How EP Group is Helping Food Processors Reduce Waste and Improve Tray Integrity

At EP Group, we’re committed to helping food processors overcome the operational and sustainability challenges they face every day. One of our latest innovations is doing just that—right at the source of production.

Through our UK-based Coppice facility, we’ve developed and implemented a new in-line Split Detection System that automatically detects and removes aluminium trays with microscopic flaws before they ever leave the production floor. These minor splits—often invisible to the naked eye—can lead to tray failure, leaky packs, product rejections, and end-user complaints.

For high-volume food processors, the ripple effects are significant: wasted materials, downtime on the line, and reputational risk when customers receive damaged or leaking packaging.

Our solution detects splits as small as 0.3 mm and operates at speeds of up to 80 trays per minute. It’s already running across the majority of our smoothwall tray presses, reducing product loss, eliminating returns caused by packaging failure, and providing customers with greater confidence in every shipment.

It’s also a win for sustainability. By eliminating avoidable waste and ensuring more trays meet their intended use, the system supports our customers' goals around efficiency, carbon reduction, and resource use. It’s a smart system that works quietly—but delivers measurable results.

This work was recognised as a runner-up in the Make UK Wales Innovation Awards, and we’re proud to bring this level of attention to detail to every order we fulfil.

To learn more about our smoothwall tray systems, or to request a sample, reach out to our team at EP Group USA. We’d be happy to support your packaging review.