Since 1936, ZIP® has been at the forefront of fire lighting, igniting a legacy of excellence. The company’s journey began with the invention of the kerosene firelighter, setting ablaze a tradition of innovation and reliability. With roots deep in Ireland, ZIP® has expanded its product range to include natural firelighters, summer charcoal, and winter fuels, all designed to meet evolving consumer demands and trends. ZIP® is an expert in lighting fires and has been for over 80 years.
ZIP® was on a mission to create a more environmentally friendly solution to firelighting, and had created a perfect natural firelighter product, but packaging them would not be so simple.
Using ingredients that are notoriously difficult to ‘feed’ through packaging machinery, and with the specific ratios of the additional components required, plus the need for the actual packaging to be ‘light and burn’ (as opposed to traditional firelighters which are removed from a pack and lit separately), there were serious considerations.
Sustainably sourced packaging was also on the agenda, adding to the complexity of the project. But here at Record, we love a challenge.
Leveraging decades of experience and deep industry connections, Managing Director of Record, Edward Murphy, tapped into his network of machinery partners to research potential solutions. His relationship with a specific manufacturer allowed him to source a specialized machine that checked every box:
Vertical Feeding: A critical requirement for handling the specific product type effectively.
Plastic-Free Material: Capable of operating with low-density brown paper sourced from a zero-emission plant.
Eco-Friendly Sealing: Utilizes a precise 0.1mm spray of non-toxic glue rather than heat-sealing plastics.
High Output: Delivers a production capacity of 210 sachets per minute while maintaining component ratios.
The machine was procured by and installed by Record’s expert team of engineers, and the product is headed to North America, Canada, Tesco UK, Lidl, Aldi, Germany, France and Italy.
The current capacity meets demand but offers significant room for growth, so is a future proof solution, but there is also the opportunity to add a second line if required in years to come.
