+100
Locations worldwide
Food Packaging Company Saves €5.3M and Reduces Carbon Footprint
A global packaging company faced a market downturn that demanded faster waste reduction and improved productivity. EFESO guided 88 improvement projects across multiple plants. The program strengthened operational capabilities while building a culture of continuous improvement.
Industry: Packaging
Service: Manufacturing
Service: Operations Strategy and Transformation
Service: Sustainability
Our Client
The client is a global packaging specialist offering sustainable solutions across flexible, food, and fiber-based materials. With operations in 37 countries and a network of more than 100 manufacturing sites, the company generates over €4 billion in annual sales and serves leading consumer brands worldwide.
+35
Countries
€4.2B
Net sales in 2023
The Challenge
Facing a market downturn, the company needed to accelerate material waste reduction while maintaining productivity and operational excellence:
- Material inefficiencies: High conversion costs and product waste were impacting profitability
- Operational capability: Maintaining a trained workforce in Operational Excellence across multiple countries
- Sustainability goals: Becoming the first-choice partner for sustainable food packaging while reducing CO₂ footprint
Real Results Achieved Together
By deploying a focused Operational Excellence program, EFESO helped the client deliver measurable financial and environmental results while enhancing team capabilities.
88
Improvement projects launched
€5.3M
annual material cost savings
4.5M
CO2 equivalents reduced annually
438
People trained as loss eradication team members
Transformation Impact
- Standardized loss analysis and playbooks facilitated best practice sharing across plants
- Remote and on-site coaching combined to maximize engagement and results
- Trained 88 team coaches to embed continuous improvement locally
- Strengthened operational culture with a clear focus on material efficiency and sustainability
Our Approach
EFESO leveraged the client’s existing Operational Excellence program, adding a targeted focus on material waste reduction. The methodology included:
- Implementing a standardized loss analysis approach and playbook to spread best practices horizontally
- Using a combination of remote virtual coaching and on-site consultants to accelerate adoption
- Establishing structured follow-up and reporting governance to track progress
- Engaging local teams hands-on to drive results and build capabilities
The approach created a sustainable operational model capable of continuing improvements and scaling across sites.
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Ready to Transform Waste Into Competitive Advantage?
- Unlock millions in material savings while building lasting operational excellence capabilities
- Stop letting market pressures force reactive cost-cutting that undermines long-term sustainability goals
- Join global leaders who’ve turned waste reduction into both profit and environmental impact
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