At Coppice, we see waste not as an inevitability—but as a challenge worth solving. As part of our long-term commitment to sustainability, we’ve taken a strategic look at where waste originates in our operations, how it flows through the system, and—critically—how it can be eliminated, reduced, or reused.

The result? A set of targeted, data-backed interventions that are already delivering positive environmental and commercial outcomes.

Smart Detection, Smarter Decisions

One of our proudest innovations is the in-house development of our Split Detection System—a bespoke, camera-driven tool that identifies micro-defects in our smoothwall aluminium trays. Built in collaboration with a local electronics partner, this system enables real-time rejection of faulty units before they reach packing lines, dramatically cutting unnecessary waste and production stoppages.

By early 2025, we had installed detection units on 84% of our smoothwall presses, resulting in a marked reduction in product waste and rework. This has not only improved our resource efficiency but also ensured a higher and more consistent level of product quality for our customers.

Closing the Loop on Scrap

We’ve also tackled post-production waste head-on through the use of an advanced Aspirator System. Rather than sending offcuts to landfill or for costly external sorting, this system captures aluminium scrap directly at the source, compresses it into cubes, and sends it back to our foil supplier for reprocessing into new rolls.

This system brings several benefits:

  • Reduced material loss

  • Lower carbon emissions from transport

  • Less on-site handling and storage

  • A closed-loop supply chain for aluminium

In 2024, this helped reduce our scrap rate to 20.8%, down from 22.9% the previous year—a significant improvement across millions of trays produced.

Designed for Circularity

These waste reduction initiatives are tightly linked to our broader mission of advancing the circular economy in food packaging. Our trays already include 25–30% post-process content, and we’re continuing to work with suppliers and customers to explore further improvements in recyclability and material recovery.

But beyond materials, our approach is about systems thinking—engineering operational efficiency that supports people, the planet, and long-term business success.

Because at Coppice, sustainability isn’t just something we talk about. It’s how we build, innovate, and grow.


📄 Download the full 2025 Sustainability Report to explore how we’re driving positive change across energy, community impact, circularity, and more:

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June 29, 2025

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