Even those businesses specifically seeking the services of a co-packer may not realise the breadth and depth of co-packers. Partnering with a co-packer becomes a powerful asset in terms of saving time and money because you have access to a multitude of services coordinated under one roof. If they don’t do a particular activity, chances are they have an affiliate who does, or they can at least point you in the right direction. They’re good that way!
Furthermore, the flexibility of co-packers allows businesses to adapt to changing demands, from handling fluctuating order volumes to managing seasonal spikes. This adaptability, combined with the broad range of services offered, makes co-packers a valuable asset, enabling companies to focus on growth while leaving the complexities of packaging, assembly, and logistics to the experts.
Emma Verkaik, CEO of BCMPA, is a passionate advocate for the transformative potential of co-packers and their role in supporting businesses across industries. Due to appear at February’s Packaging Innovations & Empack event, during her talk Verkaik will discuss how under her leadership, the BCMPA has positioned itself as a vital hub for outsourcing expertise and how co-packers bring not only efficiency but also innovation and sustainability to the forefront, enabling brands to thrive in competitive markets.
The trusted partner for all seasons
In the modern dynamic and increasingly complex business environment, outsourcing to co-packers has become more than just a convenience; it’s a strategy for survival and growth. Verkaik explains, “The BCMPA and its members are an excellent resource, offering a wealth of knowledge and experience in outsourcing across a wide range of industry sectors, including food, drink, personal care, e-commerce, fulfilment, and gift packing. This expertise allows businesses to offload tasks they might struggle with, leveraging the capabilities of highly skilled and experienced companies in providing these services.”
Economic pressures often force brands to make difficult decisions, and outsourcing has proven to be a lifeline for many. “During economically challenging times, the benefits of outsourcing often outweigh the drawbacks for brands that find it difficult to manage these functions internally,” Verkaik noted. “It’s about exploring how third-party providers can support their needs effectively. Having met BCMPA members at the event, attendees left feeling elated, knowing they had discovered a valuable resource to access the services required to support their businesses.”
Co-packers’ ability to pivot quickly to meet unexpected demands is an asset that proved invaluable during Black Friday, arguably the now peak sales period where flexibility and speed are paramount. In 2023, Black Friday sales reached an astonishing £13.3 billion, underscoring the immense pressure on businesses to deliver. Verkaik reflected on the period: “Nobody knows exactly how their orders will pan out beforehand. Everyone hopes they’ll be huge—some will be, and some won’t. The ability to scale up effectively during such times is not only a massive logistical challenge but also something that requires prior experience to execute properly.”
This scalability isn’t just about handling high volumes; it’s also about managing the aftermath. “For young brands, the importance of scaling up quickly cannot be overstated. However, it’s also critical not to carry that overhead long-term. You scale up for five days or two weeks, but then what happens afterwards? Managing that flexing capacity is key to what you’re buying into when you outsource,” Verkaik explained.
Driving digital transformation
Digitalisation is reshaping the landscape for co-packers, enhancing visibility, collaboration, and agility across supply chains. Verkaik shared her insights: “Digitalisation has been a key topic of discussion at the BCMPA for a long time. It’s increasingly recognised as a way to engage more effectively with customers and gain traction. By identifying and tracking everything down to the last minute—such as where stock is located—you can significantly reduce the time involved in processes and become much more efficient.”
BCMPA members are leading the charge in adopting digital tools that streamline labour-intensive operations like gift packing and multipacks. These innovations enable co-packers to respond faster to clients’ needs, making them more valuable partners in the fast-paced FMCG sector. Verkaik highlighted the importance of these tools: “At our recent conference, we had a presentation on digitalisation, from the co pack software provider Nulogy. Following that session, several of our members have adopted new systems, having seen the tangible benefits shared by other co-packers who spoke about how these tools have transformed their businesses.”
This shift is not just about adopting new technologies; it’s about fostering a culture of continuous improvement. “Digitalisation supports collaboration in ways that were previously impossible. For example, customers can now monitor the performance of their campaigns in real time, identifying what’s selling through and adjusting strategies on the fly. This level of insight is transformative,” Verkaik said.
Sustainability as a strategic imperative
Sustainability has evolved from being a corporate buzzword to a critical component of strategic decision-making, particularly for co-packers who sit at the intersection of supply chain and operations. Verkaik stressed the growing importance of sustainability during procurement, saying, “Leading brands like Nestlé, Tesco, and Danone shared insights at our conference into how sustainability will increasingly shape procurement processes moving forward.”
For co-packers, sustainability often means navigating the practical challenges of adopting greener practices while maintaining efficiency. “Our members serve as custodians for many of these brands, particularly newer or e-commerce-focused businesses that may lack robust systems of their own,” Verkaik explained. “Collaborating with third parties who can track and organise data, such as carbon emissions, in an accessible format is often an enlightening experience for these brands.”
A key challenge lies in balancing innovation with operational realities. Sustainable materials, while appealing in principle, often face hurdles in practice. “While recyclable products are ideal, they sometimes don’t perform well on automated lines, creating additional challenges,” Verkaik noted. “There’s a disconnect because, in 90% of cases, contract packers are not consulted about how a pack will be processed or how it will perform on the shop floor. This lack of dialogue can lead to inefficiencies despite the wealth of experience these teams have from years of handling diverse products.”
Gift packing is particularly illustrative of this challenge, as it often involves one-off, seasonal projects that differ significantly from high-speed production. “What works for one type of packaging may not be suitable for another, especially in automated settings,” Verkaik explained. Addressing this requires stronger collaboration between brand owners, packaging suppliers, and co-packers to ensure sustainable options are compatible with production environments.
Reimagining Returns and Recycling
The rapid growth of e-commerce has added a new dimension to sustainability: the handling of returns. This area, often overlooked, is increasingly becoming a critical service provided by co-packers. Verkaik highlighted the opportunities returns handling presents: “Returns handling offers brands a valuable opportunity to recover expenses invested in their packaging. Instead of discarding unsold inventory into landfills, brands can reclaim value by recycling and repurposing materials. This service, provided by third-party logistics (3PL) providers, has become an essential offering, enabling brands to optimise their sustainability practices and minimise waste.”
Unlike individual customer returns, bulk returns, where unsold inventory is sent back to suppliers, pose unique challenges. Previously, such items might have been discarded, contributing to landfill waste. Today, they are increasingly recycled or stripped of usable materials to reduce environmental impact. “This shift not only reduces waste but also adds tangible value for brands, reinforcing the role of 3PLs in driving sustainability initiatives,” Verkaik added.
Driving practical sustainability
For co-packers, sustainability is about more than just meeting consumer expectations, it’s about embedding environmental considerations into every facet of operations. Many BCMPA members have already made significant strides, from upgrading to energy-efficient lighting systems to minimising landfill waste. “Ten years ago, you might have seen lorries arriving two or three times a week to remove large skips of landfill waste,” Verkaik noted. “Today, in many cases, all that’s needed is a small desk bin, as nearly everything is now recycled.”
On the packaging front, the challenge lies in bridging the gap between innovation and production compatibility. Verkaik shared: “The focus is on finding sustainable alternatives, but ensuring these options work seamlessly with contract packers’ machine lines is crucial. Compatibility issues can impact production speeds, which makes open communication between suppliers and co-packers essential.”
This collaborative approach could unlock new levels of efficiency and innovation. “It’s about improving dialogue with packaging suppliers to ensure that new materials are not only sustainable but also effective and efficient in production environments,” Verkaik said.
Looking ahead, Verkaik believes the adoption of comprehensive sustainability tracking systems will become standard practice, even among smaller third parties. “While some carbon-tracking systems can be costly and complex, brands are increasingly valuing these capabilities, which will drive more investment in these tools over time,” she explained.
Sustainability, however, must balance economic realities, especially in challenging climates. “With tightening budgets and large labour forces, the conversation about sustainability is layered with complexities. It raises critical questions about how these initiatives can be integrated without compromising operational viability during economic crises,” Verkaik said.
Despite these challenges, Verkaik remains optimistic. “What is clear is about third parties and their sustainability responsibilities is that they are absolutely embracing these changes. By adopting energy-efficient practices, reducing waste, and fostering better communication, our members are leading the way in making sustainability a practical, achievable goal,” she concluded.
With the dual focus on reducing environmental impact and maintaining operational efficiency, co-packers are not just meeting the demands of today’s market but setting the stage for a more sustainable future.
From navigating economic pressures to embracing digitalisation and sustainability, co-packers are proving themselves indispensable to modern businesses. Verkaik’s insights at Packaging Innovations & Empack 2025 are sure to help inform and shape a number of businesses decisions involving its supply chain operations, especially those involving co-packers.
As businesses continue to face mounting pressure to balance economic resilience with environmental responsibility, co-packers stand out as invaluable partners in navigating this challenging landscape. By embracing digitalisation, fostering sustainability, and leveraging their wealth of expertise, co-packers are not just supporting the operational needs of today, they are driving the innovation necessary to build a greener, more efficient future. With industry leaders like Emma Verkaik and the BCMPA championing these efforts, the path forward is clear: collaboration and adaptability are the cornerstones of long-term success in a dynamic, sustainability-focused market.