For generations, the “stick of butter” has always looked the same on store shelves. That’s about to change. IMA Benhil GmbH has the right solution for it.
Admittedly, there’s something familiar about the folded butter packaging. Established over decades, every consumer knows exactly how to handle it. Everything as usual—and in a way, that’s a good thing. However, almost unnoticed, much has changed—just like with many other packaged products—when it comes to product protection, handling, and recycling.
Benhil asked itself: Can the classic character of butter packaging be preserved while significantly improving these features?
The answer: Yes, it can!
Let’s learn from pouch packaging—the right way!
For many years now, aroma-sensitive products—such as chocolate bars—have been successfully packaged using recyclable mono-material films in hermetically sealed, easy-to-open pouch formats. Fresh natural products like butter deserve the same level of protection.
However, further processing and marketing require the familiar cuboid shape and a tightly fitting packaging material without air pockets. This prompted Benhil to combine the advantages of sealed packaging with the gentle product handling of traditional folded wrapping.
The result is FoldWrap—a globally patented process and design for pasty products such as butter, margarine, lard, or cooking fat.
Visually almost indistinguishable from classic butter packaging, FoldWrap offers five key advantages:
- Sustainable: From mono-material films with a recycling rate of over 90%, to compostable plastics and purely paper-based packaging materials—FoldWrap is compatible with all modern, eco-friendly materials
- Hermetically sealed and hygienic packaging: The sealing prevents contact with the atmosphere. The product stays fresh for longer, and the shelf life is extended.
- Aroma protection: Preserves the aroma and sensory quality of the packaged product.
- Tamper-evident seal: Gives consumers confidence in the integrity of the product.
- Easy opening: Simply grab the marked tab → pull → done! All common consumer habits are supported—and in every case, your fingers stay clean.
Less material, no energy input!
Since the process places virtually no demands on the folding properties of the packaging material, the basis weight can be reduced by nearly 50%. Depending on the format, the cut size can also be reduced—for example, by an additional 9% for the classic German butter block.
The wrapper is simply separated from the flat packaging web—no punching or rewinding of waste is required. Sealing is achieved using a cold lacquer that reacts solely to pressure. No heating tools come near the sensitive products, and no energy is needed for sealing.
From a marketing perspective, it’s worth noting that the new packaging offers more printable surface area.
Compact machine, universally expandable.
The machine used for the process is called FoldWrap 1800, and it’s based on a proven machine concept. Naturally CIP-capable and quickly adaptable to different formats, it delivers up to 140 packs per minute within a compact footprint.
Available in trough or direct-feed versions, it can be expanded with numerous options—such as butter embossing—leaving nothing to be desired.
Together with its mirrored “sister” unit, it forms a high-performance line designed for single-person operation with full redundancy in both operation and maintenance.
Trusted partnerships driving innovation and market success.
On the packaging material side, our collaboration with Huhtamaki Flexibles in Ronsdorf has proven highly effective. Their expertise in highly recyclable mono-material films has been a valuable contribution.
Introducing new ideas—or even new packaging—in the highly conservative butter market requires courage and conviction.
That’s why we’re especially pleased to have found partners in the German market who are implementing our packaging solution in their dairies.
The products are now available in various regional supermarkets. Topics like material savings, freshness, and extended shelf life represent real contributions to quality and waste reduction—making them highly relevant trends in today’s market.
Ready to see how FoldWrap is transforming dairy packaging? Join the IMA Benhil team at Gulfood Manufacturing in Dubai! Meet our packaging experts and find out how you can elevate your product protection while cutting material costs.
For more information, visit https://imagroup.com/food/dairy-plant-based-products
or E-mail: info.benhil@ima.it
