Precision Barrier Paper for High-Speed Lines

Imporient (Birchall Tea) represents the gold standard in tea. As a 5th-generation family business, they don't just sell tea; they sell a heritage of quality, winning the prestigious "Great Taste Awards" for 15 years in a row. However, maintaining these award-winning standards with eco-friendly materials proved difficult:

• The Aesthetics Trap: Standard recyclable papers often look dull, "washed out," or cheap. For a brand serving the "UK’s finest tasting tea," compromising on shelf appeal was not an option.
• The Speed Hurdle: Imporient operates high-volume production lines for both double-chamber and prism tea bags. Transitioning to sustainable materials typically means slowing down these machines to prevent jamming or poor sealing.

The Goal: They needed a partner who could deliver sustainability without compromise—matching their high environmental standards while keeping the production lines running at full capacity and the packaging looking perfect.

We provided a holistic "High-Speed Premium Paper" solution that covers both envelopes and tags. Recognizing the client's need for uncompromised throughput, we formulated a heat-seal coating that matches the friction coefficient of plastic, ensuring the material glides through complex double-chamber and prism machines without drag or jamming.

Key achievements:

• Visual brilliance: Using high-definition flexo printing, we ensured that Birchall’s signature vibrant colors popped on recyclable paper, avoiding the "dull" look of standard eco-materials.
• Engineered performance: The specialized heat-seal coating activates instantly, allowing the material to run on both double-chamber and prism machines at original design speeds (100% capacity).
• Medical-grade precision: We applied our precise slitting technology (derived from medical projects) to ensure envelope ribbons are cut to 65.9 ±0.1mm, preventing jams on high-speed IMA machines.