation of high-performance recyclable paper packaging.
Many of these projects remain commercially confidential or are currently progressing through development, validation and commercialisation. As a result, not every collaboration can be publicly showcased.
If you would like to learn more about Ryvon's experience within a particular product category, packaging application or manufacturing process, we would be delighted to discuss our work in confidence and provide additional case studies relevant to your business.
Whether your challenge involves barrier performance, machine speed, shelf life, sustainability or the development of entirely new
packaging concepts, Ryvon has the technical expertise and collaborative approach to help bring innovative ideas to market.
