Flexible

packaging

Our Technology and Products

This is where technology and product innovation meet flexibility in plastic packaging solutions.

Explore our applied technologies and diverse range of traditional and innovative packaging solutions designed to meet stringent technical and performance specifications.

From traditional packaging to custom-designed and sustainable packaging options, we deliver excellence in every plastic solution.

Main Manufacturing Technologies

  • Our extrusion equipment and technology enable us to produce fully customisable mono and multi-layer, barrier and non-barrier films of the highest quality, durability and strength.

    Main technologies: Reifenhauser-Kiefel

  • Our solventless high-speed lamination technologies enable us to combine various substrates to enhance product durability, provide barrier properties against moisture and gases, and approve the overall strength of the material and the aesthetics of the final product.

    Main technologies: Uteco and Nordmeccanica

  • Our eight-colour flexographic printing technologies and adopted printing methodologies (such as Expanded Colour Gamut) allow for cost-effective, high-speed and high-quality picture graphics that can be applied to any packaging or film.

    Main technologies: Windmoller Holscher & Uteco

  • Our laser perforation equipment and technology enable us to scientifically determine the level of respiration of your product and the perforation necessary to enhance the freshness of your perishable goods and extend shelf life.

    Main technologies: Perfotec

  • Our bag and pouch-making technologies are extensive, enabling us to produce both standard and customisable packaging solutions in various shapes and sizes. With enhanced levels of decoration. This includes both pre-made bags and pouches.

    Main technologies: Mamata, Hudson-Sharpe, HCI

Products

We invite you to view our bespoke product offering, to take the next step in revolutionising your packaging experience and to discover how our products protect, preserve and present your products in a way that elevates your brand, enhances shelf appeal and provides unparalleled convenience for the consumer.

Once you have perused our offerings and identified solutions that could be of benefit to you, let’s collaborate to tailor our flexible packaging solutions to precisely meet your unique requirements. Schedule a meeting with our experts, and together, explore how we can elevate your packaging strategy. Your success is our priority and we are here to ensure that every packaging solution aligns seamlessly with your brand objectives.

Our Environmentally Friendly Range of Polyethylene-based Films

At Master Plastics, we have invested heavily in research and development to create, in collaboration with our customers, a growing range of patented recyclable polyethylene-based film technologies which can be utilised across several applications and for the packaging of an increasing amount of products. Various iterations of these original formats, created through the need to meet specific customer requirements, continue to expand their reach beyond the original purpose of design, driven mainly by the expressed desire of customers in both traditional and non-traditional markets to utilise recyclable packaging alternatives.  

In many applications, these bespoke products represent 100% recyclable polyethylene-based alternatives to MDO, multi-layer, laminate, less recyclable and more expensive alternatives. Improvements in material processing and waste, a reduction in energy consumption, together with enhanced performance properties, resulting in significant shelf-life extension, improved quality of content and reduction in food waste have been achieved by customers.

  • A recyclable polyethylene-based packaging material for use in horizontal form-fill-seal packaging processes, commonly used in the packaging of fresh, dry and prepared foods. A BOPP & OPP replacement film.

  • A recyclable polyethylene hybrid packaging material for use in Modified Atmosphere Packaging for both bags-on-roll and pouch-made bags used in the packaging of prepared and fresh foods. A BOPP & OPP replacement film.

  • A recyclable polyethylene-based packaging material for the production of pouches used in the packaging of dry foods. A multi-layer replacement film.

  • A recyclable polyethylene-based packaging material that controls and eliminates the growth of bacteria such as botrytis and fungi. Specifically designed with CO2 (carbon dioxide) and WVTR (water vapour transmission rates) to optimise the shelf-life of grapes, but can be adapted to many other products such as berries and lychees.

  • An antimicrobial/antifungal additive that can be deployed into Penflo, PolePouch or PoleMap creating a fully recyclable polyethylene-based packaging material alternative for deli meats, fish and cheese products.

Learn more about the opportunities and applications these bespoke products offer.

Our Complete Product Offering

  • Mono-layer, Multi-Layer, Barrier, Non-Barrier, Blown or Cast.

    Extruded in-house or bought in as an already extruded product. A vast array of polymers or substrates can be extruded, laminated or processed for value-added purposes.

    Includes: Horizontal and Vertical Form-Fill and Seal, Lamination, Mulch, Bailers, Liners, Milk Sheeting, Tubing, Base, Lidding, and Shrink-type Films.

    Learn More →

  • Various formats of pre-made bags are manufactured from the flexible films produced in-house or bought in as already extruded products based on end product performance specifications.

    Due to the extensive range and flexibility of the technologies utilised in the operations, products can be designed and customised to customer requirements.

    Learn More →

  • Various shapes, sizes and formats of pre-made pouches can be produced from various substrates including plain, coated, metalised and printed laminates.

    Pouches can include gussets, spouts or valves and have reclosable features added.

    Learn More →

Flexible Films - Reel Stock

  • Products such as shrink, cover sheet and lamination films or products that require little or no customisation due to their application.

    This is produced by making use of mono-layer, three-layer, and five-layer blown film extrusion technologies.

    This includes flexible thermoformable barrier roll stock for vacuum packaging machines such as Ulma and Multivac.

  • Flexographic printing up to eight colours, using Expanded Colour Gamut ("ECG") printing technology offering improved colour accuracy, vibrant visuals and increased flexibility in design, contributing to a more visually appealing and marketable product for customers.

    ECG affords smaller MOQ and facilitates campaign runs for SKU Range optimisation.

  • The specific choice of substrates to be laminated will depend on the desired combination of properties required from the final product, such as barrier resistance, strength, appearance and feel.

    There is a solventless laminator at each of the flexible sites within the group. Lamination is solventless although we do have access to solvent-based lamination when a very high performance is required (such as that required for the packaging of aggressive pool chemicals).

  • Depending on the application, perforation allows for controlled ventilation of standard and MAP packaging, maintaining product freshness and quality and extending product shelf life.

    Scoring facilitates easy tearing or opening of packaging to enhance customer convenience. There is duplication of this technology within the group as both the flexible operations possess it.

  • Punching and cold or hot needle perforation can be done for ventilation, allowing air circulation and preventing spoilage in certain applications.

    This includes punching round holes on various substrates including Polyethylene and BOPP, making use of an inline electromechanical punching unit with the ability to punch preset patterns on a continuous or register basis.

  • Various coatings can be applied to enhance performance, including barrier coatings, heat-seal coatings, UV coatings, anti-static coatings, and speciality coatings like anti-fog, antimicrobial and anti-fungal coatings.

    Using the latest print press technology, these coatings can be applied in register post initial printing, this includes tectile and or mat and gloss varnishes.

  • Slitting of rolls offers practical advantages in terms of customisation, efficiency, cost-effectiveness and overall convenience for our customers.

    There are some slitting/rewinding machines at each of the flexible operations.

Bags

  • MAP extends product shelf life by controlling the gas composition in a pack. By measuring and understanding the transpiration rates of the pack and the respiration rates of the product, through patented technology, we can perforate the pack in such a way as to achieve equilibrium between O2 and Co2 and maintain this gas level to extend shelf life by many multiples.

    This technology is commonly used for perishable items, maintaining freshness and quality. The MAP packaging produced can also incorporate anti-fog properties.

  • Mesh combo bags combine the benefits of traditional mesh-type bags with additional features for versatile packaging. These bags are commonly used in the agricultural, fresh produce industry, these bags offer breathability and visibility.

  • Wicketed bags are pre-loaded on a metal wicket, allowing for quick and efficient packaging in various automated or manual processes. This packaging style is commonly used for items like baked goods, produce or small parts.

    The wicketed design simplifies the packaging process, making it the convenient choice for high-volume applications. Iterations of wicket bags include captive flap and resealable glue strip with gusseted, round bottom, square bottom and standard style bags offered.

  • Equipped with a resealable zipper, these bags ensure product freshness and allow for ease of access. These bags are ideal for grapes, stone fruit, other fresh foods, and snacks, pet food and products requiring multiple uses.

  • These bags feature a sliding closure mechanism for easy opening and closing. Perfect for a variety of items, they offer a secure and accessible packaging solution. These bags are used in many applications including fresh produce such as grapes and berries.

  • Valve bags are designed with a one-way valve that allows air/gas to exit the bag while preventing external air from entering. The feature is particularly useful for packaging coffee beans and other products that release gasses, preserving freshness and extending shelf life. Valve bags are popular in the food and coffee industry.

  • Bottom seal bags (commonly referred to as Pillow Bottom Bags) are formed by sealing the bottom of the bag/tube and once filled with its contents the customer uses a band sealer or foot sealer to seal the top of the bag.

    This type of bag is versatile and commonly used, providing a reliable packaging solution for different product sizes and weights. Bottom seal bags are suitable for items ranging from dry food products to industrial packaging of chemicals and fertilisers, offering durability and containment.

  • Specifically crafted for cheese maturation, these bags create an optimal environment for the ageing process. The bags allow controlled gas exchange, moisture regulation and protection against external contaminants, ensuring the development of desired flavours and textures in various types of cheese.

  • Known for stability, flat-bottom bags are perfect for heavier items. Their sleek design enhances brand aesthetics and they stand upright for an attractive display.

  • Expandable sides (gussets) allow for increased storage capacity. These bags are excellent for bulk items and maintain stability on shelves.

  • Ideal for extending shelf life, vacuum seal bags slow down the ingress of air to preserve freshness. They are commonly used for vacuum packaging of food items, reducing the risk of spoilage.

  • Preferred for their stability and flat base, block bottom bags provide a sturdy structure when filled bags are palletised. Ideal for packing bulkier items like grains, polymer, fertiliser, and some industrial chemicals.

Pouches

  • MAP Pouches are a bespoke offering, where MAP technology is applied to pouches.

    Controlling the gas ingress, egress and respiration rates of the products, we can offer selected polymer films that optimise the gas and moisture phases to extend the shelf life of the product, resulting in better taste and appearance on the shelf - all in a fully recyclable pouch with or without a zipper.

  • Pouches are produced with a flat or block bottom that enables them to stand upright on shelves.

  • Pouches are produced with a bottom gusset that allows them to stand upright, providing convenience and visibility on shelves. There is a duplication of pouch-making technology at each of the flexible operations.

  • Simple, flat bags that are used for items like snacks or powders.

  • Presents pouches designed with two separate compartments within a single pouch, allowing for storage and packaging of different products or components within the same package. Useful for products that require segregation or portion control.

    They are usually fitted with a peelable strip between the two compartments and the strip will shear when the filled pouch is squeezed to allow the products in the two compartments to mix (e.g.: dried nutritional food in one compartment and water in the other compartment).

  • Features a resealable zipper, offering convenience for consumers to open and close the packaging.

  • Featuring a sliding closure mechanism for easy opening and closing. Offers a secure and accessible packaging solution.

  • Pouches include features like one-way valves to release gas produced by-product while preventing air from entering, ensuring freshness.

  • Equipped with a spout for easy pouring, commonly used for liquids like sauces and beverages.

  • Designed for the vacuum packaging of products, extending the shelf life of products by reducing oxidation and spoilage.