Lidding plays a crucial role in ensuring food safety and extending its shelf life. Two commonly used types of lidding are die-cut lids and reel-fed lids as they provide a secure seal to pots and containers keeping food uncontaminated and fresh. While both types are made from similar materials, die-cut lids offer several advantages over reel-fed lids, with the most significant being reduced material waste during the manufacturing process.

Die cut lids are also more visually pleasing with minimal excess material when sealed onto the container – e.g. 0.25mm per side and a ‘clean’ precise cut as opposed to reel-fed applications which can have as much as 5.00mm excess per side and a ‘jagged’ edge.

Minimising environmental impact

Die-cut lids require less material because they can be precisely positioned and interlocked to maximize the  overall yield, unlike reel-fed lids. Typically, die-cut lids result in only 3mm side waste and less than 3mm between each die cut, whereas reel-fed applications often have waste exceeding 20mm.

Internally conducted analysis comparing a 101mm lid size reveals that the waste difference between die-cut and reel-fed is at least 44 percent. (Calculations are based on factors such as material width, feed length, and lids per metre).

The disparity in waste is evident when visually presented, as illustrated in the image below. Unlike reel-fed products where lids do not interlock, die-cut lids create a significantly smaller waste gap.


Left image: REEL FED

Right image: DIE CUT

Customer case study

A major dips manufacturer, supplying a renowned fast-food company, recently opted for die-cut lids over reel-based material. Their decision was influenced by the reduced material waste during manufacturing at the packaging company, minimized potential downtime and costs associated with cutting blades, and the fact that their production process generates zero waste. 

If you’re looking for a more sustainable alternative, why not consider transitioning to die-cut lids. Please drop us a line to find out more.