A recent project with a leading national quick service restaurant brand demonstrates how strategic packaging innovation can unlock measurable efficiencies across large scale foodservice operations.
The Client
Our client is a major UK based pizza delivery and takeaway brand, recognised nationwide for its extensive menu and high order volumes. With millions of side orders prepared annually, maintaining consistency, speed and product quality while managing labour demands presents a significant operational challenge.
The Challenge
Prior to partnering with GM Packaging, the client’s side order preparation process involved several manual stages, creating inefficiencies across multiple areas of the business.
Key operational challenges included:
Labour intensive preparation
Frozen side items were removed from storage, transferred onto metal trays lined with greaseproof paper, baked, and then manually moved into secondary packaging after cooking.
Increased staffing pressures
High demand periods required additional labour to manage side order preparation efficiently.
Health and safety concerns
Frequent handling of hot trays and packaging increased the risk of workplace injuries, particularly burns.
Reduced operational speed
Each side order added valuable seconds to overall preparation and dispatch times, impacting service efficiency.
Multiple handling touchpoints
The existing process created unnecessary product handling, increasing hygiene and contamination risks.
The client required a packaging partner capable of developing an innovative, scalable solution that could simplify operations without compromising product quality or brand presentation.
The Solution
GM Packaging collaborated closely with the client to design and deliver a bespoke ovenable tray system that streamlined the entire preparation process.
The new solution allows products to move directly from freezer to oven before being inserted into a branded outer sleeve for final presentation and delivery, removing the need for manual decanting.
Key benefits of the bespoke packaging solution:
Streamlined workflow
A simplified end to end preparation process, reducing unnecessary handling and operational complexity.
Improved heat retention
The packaging maintains food temperature more effectively, delivering products approximately 3°C hotter upon arrival.
Enhanced workplace safety
A cool touch exterior enables safer handling after baking, reducing burn risk for employees.
Labour efficiency gains
The redesigned process saves up to 60 seconds per order, significantly reducing preparation time.
Greater operational flexibility
The solution supports advance preparation ahead of peak trading periods, helping to reduce staffing pressure during busy service windows.
GM Packaging provided a full service development approach, from identifying operational pain points and creating initial prototypes through to testing, commercial rollout and continuous optimisation.
The Results
The implementation delivered significant and measurable business impact across operational efficiency, employee safety and customer satisfaction.
Key outcomes included:
Substantial labour cost savings
Estimated annual labour savings of approximately £930,000 through reduced preparation time and improved productivity.
Faster service delivery
A 20 to 30 second reduction in order to delivery times, helping improve speed of service and customer experience.
Improved product quality
Higher delivered food temperatures contributed to better product consistency and enhanced customer satisfaction.
Safer operational processes
Reduced manual handling and fewer touchpoints created a safer, more efficient working environment for staff.
Scalable commercial application
The packaging format offers strong potential for adoption across other foodservice brands with minimal modification.
Packaging That Delivers More Than Protection
This project demonstrates how thoughtful packaging innovation can generate value far beyond product containment. By addressing operational inefficiencies through tailored design, businesses can unlock measurable cost savings, improve workforce safety and enhance the end customer experience.
At GM Packaging, we work with foodservice operators to develop packaging solutions that solve real operational challenges and support long term growth.
