Mainetti, an Italian packaging solutions manufacturer, opened a new flexible packaging facility in Dhaka, Bangladesh in February 2024 to strengthen its sustainable packaging business.
The facility meets the evolving needs of retailers and enables Mainetti to provide responsible plastic packaging to a wider array of international retailers, manufacturers and brands. It helps in expanding the company’s Polyloop recycling initiative, which transforms used plastics into entirely recycled products.
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The development is part of the company’s ambitious five-year growth strategy for flexible packaging. It furthers the company’s Full Circle strategy, which aims to decarbonise operations and promote a circular economy.
Location
The facility is situated within the Dhaka Export Processing Zone in Savar, Dhaka, Bangladesh.
Bangladesh is a key growth market for Mainetti. The facility strengthens the company’s position and offers a substantial platform to serve local garment manufacturers, who in turn supply retailers worldwide.
Mainetti’s flexible packaging facility details
The facility spans 85,000ft² (7,897m²) and includes amenities such as a full canteen and prayer room for employees. It is constructed to modern standards, incorporating eco-friendly manufacturing methods to help reduce carbon emissions.
The facility produces 1.3 million bags a day, including transit bags, self-seal adhesive bags and display bags. It can also manufacture paper banderoles, hangers, care labels and tags incorporating radio frequency identification (RFID) technology.
The increased production capacity improves stock availability, thereby enhancing delivery times for Mainetti’s customers.
Sustainability features
The company intends to reduce the facility’s environmental footprint by installing solar panels, which will generate 650kW of clean energy.
Rainwater harvesting has been initiated at the facility with the installation of ridge ventilators on the roof. In addition, the usage of skylights reduces the facility’s energy consumption.
Specially constructed wall panels in the facility also significantly reduce noise pollution.
Product portfolio
Mainetti’s range of sustainable products features garment shrouds, self-sealing and flat-pack bags, product display bags, e-commerce sacks and plastic shopping bags.
Mainetti’s international research and development team introduced M-Film™, a unique range of flexible packaging films that consider the composition of the base material and its lifecycle. It comes in multiple thicknesses and varying percentages of recycled content, making it the perfect base for Mainetti’s Polyloop technology.
M-Film Air serves as an option for lightweight or thinner plastic bags, containing up to 100% recycled content, helping brands to minimise the use of virgin materials.
M-Film Land offers a high-quality solution for polybags, made from organic polymers that significantly accelerate biodegradation.
M-Film Earth is crafted for industrial compostable bags, utilising resin-based products sourced from fully renewable resources.
Additionally, the company manufactures 100% low-density polyethylene recycled e-commerce mailing bags, ensuring that design, colour and quality remain uncompromised while using sustainable materials.
Contractors involved
Design & Development Solution, a consultancy company, was involved in the development of the Mainetti packaging facility.
The company’s responsibilities included architectural design, landscaping, 3D modelling, reinforced cement concrete structural design, steel structural design, electrical design, fire safety design, plumbing design, effluent treatment plant design and bill of quantities. It was also involved in the design of the internal road network system, drainage system, rainwater harvesting, wastewater management and construction management.
The construction company Star Delta Engineers managed the construction of the facility.
Aegis Services, a division of SQUARE, known for providing security guard services and automation, was responsible for the supply, installation, testing, and commissioning of the fire alarm and detection system (by Cooper) and the aspiration system (by Securiton) for the facility.
