In the competitive world of board packaging, where the demand for sustainability and innovation drives business decisions, Iron Forest Packaging (IFP) has been redefining carton packaging with a sharp focus on technical design that balances environmental responsibility with cost efficiency.

WHAT began as a side hustle for IFP’s managing director Bernard Verwey soon transformed into a fully fledged business. He started out creating packaging designs for automotive parts. But this grew into something much bigger, especially during the pandemic when companies reached out for hand sanitiser packaging solutions. That’s when IFP officially came into existence in September 2020.

During the early stages, IFP partnered with some of the most robust corrugated and cartonboard converters in South Africa. This collaboration allowed the company to provide high-quality packaging quickly, meeting the urgent needs of businesses during the global crisis. However, the company’s breakthrough moment came when it was approached by an automotive component manufacturer facing severe damage issues with its exported bicycle carriers. IFP’s innovative redesign of the packaging not only solved the damage problem, but also significantly reduced the environmental impact by replacing polystyrene inserts with self-locking corrugated inserts.

Customer-centric innovation

IFP’s technical design capabilities push the boundaries of what packaging can achieve. The designs are not off-the-shelf solutions, but bespoke creations that cater to the specific needs of each customer.

Bernard and his team are committed to finding eco-friendly solutions that meet the complex needs of customers. ‘We wanted to do things differently,’ remarks Dorette Calitz, the company’s technical sales manager. ‘Our approach is not just about meeting a specification, it’s about understanding our customers’ processes, identifying their struggles and offering innovative solutions that improve efficiency and reduce environmental impact.’

By conducting thorough assessments of customers’ packaging needs, the team can provide solutions that save money not just on packaging materials, but also on process times, damage reductions and returns. ‘We don’t just sell boxes,’ Bernard asserts. ‘We offer a comprehensive service that includes design, implementation and ongoing support, ensuring that our solutions continue to deliver value over time.’

By leveraging advanced CAD software, IFP is able to create packaging designs that maximise strength and durability while minimising material usage. This technical precision translates directly into cost savings for customers. For instance, by reducing excess material in packaging without sacrificing integrity, businesses see significant reductions in raw material costs and shipping expenses.

Moreover, IFP’s team shares insights into their process of continuous testing and iteration. They conduct rigorous stress tests on prototypes to identify potential weak points and optimise the design accordingly. ‘This not only enhances the product’s protection, but also prevents costly product damage and returns, further saving businesses money,’ Bernard adds.

Expanding horizons

Key to IFP’s success is its small but highly skilled team. With over 12 years of experience in the automotive industry, Bernard brings a wealth of knowledge in process optimisation and design. Dorette, a trained packaging technologist, has a deep understanding of packaging materials and extensive experience in the printing industry. Her expertise in ISO 9001 standards and manufacturing processes adds a critical layer of quality assurance to IFP’s offerings.

Dorette’s contributions have already yielded significant results. She recounts a project with GM Graphix where a simple redesign of packaging for printing plates resulted in savings of nearly 60%. ‘It’s about more than just saving money,’ Dorette explains. ‘It’s about improving the entire process, from the way materials are handled to how they are stored and protected. Our solutions extend the lifespan of products and reduce waste, which is a win for both our customers and the environment.’

IFP is not content with resting on its laurels. The company has big plans for the future, including the potential establishment of a small production facility in Gauteng by 2025. This facility will further strengthen IFP’s ability to support converters and offer specialised services such as die cutting, hand gluing and stitching. ‘Although we’ve flown under the radar without a proper facility,’ Bernard admits, ‘we’re now ready to take the next step and scale our operations.’