The Challenge

Icertech wanted to reduce the carbon footprint of its packaging by moving away from traditional polystyrene.

While polystyrene was effective, identifying a replacement was far from straightforward. The business needed to balance sustainability with cost, durability, technical performance and temperature control. A material may look promising on paper, but it still has to perform in real conditions.

With a range of emerging bio-based, recyclable and compostable options available, the team needed a clear, evidence-based way to understand which materials offered the strongest potential.

The Support

Icertech worked with BIC Innovation through the Welsh Government’s Smart Flexible Innovation Support programme to explore the options and build a structured pathway towards credible alternatives.

Together, we assessed ten potential materials that could replace polystyrene in chilled packaging applications. These included a mix of novel bio-based options, recyclable materials and compostable technologies, each with its own strengths and trade-offs.

BIC Innovation carried out a detailed cost-benefit analysis, looking at the commercial, technical and environmental implications of each option. This helped narrow the field and identify the materials with the strongest potential.

Specialist academic expertise was then brought in through Bangor University’s Biocomposites Centre, where a full lifecycle assessment was completed. This provided independent evidence of the environmental impact of the shortlisted materials, from sourcing through to end of life.

With this insight in place, Icertech moved into practical testing. The team gathered samples and put the shortlisted materials through temperature-controlled trials in their own chamber, helping to understand how each option would perform in real-world conditions.

The Results

The work has given Icertech a clearer route away from polystyrene and a stronger evidence base for future product development.

Two new low-carbon packaging products are now in development for commercial launch in 2026. The project has also helped the business build confidence in its decision-making, with each material assessed not only for sustainability, but also for cost, performance and suitability for chilled packaging applications.

For Icertech, the support has come at an important point in its sustainability journey.

“This project has given us clarity and confidence at a crucial point in our sustainability journey. With BIC Innovation and Bangor University’s support, we were able to look at a wide range of potential materials and understand not just their environmental benefits, but how they perform in real-world conditions.

The collaboration with the Biocomposites Centre added another layer of robust evidence. As a result, we’re now progressing two new low-carbon products that we believe will make a meaningful difference for our customers and our footprint.”

Simon Morris, Sustainability & Innovation Manager, Icertech

Looking Ahead

With two new products moving towards launch, Icertech is now better positioned to respond to growing customer demand for more sustainable chilled packaging solutions.

The project has also strengthened collaboration between industry and Welsh research expertise, showing the value of combining commercial insight with academic rigour when tackling complex innovation challenges.

For Icertech, the work is an important step towards reducing carbon impact while continuing to provide the reliable, high-performance packaging its customers depend on.

Funding Acknowledgement

Icertech received support through the Welsh Government’s Smart Flexible Innovation Support programme.