24 Plastics in Packaging © 2018 Sayers Publishing Group • September

THERMOFORMING

Based south of Brussels, Belgian converterSabert Europe is an important packagingproducer for the foodservice, retail and

cash and carry sectors. The history of SabertEurope started in 1988 when Philippe Leemansstarted out as a commercial agent in Europefor Sabert USA. For British customers, he wasimporting metallic and marbled PVC traysmainly for caterers.

In 1990, Leemans created a structure thatbrought together production tools and distri-bution networks and he switched productionto PET. The year 2000 saw the start of thermo-forming and five years later the company’sfirst extrusion line at the Nivelles plant.Today, the company’s packaging product offeringhas expanded considerably with three specificranges: Cold and fresh PET dishes; hot PP;and an ecological solution in pulp.

“Since the 1990s we operated a doublediversification. First, we focused on marketevolution to closely follow consumer habits(such as nomadic, fast food, take-away, andultra-fresh) and broaden our offering of tableand catering products with up-scaled products,easy to use and suitable for various occasions.At the same time, we have broadened ourpackaging to suit products to be heated, freshproducts and ‘sustainable’ containers madefrom renewable resources,” said Leemans.

In fact, thanks to ever-increasing sales inEurope, Sabert’s BePulp range is highlyregarded. The container is made of 100 percent bagasse or sugar-cane-fibre cellulose inZhongshan’s Sabert factory in China andbrought into containers in Belgium throughthe port of Antwerp.

The BePulp range comes in bleached andnon-bleached formats, is suitable for microwav-ing, is resistant to temperatures up to 120 degC and can be cooled to minus 10 deg C. Theproduct range has no coating whatsoever asSabert Europe wanted the BePulp packagingto be 100 per cent consistent and appealing toconsumers who often require transparency forfresh products. Therefore, the lids are thermo-formed in transparent rPET and manufacturedat the Nivelles factory.

Chief executive Leemans continued: “Weacquired the BePulp Company in 2012 to com-plete our offering. Today it is a successfulrange of products that contributes about afifth of our total sales. Today, France is ourmain export market in Europe with around 30per cent of sales thanks to very large distribu-

tors. But the UK is definitely the booming one.Between 10 and 20 per cent of our BePulp goesto the leading European market in out-of-home packaging. Scandinavia, the Netherlandsand Belgium are also growing markets, provingthat consumer demand is there now.”

Next year, a new Sabert production sitededicated to BePulp products will be operationalin Greenville, Texas (USA). Fibres from agri-cultural residues (primarily wheat) will be theraw material.

“We look forward to this new factory withup-to-date technology. Today, the process isquite labour intensive in our Chinese factory,so further development in the production is

needed to satisfy the growing demand for suchpackaging. The American market is huge, andthe consumer’s environmental conscience ison the rise, so this is a big opportunity forSabert. From our facility in China, we arefocusing on serving the four ‘mature’ marketsof Australia, Singapore, Hong Kong and Tai-wan,” said Leemans.

In Belgium, BePulp containers are certifiedby Vinçotte (recently acquired by the AustrianTUV) with ‘OK Compost’ and ‘OK CompostHOME’ labels. These labels guarantee that

Double diversification

Sabert EuropeTurnover (2017): €48 million ($55m)Sabert Europe staff: 56 full-time equivalentsType of customers: Distributors, processors in food, supermarkets, Cash & carrySectors: Restaurant chains, restaurants, caterers, distribution chains, on-the-go food and delivery meals

Sabert GlobalUSA: Three production sites (+ Greenville in 2019), One R&D centre. 400 workersChina: One production site in Zhongshan. 400 workers

With three extruders and 12 thermoforming machines, one Belgianthermoformer is an important supplier to the European packaging market.Dominique Huret visited the company to find out more

BePulp is made frombagasse or sugar-cane-fibre cellulose.Right: Sabert Europe’sPhilippe Leemans wantsauthorities to solve theindustrial compostingbottleneck

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Plastics in Packaging © 2018 Sayers Publishing Group • September 25

the packaging is respectivelybiodegradable in an industrial com-posting plant or in a garden compostpile along with kitchen waste. The‘OK Compost’ breaks down by up to90 per cent in 90 days in an industrialcontext and the ‘OK Compost HOME’in 120 days in domestic compost.

Philippe Leemans added: “Atpresent, if private composting is agrowing trend, industrial facilitiesremain a bottleneck. Switzerland issetting an example in this field. Let’shope that an increasing demand for such prod-ucts will push authorities to develop them.”

The BePulp range also complies with theEuropean standard EN 13 432, which definesthe characteristics of packaging that can berecycled by composting and biodegradation.

“Last May the European Commission pro-posed new European rules to target the tenmost commonly-used plastics products foundon European beaches and seas. When alterna-tives are readily available and affordable, dis-posable plastics products will simply be bannedfrom the market. In France already, theGrenelle of the environment promoted bySégolène Royal prohibits plastics plates andgoblets in supermarkets by 2020. We industrials

must prepare ourselves because the consumerwill continue to consume on-the-go, have theirfood delivered and sometimes party with dis-posable glass, plates and cutlery.”

Expertise in recycling and mixing PETmakes Sabert a reference in the sector. TheNivelles plant generates half of its sales fromthermoforming, with a large share in rPETand PP. The huge silos and facilities forgrinding, weighing and melting granules speakfor themselves.

“Since the very beginning of our production,we have been collecting all waste and PETproduction waste for crushing, melting and

reuse. With 70 per cent of post-consumer recy-cled PET, our recycling process is certified‘food contact’ by EFSA, the European FoodSafety Agency.

“However, in order to preserve the physicalproperties of the packaging, 30 per cent ofvirgin PET granules are required. For ourblack packaging, up to 80 per cent recycled isused. Our cutlery is made from CPLA (‘crys-talised’ PLA) to resist heat. You would notwant your spoon disintegrating in your cup ofcoffee,” concluded Leemans with a smile.

More information from Sabert Europe, 4 rue de I’Industrie, 1400

Nivelles, Belgium. Tel: 32 67 888 444. Web: sabert.eu

Online Auction Sale Bandera Plastic Extrusion, Clever Shrink Sleaving, Amut & Illig Thermoforming, OMSO & Van Dam Printing previously used in the production of Disposable Cups & Containers for Theca Srl Turate (Co)

Bidding Ends: Tuesday 9th October 2018 at 3.00pm (UK Time)

Please Contact Our Office for Further Information: Cottrill & Co, 401 407 Tyburn Road, Erdington, Birmingham, B24 8HJ

Tel: + 44 (0) 121 328 2424 Fax: + 44 (0) 121 327 9550 Email: info@cottandco.com Website: www.cottandco.com

Cottrill & Co is a Trade Name of Cottrill & Associates Ltd

For full info please visit our Website: www.cottandco.com

Sleeving Line comprising: Vertical Cups Loader, 2 Portable Double Sleeve Reel Storage Units, Clever GSD 422 Sleeve Applicator, Clever STJ3 1Air Steam shrinking Tunnel & Stacking Cup unloader (Line Built 2011)

AMP 850 2F Thermoforming Machine (2006) Qty TRIA & MECCANOPLASTICA Granulators (3) ILLIG RDM 70k Automatic Pressure

Forming Machines Colour Dry Offset Cup

Printing Machine (2002) (4) VAN DAM 565 MTO/UV, 6 Colour Dry

Offset Printing Machines (1999) DS2 CF 4 UV, 6 Colour Dry Offset

Printing Machine (2) OMSO DM55/5UV, 6 Colour Dry Offset

Printing Machines

AQ10 Single Station Silk Screen Rotary Printing Machine

Product Elevator with Overhead Delivery System

Thermoforming Machine (1996)

RDM 63/10 Thermoforming Machine - ASSIMPLAST Thermoforming Machine

RDM 63/10B Thermoforming Machine Qty Custom Built Stacker Units (2) Plastic Sheet Extrusion Lines Mixing Extruding and Re-granulating Line (5) Extruding and Thermoforming Lines Qty ERG SM8 Dual Carton Tape & Cut Machines Qty Mobile Winder Units

Qty Silos, Mixers & Filtration Systems Qty Chillers by Crosta Giuseppe, OMF,

Green Box, Uniclima DSD241 Air Compressor

FNGJ 32 Universal Milling Machine 02 Horizontal Grinder

Edging Machine & DANIA Lathes

FR40 1000mm Radial Drill Saws

2) STILL Fork Lift Trucks, FIAT & TOYOTA Pedestrian Trucks, Qty Pallet Trucks, Qty Overhead and Jib Cranes, plus many more items

In Association with

Cold and fresh PET dishes, hot PP, and pulp packaging are the focal points of Sabert Europe’s production

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