Packaging material development that only succeeds in theory doesn’t move the industry forward. We engineer for production realities: line conditions, downstream automation, sustainability targets, and cost control. Every material is developed with its full lifecycle in mind.
Below is a breakdown of the key steps in our development process, each designed to ensure materials perform reliably in real-world manufacturing and packaging environments.
Every project begins with a question: what problem does this material need to solve?
Whether it's a thermoformable tray or a hot-fill barrier structure for food, we start by identifying performance gaps that existing materials can’t solve. Collaboration between our R&D engineers and customer teams drives early development.
In the lab, we assess:
From day one, we evaluate each material through a dual lens: Can it meet the technical requirements and can it do so sustainably?
Once a formulation meets lab standards, it moves to production-scale validation on ICPG’s extrusion and forming equipment. This step is critical to confirm that the material runs efficiently and consistently.
At this stage, our engineers evaluate:
This process bridges the gap between formulation and manufacturability, ensuring that packaging material development translates to performance on real equipment.
Our materials are tested beyond our walls. We work with customers to trial new structures on their own equipment, under actual production conditions.
During trials we assess:
ICPG’s technical team works on-site when needed, adjusting parameters to ensure the material performs without requiring new infrastructure.
Once a material reaches the market, the validation continues. We support post-production testing to measure how the material performs throughout its full lifecycle.
This includes:
Each data point feeds back into R&D, allowing continuous improvement and closing the loop between innovation and real-world application.
Today’s packaging demands more than a recyclability claim. It requires materials that process efficiently, meet regulatory expectations, and align with sustainability goals, without sacrificing commercial feasibility.
Our approach to packaging material development includes:
The most sustainable packaging is the kind that can be manufactured, filled, sealed, and recovered efficiently, and at scale.
Engineering for reality means more than making packaging that runs. It means developing materials that deliver consistent performance across demanding food packaging environments, without compromising sustainability or cost efficiency.
Reach out to IPCG to learn how our process-driven approach to packaging material development supports innovation that performs in the real world.