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Springfield, MA – Dennis Group, a leading design-build firm dedicated exclusively to the food and beverage industry, highlights its Growth-Ready Facility Planning approach, a structured program that helps manufacturers design facilities prepared for phased expansion, evolving production demands, and long-term operational flexibility.

While many capital projects focus primarily on immediate capacity, Dennis Group’s Growth-Ready Facility Planning approach is designed to align early design decisions with strategic future expansion. The approach combines scenario modeling, code and infrastructure assessments, and phased utility and site strategies to reduce the risk of costly retrofits and operational disruption as facilities grow.

The approach begins at the concept stage with expansion scenarios and master plan development that account for ultimate build-out. In addition to these forward-looking strategies, it also incorporates core facility design considerations such as process and material flows, wall and column placement, storage and warehouse requirements, and future automation to ensure day-one efficiency alongside long-term scalability. Life safety and egress evaluations analyze exit travel distances, ceiling heights, fire separations, and fire pump capacity to ensure facilities remain compliant as footprints increase. Utility phasing playbooks address centralized systems such as steam, compressed air, and refrigeration, prioritizing modular headers, right-sized equipment by phase, and oversized rooms and access paths instead of inefficient excess capacity.

Site and infrastructure planning are also core components of the framework. Stormwater modeling establishes long-term drainage backbones sized for future roof area, helping avoid excavation, grading changes, and re-permitting during expansion. Dock and truck circulation strategies incorporate structural knock-outs and phased traffic planning to maintain shipping continuity as new square footage is added.

Because Dennis Group delivers integrated design-build services in-house, the Growth-Ready Facility Planning approach aligns process engineering, utilities, building systems, packaging integration, and construction from the outset. This multidisciplinary coordination enables earlier identification of code-limited spaces, infrastructure bottlenecks, and site constraints that can otherwise surface late in the project lifecycle.

Since 1987, Dennis Group has focused exclusively on food and beverage facilities across North and South America. By packaging its expansion expertise into a defined, repeatable planning framework, the firm provides manufacturers with a practical roadmap to protect capital investment, support phased growth, and reduce long-term expansion risk.

Manufacturers can engage Dennis Group’s Growth-Ready Facility Planning approach during early master planning for greenfield projects or as part of pre-expansion assessments for existing facilities.

For more information about Dennis Group’s growth-ready facility planning and design-build services, visit www.dennisgroup.com.

 
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At London Packaging Week, as the aisles began to thicken with designers, buyers, sustainability leads and innovation scouts, a small but magnetic crowd formed at the Supplier Gallery. In a show celebrated for its aesthetics, engineering, luxury storytelling, and technical ingenuity, one winner stood out for a reason altogether different. It wasn’t just a new material. It wasn’t a slightly lighter box. It wasn’t a marginal efficiency.

It was a system.

A rethink.

A challenge to the very foundations of how e-commerce packaging works.

When Movopack and Decathlon Italia were announced as the Supplier Gallery Winner, the applause felt less like a nod to novelty and more like the industry recognising a shift: a future where packaging doesn’t end in the recycling bin, but begins a circular life of 20, 30 or even more journeys.

For Eleonora Protopapa, Movopack’s Chief Marketing Officer, the win was more than a trophy. It was validation. “It was a very positive show for us,” she reflects. “We already have meetings being booked. Our main objective was brand awareness, lead generation, and initial customer acquisition. And in that respect, it was exactly what we hoped for - especially as this is one of our first real-life touchpoints in the UK since expanding here late last year.”

Yet the success at London Packaging Week was simply the visible moment in a much larger story - one that starts with a deceptively simple idea: why should packaging be used once?

The reuse revolution

In an industry dominated by century-old incumbents, the rise of reusable packaging has felt inevitable yet strangely elusive. The logic has always been compelling: reduce waste, reduce emissions, reuse assets, lower long-term cost. And yet, adoption has lagged behind rhetoric.

That’s because innovation was never just about the product. It was about the system.

The logistics. The refurbishment. The customer experience. The economics.

Movopack understood that from day one. Its Packaging-as-a-Service (PaaS) model offers not only the physical packaging - designed to be reused more than 20 times - but also full end-to-end management: reverse logistics, refurbishment, sanitisation, redistribution, and live data tracking, as well as support with communication and promotion of the project.

“People often focus only on the material,” Eleonora explains. “But here, the innovation is not just in the product - it runs through the full business model. That’s how it distinguishes itself from anything else at the show.”

The numbers are startling. An independently verified Life Cycle Assessment shows that each Movopack unit reduces CO emissions by up to 84%, packaging waste by 98% compared with a cardboard box made from 70% recycled paper and dramatically cuts energy and water consumption. In a world of incremental sustainability claims, these are leaps.

But perhaps the most genius part of the system is that, for the consumer, it’s effortless. After unboxing their purchase, they fold the packaging flat and drop it into any postbox, or partner stores, across Europe, free of charge. Movo handles the rest.

“Many people assume reusable systems are complicated or expensive,” Eleonora says. “But in the long run, they actually save brands money. You reuse packaging, cut single-use costs, and are exempt from upcoming EPR regulations. The economic evidence is just as strong as the environmental one.”

From Italy to Europe: How Decathlon became the proof point

While Movopack operates across Europe, its boldest partnership so far is with Decathlon Italia, the sports retail giant whose scale makes any sustainability initiative immediately meaningful.

The partnership began as many modern collaborations do - a conversation, a spark of interest, a meeting at an innovation fair. What followed was a model example of true co-creation.

“We build the packaging entirely around the customer’s needs,” Eleonora explains. “Dimensions, materials, opening mechanisms, design - everything is bespoke. We don’t offer a standard box with our logo. The packaging becomes their brand moment.”

This distinction matters.

Many reusable packaging systems in Europe rely on generic bags printed with the supplier's identity. Movo flips the dynamic: the packaging becomes part of the brand’s storytelling, not an interruption of it.

“Think about receiving a Decathlon order,” Eleonora says. “If it arrives in a generic reusable pack, the emotional effect is lost. Instead, we wanted the customer to experience something that feels premium, aligned, and considered.”

The Decathlon pilot began with a test phase - a necessary step for any retailer managing vast operational complexity. The early results were immediately promising: a 26% organic return rate, achieved without incentives, purely through consumer goodwill and clear instructions.

“That number is extremely significant,” Eleonora notes. “Especially because, with Decathlon, we didn’t have access to all the touchpoints we would normally use to guide behaviour - like transactional emails or website pop-ups. So, we had to get creative.”

Movo added communications directly onto the packaging:

A message printed on the security seal.

A flyer inside the parcel explaining the return process.

A sticker reinforcing the instruction.

It worked.

The pilot will expand into retail, with in-store collection points and reusable shoppers now in development. The Decathlon partnership is now becoming the backbone of Movopack’s social proof, especially as the company turns its attention to the UK.

Crossing the channel: Why the UK is Movopack’s next big bet

With one of the most mature e-commerce ecosystems in the world, the UK represents both a huge opportunity and a complex challenge.

“The UK has a higher buying power than Italy,” Eleonora says. “Our price points are more competitive here. And the volume of e-commerce is three times.”

Yet entering a new market requires more than logic and LCA data. It requires trust.

“In Italy, we have major brand recognition thanks to Decathlon and other strong partners,” she notes. “In the UK, we’re new. So, the challenge is building social proof — getting that first major brand that becomes the reference point for the rest.”

London Packaging Week was therefore a strategic milestone - a moment to gather leads, build visibility, and let UK retailers experience the system firsthand.

“It was one of the first times we got real-life touch with the UK audience,” Eleonora says. “And we’ve already booked for next year.”

Beyond sustainability: A business model that strengthens brands

For all the environmental benefits, what makes Movopack truly compelling is how it enhances a brand’s relationship with its customers.

If a consumer returns packaging via a postbox or brings it back to the store, they can be rewarded with discounts, loyalty points, or incentives. These incentives increase average order value, repeat purchase behaviour, and footfall to physical retail.

“You can position yourself as a sustainable brand,” Eleonora explains. “You increase customer retention. You tell a story your audience wants to hear. And you impact key business metrics directly.”

In a world where packaging is often seen as a commodity, Movo turns it into a driver of engagement, loyalty and narrative.

Operations, touchpoints, and the real work of change

The biggest barriers to adoption are rarely philosophical. They’re operational.

“When you introduce something new, even if it’s more efficient than cardboard, you’re disrupting your customer’s processes,” Eleonora says. “So, the smooth transition is essential.”

Movo’s operations team collaborates directly with the retailer’s logistics and warehouse teams to ensure a seamless onboarding process. KPIs are set. Return rates are monitored. Tests are run.

Touchpoints become critical. A sticker can shift behaviour. A sentence on a seal can drive action. A small flyer can unlock circularity at scale.

These micro-details accumulate into macro impact - turning return logistics from a theoretical idea into a living, functioning system.

A mindset shift: From waste to worth

For Eleonora, the emotional core of Movopack’s mission lies in simplicity.

“While customers can repurpose the packaging for gym gear or storage, the real impact happens when they return it,” she says. “Every return means significantly less CO, less energy, and less water used - a simple action that keeps the system truly circular.”

And that is the essence of the movement Movopack is building. Not guilt, or obligation, or complicated sustainability dashboards. Simply a better choice made easy.

A circular future, delivered

As the industry pushes toward net-zero goals, EPR compliance, waste reduction and the reinvention of delivery systems, Movopack feels less like an alternative and more like an inevitability.

The win at London Packaging Week wasn’t just a vote for a product. It was a vote for possibility - for a world where packaging doesn’t end in the bin but begins a journey.

A world where brands save money, strengthen relationships, and reduce their footprint. A world where consumers participate effortlessly in circularity. A world where the box itself isn’t the end of the story, but the beginning.

“We know the product is valid, and we know the model works,” Eleonora says. “Now it’s about bringing that same impact to the UK, just as we’ve done in Italy.”

Judging by the energy in the aisles of London Packaging Week - and the growing list of brands lining up to talk - that future might be closer than anyone imagined.

 
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(Madison, IN) – Madison Chemical introduces new ENVIRO-CLEAN SY-HD – a moderately alkaline, chlorinated liquid designed as a one package, general purpose foaming cleaner that works well in virtually all water conditions. This chlorinated, moderately alkaline detergent produces thick, stable, wet foam needed for cleaning vertical and overhead surfaces without dry-out or run-off. Formulated to perform in challenging environment, it is free of phosphates, NPE surfactants, PFAS, and EDTA, and is Prop 65 compliant, so it has minimal environmental impact. With moderate to high foam characteristics, ENVIRO-CLEAN SY-HD is ideal for cleaning difficult-to-reach areas in food, beverage, and dairy processing plants.

This versatile cleaner is typically used at 1 to 10% by volume in water at ambient to 140°F. Conditions of use vary considerably due to the extent of and differences in soils and deposits as well as the base materials from which they are removed. Madison Technical Sales Representatives are available to assist in determining dilution rates and contact times.

Before using ENVIRO-CLEAN SY-HD food products and packaging materials must be removed from the room or carefully protected. After use, all surfaces must be thoroughly rinsed with potable water. ENVIRO-CLEAN SY-HD is safe to use on ferrous, stainless, and most cuprous materials when used as directed; may etch aluminum, zinc, and yellow brass. Not for use on painted surfaces.

ENVIRO-CLEAN SY-HD is part of the ENVIRO-CLEAN line of cleaning chemicals developed to provide superior cleaning performance while meeting modern environmental standards. They are designed for the increased focus on the relationship between cleaning chemistry and wastewater systems, both municipal and within production facilities. The full lineup includes a range of alkaline, acidic, and neutral products that are free of phosphates, NPE Surfactants, PFAS, and EDTA while remaining Prop 65 compliant.

Madison Chemical is a chemical formulator providing cleaning, sanitation, and maintenance products for the food and beverage processing industries. They also produce products for surface preparation, metalworking, industrial maintenance, transportation, wastewater treatment, winery, pulp and paper, and other industries. Since 1947 they have served customers from their Madison, Indiana headquarters and through a nationwide network of direct Technical Sales Representatives. For additional information, visit www.MadChem.com, write to them at Madison Chemical, 3141 Clifty Drive, Madison, IN, 47250, call (812) 273-6000, or email solutions@madchem.com.

 
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Klöckner Pentaplast (kp), a global leader in rigid and flexible packaging and specialty film solutions, has launched, its latest innovation designed specifically for vacuum skin packaging (VSP) for processed fish.

The new boards can contain up to 100% recycled content, helping brands comply with evolving regulatory requirements. Their lightweight, mono-material construction helps lower carbon impact and reduce EPR fees to the minimum in most European countries, while the board’s open-flap design maximises pallet efficiency to improve logistics performance.

To deliver a dependable, high-quality solution for VSP applications, kp Evolve® Fish Boards offer strong vacuum-skin performance and excellent shelf clarity, and are fully recyclable in established PET recycling streams.

At the core of the design is advanced retention-chamber geometry, which replaces the need for absorbent pads and adhesives. This system guides any released juices away from the product surface and into dedicated micro-vacuum retention zones, helping prevent liquid build-up and reducing the risk of leakage during distribution and handling.

Paul Rawlings, Launch Manager at kp Food Packaging, commented: “kp Evolve® Fish Boards are engineered for smooth runs on high-speed automated packing lines thanks to the board’s central section, which enhances overall strength and processing efficiency. Available in a wide range of sizes, the boards meet UK and EU design-for-recycling requirements. And when brands choose to include kp Tray2Tray® recycled PET, the solution supports a closed-loop system for food trays.”

“For brands looking to advance their sustainability commitments and reduce environmental impact without compromising on performance, kp Evolve® Fish Boards offer an effective and commercially ready solution.”

Thanks to the boards’ innovative design features, consumers can lift the fish cleanly out of the pack without any mess or cleaning-up involved. Once used, the pack can be rinsed and recycled via established PET recycling systems.

For more information on kp Evolve® Fish Boards,  

 
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Sidel introduces the EvoFILL PET, its new filling solution for water and still beverages. It is the fastest filler ever developed by Sidel, and combines advanced fluid dynamics engineering with a next generation filling valve. It is set to support producers wishing to unlock higher efficiency in reduced space, without compromising product quality or line flexibility.

As beverage producers face growing pressure to increase output while maintaining the highest standards of hygiene and sustainability, filling technology is becoming a critical differentiator on the production line.

While plain and carbonated bottled water remain the most popular choices among consumers, the rise of functional and flavoured water is transforming the market by driving profitability and spurring brand innovation. This segment is forecast to grow at a CAGR of 3.7% from 2024 to 2028, fuelled by health consciousness, lifestyle changes and rising incomes.

Sidel’s EvoFILL PET has been developed to meet these demands head on, delivering high speed, optimised product flow and a more compact, ergonomic design for still beverages in PET bottles.

Redefining filling performance for still beverages

At the heart of the EvoFILL PET is a completely redesigned filling valve, engineered following an in depth fluid dynamics study to optimise product flow during filling. This innovation enables a significant boost in filling speed, of up to 20%, allowing the filler to reach outputs up to 90,000 bottles per hour in more compact space.

Hygiene by design, with easier cleaning and maintenance

Hygiene has been a central design focus for the EvoFILL PET. The highly hygienic filling valve design is complemented by optimised cleaning operations that reduce downtime, water usage and chemical consumption.

The filling valve features volumetric flowmeter control and a no contact filling principle, eliminating the need for components to be replaced when changing fill levels. This not only simplifies operations but also enhances overall line hygiene, helping preserve beverage quality across a wide range of still products.

Automatic CIP dummy cups, shorter internal and external cleaning cycles, reduced thermal dispersion and fewer components and surfaces to clean all contribute to faster, more efficient cleaning.

A more compact, ergonomic filler

The EvoFILL PET introduces a no base layout that delivers a footprint reduction of up to 15% compared to previous designs. This more compact configuration improves line integration and frees up valuable floor space in the filling hall.

Improved accessibility to key areas such as the external caps buffer and roof HEPA filters enhances ergonomics and simplifies maintenance tasks, supporting safer and more efficient operations for line operators and maintenance teams alike.

Flexibility to match evolving production needs

To support a wide range of production configurations, the EvoFILL PET is available in flexible layouts, including stand alone, Combi and Super Combi solutions. This adaptability allows producers to select the configuration best suited to their current requirements, while remaining future ready as portfolios and volumes evolve.

“Sidel’s new EvoFILL PET has been engineered to help customers increase output while simplifying operations and maintaining the highest standards of beverage protection, delivering performance without compromise”, explains Tommaso Tegoni, Product Manager Filling at Sidel.

“With fast and easy automatic changeovers, the extended lifespan of key components and optimised total cost of ownership, the EvoFILL PET is designed to deliver long term value alongside high performance.”

Find out more about Sidel’s filling technology and how you can access this kind of support for your business on the Sidel website.

 

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