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Welcome to PackaForge – Innovating Sustainable Packaging for Tomorrow

At PackaForge, we harness the power of circular‑economy principles to deliver bespoke, eco‑responsible packaging solutions across New Zealand. From compostable mailers to moulded‑fiber inserts, our mission is to protect your products—and the planet—without compromise. Whether you’re a boutique artisan or a large‑scale retailer, our end‑to‑end services ensure your brand makes a positive environmental impact at every touchpoint.

About Us – Engineering a Circular Future

PackaForge was established in 2015 by Dr Olivia Grant, a materials engineer passionate about biomaterials, and Tom Reynolds, a circular‑economy strategist determined to eliminate packaging waste. What started as a small Hamilton workshop transforming cardboard offcuts has grown into a fully ISO 9001/14001‑certified facility with two high‑speed production lines and an in‑house R&D pilot plant. Our multidisciplinary team—comprising chemists, packaging engineers, graphic artists, and sustainability analysts—collaborates closely with Callaghan Innovation to pioneer algae‑derived foams, PFAS‑free barrier coatings, and mycelium‑grown insulation. We operate a closed‑loop manufacturing process: every scrap fiber, paperboard offcut, and production surplus is reintegrated back into our material stream, achieving near‑zero solid waste. By actively participating in New Zealand’s Packaging Declaration Scheme and preparing for future EU eco‑design standards, we ensure your packaging meets today’s regulatory demands and tomorrow’s environmental expectations. At PackaForge, innovation isn’t just a buzzword—it’s the foundation of every box, pouch, or insert we produce.

Our Services

Custom Design & Rapid Prototyping
Leveraging CAD structural simulations and 3D‑printed mockups, we iterate packaging designs in days, not weeks. Our team evaluates crush strength, moisture resistance, and material compatibility under real‑world shipping conditions. You receive virtual AR previews and low‑run samples for functional and aesthetic testing. Collaborative design workshops integrate your brand’s identity, sustainability goals, and logistical requirements into every prototype. This agile approach accelerates time‑to‑market and minimises costly revisions.

Corrugated & Rigid Box Manufacturing
Our corrugators handle single‑, double‑, and triple‑wall boards up to 8 mm thick, supporting runs from 1,000 to 200,000 units. We offer kraft, white‑top SBS, and moisture‑resistant paperboards—all FSC‑certified and fully recyclable. Inline flexo‑printing with soy‑based inks in up to six colours delivers crisp graphics and registered finishes. Automated die‑cutters ensure precision dimensions, while quality‑control scanners detect flaws in real time. From e‑commerce shipments to retail-ready packaging, our scalable production meets diverse volume requirements with consistent quality.

Flexible Packaging & Barrier Films
Our stand‑up pouches, zipper‑seal bags, and vacuum pouches employ compostable PLA/PHA laminates laminated with water‑based adhesives to achieve oxygen, moisture, and aroma barriers rivaling conventional plastics. We engineer multi‑layer constructions with degassing valves, tear notches, and resealable closures tailored to coffee, snacks, pet food, and fine powders. Materials comply with EN 13432 home‑compostability standards and FSSC 22000 for food‑contact safety. Custom matt, gloss, and soft‑touch finishes elevate unboxing experiences while maintaining compostable credentials.

Moulded Fiber & Mycelium Insulation
Replace polystyrene with molded pulp inserts made from bagasse, wheat‑straw fiber, or recycled newsprint. Our lines produce protective trays, clamshells, and bespoke cushions that cradle glassware, electronics, and fragile artifacts. For advanced insulation, we offer mycelium‑grown foam blocks and algae‑based packing peanuts that outperform synthetics in thermal resistance and shock absorption. Both options are home‑compostable, EN 13432‑certified, and free from harmful chemicals. Plant‑based dyes and custom embossing add branding opportunities without sacrificing circularity.

Kitting, Fulfillment & Inventory Solutions
Streamline your supply chain with our pick‑and‑pack, subscription‑box assembly, and vendor‑managed inventory programs. Real‑time barcode scanning and cloud dashboards maintain accurate stock levels and minimise over‑ordering. Just‑in‑time deliveries synchronise with your production schedules, reducing warehousing costs and carbon emissions. Dedicated account managers provide weekly performance reports and volume forecasts, helping you adapt to seasonal demands. This turnkey service lets you focus on growth instead of logistics.

Life‑Cycle Analysis & Sustainability Consulting
Our sustainability analysts perform full cradle‑to‑grave assessments, quantifying carbon footprint, water usage, and end‑of‑life scenarios. We craft material‑substitution roadmaps that swap high‑impact inputs for renewable alternatives. Take‑back and closed‑loop initiatives reintegrate used packaging into new production cycles, cutting raw‑material demand. Interactive workshops equip your procurement and design teams with circular‑economy principles. Regulatory guidance ensures compliance with NZ EPA rules and international export standards—future‑proofing your packaging strategy.

Our Advantages

True Circular‑Economy Leadership
At PackaForge, every process is designed for circularity: 98% of on‑site waste is reincorporated into production, drastically reducing landfill contributions. We partner with local councils and composting facilities to establish community take‑back programs, ensuring consumers have accessible end‑of‑life pathways. Regular audits track material flows, identifying further opportunities for reuse and process improvements. By choosing us, you demonstrate leadership in resource stewardship and align your brand with pioneering environmental practices. Our closed‑loop model transforms packaging from waste into a renewable resource—and inspires industry‑wide change.
Cutting‑Edge Material Innovation
Our R&D lab, in collaboration with Callaghan Innovation, has engineered proprietary algae‑based foams and PFAS‑free barrier coatings that outperform conventional plastics in both performance and compostability. These biomaterials offer superior cushioning for fragile goods and robust protection for cold‑chain logistics. We hold patents on our non‑toxic coatings and continuously benchmark against global standards to refine formulations. Continuous field trials and consumer feedback loops ensure our materials meet real‑world demands. This relentless innovation keeps your packaging at the forefront of sustainable science.
Scalable, Flexible Production
From boutique orders of 500 units to mass runs of 500,000, our modular production lines adapt quickly to volume changes and urgent deadlines. Automated board feeds, robotic die‑cutters, and inline print‑inspection systems maintain consistent quality across batches. Rapid job‑change protocols minimise downtime, allowing us to switch between projects in under two hours. This agility supports seasonal campaigns, product launches, and evolving market needs—delivering both speed and reliability. Your deadlines become our commitments, every time.
Brand‑Elevating Finishes
We offer a spectrum of premium finishing options—UV spot varnish, embossing, debossing, foil‑stamping, and soft‑touch laminations—to create memorable unboxing experiences. Our design team collaborates on finish selection to reflect your brand’s unique story and sustainability ethos. High-definition mock‑ups and physical prototypes ensure every detail matches your vision before full‑scale production. Thoughtful finishing elevates perceived value and customer engagement, turning packaging into a strategic marketing asset. With PackaForge, your packaging becomes a powerful touchpoint in brand storytelling.
Compliance & Certification Confidence
PackaForge maintains ISO 9001 and ISO 14001 certifications, demonstrating rigorous quality and environmental management systems. Our products meet EN 13432 home‑compostability standards, FSSC 22000 for food safety, and NZ’s Packaging Declaration Scheme requirements. For export markets, we provide custom documentation for EU eco‑design compliance and US FDA food‑contact standards. Detailed material‑safety data sheets, certificates of analysis, and audit support streamline your regulatory approvals. This comprehensive compliance framework eliminates uncertainty, letting you focus on market growth.
Transparent Partnership & Service
We believe in open, honest collaboration—our quotes cover design, prototyping, production, and delivery with no hidden fees or surprise surcharges. Each client is assigned a dedicated account manager who coordinates cross‑functional teams and provides weekly status updates. Post‑delivery performance analyses identify cost, waste, and carbon‑reduction improvements for future runs. Our service ethos is built on responsiveness, reliability, and mutual success. Choosing PackaForge means gaining a trusted packaging partner invested in your long‑term goals.

We invite you to get in touch to explore how PackaForge can transform your packaging into a competitive advantage and environmental asset. Email us to arrange a virtual design workshop, plant tour, or sample evaluation—our experts will walk you through material options and performance benchmarks tailored to your needs. Whether you’re launching a new product line or seeking to green your existing packaging, we’re here to co-create solutions that align with your brand and sustainability ambitions. Reach out today and let’s forge a circular‑economy future together!

📍 Address: 20 Knight Street, Hamilton 3204, New Zealand
📧 Email: packaforge@mail.com
🕒 Hours: Mon–Fri 7 AM–5 PM | Sat 8 AM–12 PM | Sun Closed