Client Overview
Solidus, a leader in laminated solid board packaging across Europe, is committed to sustainability and innovation. With operations in Belgium, the Netherlands, the UK, and Spain, Solidus Innova focuses on reducing plastic use by developing eco-friendly packaging solutions. As part of this commitment, Solidus is actively engaged in the “Zero Plastics” project, which aims to minimize the use of non-biodegradable plastics in food packaging. Their Spanish facility in Ibiricu de Egüés has been at the forefront of creating new products that replace supermarket plastics with recyclable alternatives, such as solid board, which can be recycled up to 25 times.

Challenge
To design and prototype new packaging solutions like MAP and top-seal trays, Solidus needed a manufacturing technology that could handle complex designs quickly and cost-effectively. Traditional CNC aluminum machining was slow, expensive, and limited in flexibility, hindering rapid innovation.

Solution
Solidus partnered with Wehl Green, a service bureau specializing in Stratasys’ SAF technology. Using the latest SAF ReLife process, Wehl Green repurposes what was once considered waste powder, transforming it into high-quality parts that perfectly align with Solidus’ sustainability objectives. Notably, this included a SAF ReLife mold crafted by Wehl Green. This mold is now being used in a cardboard production line to achieve the final packaging shape, producing up to 6,000 cardboard packages per hour. SAF technology offered the design flexibility, speed, and efficiency Solidus needed for rapid and efficient design iteration.