As a leader in packaging and wrapping solutions for fresh dairy products and desserts, BW Packaging supports manufacturers as they adapt to evolving market requirements—offering multiple solutions to meet today’s challenges.
One of the latest innovations appearing on store shelves is a three‑layer gourmet dessert packaged in a single cup thermoformed from transparent PET. Combining premium visual appeal with recyclability and cost efficiency, this packaging format responds directly to growing market expectations.
Balancing differentiation, recyclability, and profitability is a complex challenge for marketing and production teams alike. At the request of a major global dairy player, BW Packaging rose to this challenge with a highly advanced solution.
The proposed system is an Arcil Form‑Fill‑Seal machine equipped with three fillers, capable of producing up to 40,000 cups per hour. It precisely fills three distinct flat layers: a fruit‑based bottom layer with large, clearly visible pieces, a middle layer of high‑protein yogurt with a smooth surface, and a uniform topping of fruit coulis.
The cups are sealed with a heat‑sealed PET lid, trimmed inline to deliver a smooth, glossy finish. This surface quality clearly stands out compared with the honeycombed or micro‑perforated lids often found on premium preformed cups.
Designed for flexibility and hygiene, the machine operates in ultra‑clean conditions. Two of the fillers can be removed for purging or cleaned in place (CIP) during masked time, allowing maintenance and product changeovers without interrupting production.
Filling accuracy and product presentation are uncompromised. The use of crystal‑clear, thermoformed PET showcases the dessert’s layered structure with a 360‑degree view, enhancing shelf appeal. Made from 100% PET, the packaging offers a glass‑like appearance while being fully recyclable as a mono‑material solution.
As market trends push manufacturers to rethink traditional production practices, BW Packaging helps guide this transition—delivering solutions that address recyclability, elevate premium positioning, and maintain low production costs.
