Innovation & New Product Development

Our Consultancy approach to NPD to help solve your packaging challenges is to:


  • Collaborate with your team from initial project scoping to the manufactured of your finished packaging products
  • Consult with you throughout the creative design process
  • Deliver technical expertise and advice for the optimum recyclable and recycled materials.
  • Develop 3D visuals, and fully rendered artwork visuals for your review and client approval
  • Manufacture pre-production prototypes and samples for feasibility trials and testing
  • Upon client approval, we proceed to full manufacture and production


We are Serious about Sustainability. Sustainability is at the heart of the Charpak business. Charpak has been at the forefront of designing sustainable packaging for many years.  Not only do we manufacture packaging from super-cleaned and recycled plastics, we also Design for Recyclability. 


Our 2019 patented innovation Twist-Loc has been designed as a 100% recycled Tub.  Made from a minimum 75% recycled plastic, the tamper-evident tub removes micro-plastics through its unique design with it’s integrated mechanism removing the traditional tear-off-tab.  You can find more information on Sustainability and Twist-Loc here.

Whether you’re looking to improve the circularity of your packaging, re-formulate your existing packaging, increase your sales, launch a new product or solve manufacturing and production challenges we’ll work hand-in-hand with you to achieve your best solution.


Charpak Ltd UK designers and manufacturers of rigid plastic packaging



A comprehensive design briefing is developed with you at your initial scoping meeting. Charpak’s consultative approach targets right first time, every time.


  • All technical, manufacturing and engineering specifications are gathered in addition to environmental considerations, sustainability goals, sealing and any primary or secondary packaging requirements.


  • Our team can provide expert advice on optimum material specifications and thickness, ensuring you receive perfect packaging, to deliver your fit for purpose thermoformed packaging.


We recommend involving Charpak early in your NPD cycle, to guarantee you benefit from the highest quality expertise.

Charpak Ltd Our People


Using the latest design technology, Charpak present clients with outstanding design proposals and full rendered visualisation and 2D drawings. You receive:


  • Exceptional full rendered creative presentations enabling you to finetune and revise any concept designs.


  • CAD designs saving you substantial CAPEX investment in tooling, before committing to manufacture.


Charpak copyrighted creative design ideas, including imaginative and innovative blue-sky concepts, are fully thermoformable. Charpak always keep your manufacturing processes front of mind.

Automotive component protective packaging


Charpak manufacture the highest quality sample products prior to large-scale manufacture and full production.  The in-house dedicated Prototype and Sampling team are based at Charpak HQ. Following approval of CAD Designs:


  • Prototyping: Prototype mould tools are produced for clients following approval of the CAD drawings.


  • Samples: Highest quality hand-formed samples are produced from these prototypes for proof of concept, consumer tests, trial production runs, in-transit testing and more.
recycled plastics thermoformed prototype moulds and samples


Following client approval of prototype samples, production tooling is manufactured in-house using our state-of-the-art high speed, high precision CNC Milling machines.


  • Using the latest software to convert 3D prototype models into production tooling gives full confidence that the final product will precisely match prototype samples.
Charpak Tooling and CNC Engineering Recycle Me


The Charpak BRC AA & ISO approved production facilities guarantee your packaging is manufactured in controlled, hygienic conditions.


  • Charpak delivers a flexible rapid response with 24 hour manufacturing capabilities.
  • Charpak manufacturing delivers an agile operation; including sample production or full manufacture.
  • Quality is assured at every stage of design and manufacture
Charpak Production Quality Standards ISO BRC Accreditation


Charpak source all plastics raw materials with full traceability. The ideally located warehousing facilities in Cambridgeshire have direct access to road, sea ports and air freight for nationwide UK and international distribution.


  • The warehouse and distribution team manage an exceptional just-in-time delivery system and stock holding for key clients.
  • Large scale manufacture also enables clients to call off products from stock for delivery as and when required.
  • Charpak distribute UK nationwide and internationally via our in-house fleet and third party logistics providers.
Charpak Distribution UK Ireland Scotland Europe International map

The Charpak WOW

THE entire process is all in-house

Contact our technical experts, design engineers and packaging technologists on 01480 434 434 or to see how our award-winning team can help your business achieve its packaging and sustainability goals.

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