DESIGN

In the Design phase, Varden collaborates with clients to create customized packaging solutions tailored to their specific needs. This involves understanding the product requirements, target market, and sustainability goals.

Using innovative plant-based materials, Varden develops initial concepts and visual models that align with environmental standards and consumer expectations. This stage includes brainstorming sessions, sketching, and digital modeling to visualize the packaging’s form and function.

The aim is to blend aesthetic appeal with practical functionality, ensuring that the designs are both attractive and capable of protecting the product during its lifecycle​.

PROTOTYPE

During the Prototype phase, the concepts developed in the Design stage are translated into tangible prototypes. This involves creating physical samples using Varden’s proprietary paper thermoforming technology, which provides a realistic assessment of the packaging’s performance.

Testing is crucial at this stage to evaluate the prototypes’ barrier properties against oxygen and moisture, mechanical strength, and overall usability. Feedback from clients and internal evaluations helps refine the prototypes.

This iterative process ensures that any design issues are addressed, and the packaging meets both client specifications and industry standards​

CERTIFICATION

In the Certification phase, Varden’s prototypes undergo rigorous testing and validation to obtain necessary regulatory approvals and certifications. This step involves compliance with international standards for safety, quality, and environmental impact. Testing includes barrier performance, biodegradability, recyclability, and food safety (where applicable).

Certification ensures that the packaging meets legal and market requirements, such as those enforced by the EU Plastic Packaging Levy. This phase is essential for ensuring that the packaging can be legally and effectively used in the intended markets, providing assurance to clients and end-users

PILOT MANUFACTURE
by Varden

The Pilot Manufacture phase involves producing a limited batch of the packaging to validate the manufacturing process and assess scalability.

Varden uses its pilot facilities to simulate full-scale production, allowing for adjustments to optimize efficiency and quality.

This phase includes setting up production lines, fine-tuning machinery, and conducting small-scale trials. The goal is to identify and resolve any issues before full-scale production, ensuring the packaging can be manufactured consistently and cost-effectively.
Data collected during this phase helps refine production parameters and supports a smooth transition to larger-scale manufacturing

SCALE MANUFACTURE
Under License

In the Scale Manufacture under Licence phase, the production process is handed over to the client or a licensed manufacturer for full-scale production.

Varden provides comprehensive support, including technology transfer, training, and ongoing consultation to ensure the packaging can be produced at high volumes while maintaining quality and performance standards.

This phase involves integrating the packaging into the client’s supply chain, optimizing production workflows, and scaling up to meet market demands. The licensing agreement allows clients to benefit from Varden’s innovative technology while managing their production operations independently​.

Technology

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