Crisps in recyclable packaging - the puzzle that took 2 years to crack!

The first sales of Earthnutz were in zero waste stores without packaging at all. This felt like a fitting beginning. 

Then we released our Peanut Protein Crisps in paper-based bags. They didn't have as long a shelf life as the silver, metal crinkly packets, but that was okay for a while. It gave us the opportunity to launch into independent stores run by people who valued quality, artisan food. We built up a wonderful community of food-loving people and the demand and feedback from customers was immense! The shelf life was our biggest drawback, though, and it meant that we couldn’t scale the brand as much as we wanted. It was tying us to small production runs and small orders.

So, that’s when the testing really began. We tried every type of eco-packaging on the market and when I say everything, I mean EVERYTHING - compostable, biodegradable, flexible, recyclable. It needed to keep the product fresh for longer, while also being easy for the customer (anywhere in the UK) to dispose of, outside of landfill!

That’s when I realised that maybe this was an impossible ask. It seemed like nothing fit the bill. We tried adding nitrogen to the bag to remove the oxygen (a practice that is common in the industry), different methods of sealing the bags, different temperatures, pressures etc. and nothing was working. 

After months of scouring Google, getting samples, making enquiries and attending packaging conventions, we eventually found a supplier that looked really promising. The only problem was, the machinery required to seal the packaging was still in development.

From start to finish, it's taken a year to get from discovery to packaging on the shelves. 

But the slog has been worth it! Because we're finally there with a packaging that is fully recyclable from home and keeps the product fresh for longer!

The moral of the story? Nothing is ever as simple as it seems……

And perseverance always wins 🙂

We're really proud of where we've got to, but make no mistake, it's been a difficult journey to get here. We've worked really hard on rebranding the product to make it stand out. I hope you love how it looks on the shelves, as much as we do!

And you can click here to give it a try for yourself.

P.s. for those of you wondering, the next step in our journey is to go completely plastic free by swapping out the plastic lid for a paper one. Watch this space, we’ll be announcing it as soon as it’s ready!