+100
Locations worldwide
Food Packaging Company Saves $6M and Reduces Carbon Footprint
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 $4.6 billion in annual sales and serves leading consumer brands worldwide.
+35
Countries
$5B
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
$6M
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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Operations Strategy and Transformation
Helping organizations rethink how they create value. We strengthen performance, build resilience, and accelerate growth across every layer of your business.
Sustainability
ESG pledges require embedded operational transformation. We deliver measurable impact through circular economy practices, carbon reduction programs, and sustainable value chain redesign.
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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