Solidus, a leader in laminated solid board packaging across Europe, is committed to sustainability and innovation. With operations in Belgium, the Netherlands, the UK, and Spain, Solidus Innova focuses on reducing plastic use by developing eco-friendly packaging solutions. As part of this commitment, Solidus is actively engaged in the “Zero Plastics” project, which aims to minimize the use of non-biodegradable plastics in food packaging. Their Spanish facility in Ibiricu de Egüés has been at the forefront of creating new products that replace supermarket plastics with recyclable alternatives, such as solid board, which can be recycled up to 25 times.
To design and prototype new packaging solutions like MAP and top-seal trays, Solidus needed a manufacturing technology that could handle complex designs quickly and cost-effectively. Traditional CNC aluminum machining was slow, expensive, and limited in flexibility, hindering rapid innovation.
Solidus partnered with Wehl Green, a service bureau specializing in Stratasys’ SAF technology. Using the latest SAF ReLife process, Wehl Green repurposes what was once considered waste powder, transforming it into high-quality parts that perfectly align with Solidus’ sustainability objectives. Notably, this included a SAF ReLife mold crafted by Wehl Green. This mold is now being used in a cardboard production line to achieve the final packaging shape, producing up to 6,000 cardboard packages per hour. SAF technology offered the design flexibility, speed, and efficiency Solidus needed for rapid and efficient design iteration.
1. Faster Design Iteration: SAF technology enabled Solidus to rapidly refine and validate designs, accelerating development cycles and enabling efficient production readiness.
2. Cost Efficiency: By eliminating CNC machining for prototyping, Solidus reduced material and labor costs significantly.
3. Sustainability: Leveraging SAF ReLife, Solidus achieved its goal of integrating sustainable practices into its production process, saving up to 90% in carbon footprint vs standard production with fresh materials.
4. Enhanced Collaboration: The reliable delivery times and technical expertise of Wehl Green strengthened their partnership with Solidus.
The adoption of SAF technology has empowered Solidus to stay ahead in the competitive packaging industry while reinforcing its commitment to sustainability. The ability to rapidly iterate and innovate has proven critical in replacing plastic packaging with eco-friendly alternatives, ensuring a cleaner future.
Solidus’ success demonstrates how Stratasys’ SAF technology, combined with innovative partners like Wehl Green, can transform industries by enabling sustainable, efficient, and flexible manufacturing. This case underscores the role of additive manufacturing in driving environmental responsibility and operational excellence.
