Innovative packaging for Parmesan creams: the collaboration between Packstyle and TFA

Introduction and Background

TFA S.r.l. (Trasformazione Formaggi e Alimentari) is a family-run company founded in 1998 in the hills of Reggio Emilia, specializing in the production of high-quality cheese creams, particularly spreadable Parmigiano Reggiano creams. Using a traditional process that melts the cheese with steam and without adding preservatives or colorants, TFA was among the first to create a spreadable Parmigiano cream.

This drive for innovation, combined with a strong focus on quality, led the company to seek packaging solutions capable of enhancing the product and supporting new sales channels, such as e-commerce and gourmet shops. Moving away from traditional glass jars or rigid plastic containers also meant embracing a new form of visual and functional communication, aligned with the expectations of modern consumers. Packstyle proved to be the ideal partner to embark on this path of innovation.

The Challenge

The main challenge was to develop new packaging in the form of a doypack with spout (a stand-up pouch with a dispensing cap) for TFA’s Parmesan cream. This format, a resealable flexible pouch equipped with a spout for pouring, offers significant advantages in terms of convenience and preservation, but it is still uncommon for spreadable dairy products.

Additionally, TFA needed to start production with limited quantities while maintaining the possibility of scaling up over time, allowing the company to test new product lines and expand its range without immediately facing the constraints imposed by traditional suppliers. Large-scale distributors and major packaging manufacturers rarely cater to these needs: producers like TFA often struggle to find suitable solutions because conventional suppliers require industrial-scale orders and do not offer highly customized services for small production runs.

Beyond quantity-related constraints, there was a crucial technical obstacle: Parmesan cream contains a certain amount of moisture and oils, and the first packaging tests in doypacks revealed an issue with water loss from the packaging. In other words, with the initial materials and parameters, micro-leakage or condensation could occur, potentially compromising both the product’s quality and the integrity of the pouch.

“Finding suitable packaging for our Parmesan creams looked challenging: we needed to solve a non-trivial technical issue and find a partner willing to work with small quantities. With Packstyle, we turned a challenge into a strength.”

– Owner of TFA

This issue needed to be resolved absolutely before launching the product on the market, as even minimal leakage or liquid evaporation would have negatively impacted both the cream’s shelf life and the brand’s image. TFA needed a partner capable of addressing this technical challenge with a tailored approach, experimenting with new material and process solutions to achieve packaging that was perfectly sealed and suitable for the product’s specific characteristics.

The Journey with Packstyle

Aware of these needs, Packstyle embarked on a joint Research and Development (R&D) project with TFA that lasted about a year. More than a simple supplier–client relationship, it became a true technical collaboration: the TFA and Packstyle teams worked side by side to design, test, and refine the new packaging.

From the very first meetings, it was evident that the solution would require a mix of material innovation and adjustments to the production process. The project began by defining key requirements: the packaging had to optimally preserve the cream (preventing liquid loss and maintaining aroma and freshness), withstand possible heat treatments such as pasteurization or hot filling, and offer convenience for the end user.

Packstyle contributed its expertise in multilayer films and digital printing for food packaging, presenting several options of high-barrier laminated films. Over the following months, prototypes of doypack pouches were produced with various combinations of materials and thicknesses. TFA filled them with its Parmesan cream and subjected them to a series of tests: seal integrity checks, accelerated shelf-life assessments, stress tests at different temperatures, and organoleptic evaluation of the product over time.

A particular focus was placed on the issue of water loss. Packstyle carried out analyses to identify the exact cause: were there micro-leaks due to material permeability, or imperfections in the seals? The tests revealed that a total moisture-barrier material was needed, as well as fine-tuning of the sealing parameters for both the spout and the pouch joints.

During the R&D process, Packstyle experimented with films that included additional layers and specific treatments (including the use of an ultra-thin aluminum layer in the intermediate section of the laminate to completely block water-vapor escape).

“We provided expertise and technology, but above all we listened to the client and worked side by side. The result is a custom-made packaging solution that adds real value to the product.”

– Nicoletta Garbo, CEO of Packstyle

In parallel, the sealing machines were fine-tuned to optimize the closure around the spout: temperature, pressure, and sealing time were carefully calibrated to avoid damaging the film while ensuring an airtight seal. This iterative process of prototyping and testing required patience and precision. Thanks to constant dialogue between TFA and Packstyle, every obstacle was addressed promptly. After a structured process of analysis and improvement, the optimal packaging configuration was identified and became ready for the production phase.

The Solution

At the end of the R&D process, Packstyle developed a customized packaging solution that fully meets TFA’s requirements. It is a spouted doypack made from high-barrier multilayer film, specifically designed for creamy dairy products. The chosen material is a three-layer laminate: this structure provides total protection against oxygen and moisture, preserving the Parmesan cream from air exposure and preventing any water leakage. The inner layer, in contact with the food, is polyethylene, suitable for heat sealing and certified for food contact; the middle layer provides the functional barrier; the outer layer adds strength and allows for high-quality printing.

From a graphic standpoint, Packstyle employed digital printing to enhance the visual identity of TFA and its “Carpinello” brand, ensuring color fidelity, detailed definition, and uniform print quality.

This combination made it possible to create packaging with a premium look, featuring vivid colors, sharp details, and high-quality finishes, achieved through the perfect integration of digital printing and materials available in different finishes (matte, glossy, or soft-touch), depending on the brand’s needs.

Moreover, digital printing enabled multi-design customization, allowing multiple graphic variants to be produced without additional setup costs, a tangible advantage in terms of flexibility and time-to-market.

A key element of the solution was the calibration of the packaging process. Packstyle provided TFA with detailed operational guidelines for filling, sealing, and closing, ensuring the pouch’s integrity and preventing condensation or leakage.

During the initial production runs, Packstyle technicians provided on-site support, working alongside the TFA team to efficiently integrate the new packaging into the production line.

• High-barrier laminated material suitable for food contact.
• Innovative format: stand-up doypack with resealable spout, practical and protective.
• Customization and visual quality: digital and multi-design printing.
• Ongoing technical support: testing, guidelines, and hands-on assistance for a smooth transition to the new packaging.
  
  

Results and Benefits

The introduction of the new packaging delivered tangible results:

• Production and customization of small batches: from 50 to 50,000 units, economically and sustainably, allowing product testing without the risk of unsold stock.
• Competitive advantage: introducing packaging that is unique in its segment.
• Online launch and brand positioning: leveraging the packaging to convey an innovative brand image, effectively positioning the product on the market and reaching consumers directly.

The flexible pouch has also improved shipping costs, reducing breakages and bulk compared to rigid jars, thereby simplifying logistics operations.

TFA’s experience demonstrates that packaging can be much more than just a container: it is a strategic branding tool. Thanks to the collaboration with Packstyle, the company turned a technical necessity into a concrete opportunity to differentiate itself in the market. The new spouted doypack has not only improved product functionality and preservation but also strengthened the brand’s visual identity, conveying quality, innovation, and consumer care.

For TFA, having flexible, customizable, and visually appealing packaging meant standing out in a competitive sector, enhancing the value of its product, and positioning itself clearly across both traditional and online channels. Packaging has thus become a true brand differentiator, capable of communicating the company’s values and fostering new commercial opportunities.