Cleaner, greener and BRC certified

Since start-up in 2005, under the experienced eye of MD, Adrian Jackson, Maverick Flexible has grown by leaps and bounds and today commands an impressive position in the supply of blown film and high-barrier eight-colour flexo-printed, thermally-laminated films, meeting the changing demands of flexible packaging converters and brand owners – typically those involved in liquid and dry food packaging – for stand-up pouches and form-fill-seal applications.

‘These are exciting times and we’re experiencing exceptional growth,’ reports an understandably proud Adrian Jackson. ‘We have something special, something different to offer the food packaging market and our association with Maverick Engineering, especially its strong presence in the liquid packaging market, is another compelling advantage.’

Getting the BRC ticket

And now the latest news from this go-ahead enterprise is the successful implementation of the stringent BRC/IOP Global Standard for Packaging & Packaging Material.    

Since 2007, Maverick has been FDA/IMS compliant – following a successful audit carried out in conformance with the sanitation standards of Packaging Consultants International and the US Public Health Services.    

With US compliance safely under its belt, the team then decided to go for the BRC/IOP standard – in recognition of local demand for this accreditation and potential export opportunities.   

Aided in no small measure by Grant Wareham of Wareham & Associates, Maverick Flexible undertook the long and arduous road to becoming recognised as a world-class producer of eight-colour reverse-printed PET/PE laminations, ideally suited to the form-fill-seal market.   

‘Starting with a detailed analysis of our business, Grant did a highly-professional job, with goals set each step of the way,’ Adrian confirms. ‘Having BRC and FDA certifications will certainly open further doors for us in South African and European markets,’ he maintains.   

The most recent addition to the management team is Tamara Marais, quality and systems manager. ‘We had already established a base for the BRC process,’ Adrian explains, ‘but we needed Tamara’s particular skills and food industry background to focus on the necessary attention to detail.’   

Safety first, all the way

On the technology front, Maverick boasts an impressive line-up – from Macchi film blowing technology to extrusion lamination and – thanks to the latest acquisition, an eight-colour Uteco Emerald flexo press – world-class printing.   

‘Over the years,’ Adrian continues, ‘we’ve enjoyed growing success in film blowing and thermal lamination, and now we can add top-quality printing to our arsenal! With our particular focus on printed and thermally-laminated films offering low oxygen transmission and high barriers, we’re ideally placed to supply the demanding needs of our customers, and the brand owners themselves.’   

And it’s safety first, all the way, as confirmed by the recent BRC certification. Maverick’s environmentally-friendly thermal lamination process uses neither solvents nor chemicals, so there’s no danger of unsafe migration from food packaging. Also bringing customer’s peace of mind is an on-site laboratory that features testing facilities for oxygen transmission rate (a Mocon Oxtran system), tensile strength and interply bond, COF (coefficient of friction) and flex durability testing (a Gelbo system).    

These testing facilities have a twofold advantage. They complement Maverick’s ongoing R&D efforts, and they assist in implementation of the company’s product safety and quality management system designed to meet the requirements of the BRC/ IOP Global Standard.   

As Tamara Marais insists, Maverick Flexible has an obligation to manufacture safe and legal products. ‘We believe our product safety and quality management system allows for continuous improvement and better control, thus ensuring sustainability,’ she says.   

Tamara goes on to explain that supplier risk assessments ensure that raw materials are of the highest quality and safe for food contact; and that any areas of concern are identified through non-conformance and corrective action processes, and through third-party annual compliance audits. HACCP principles are employed for risk assessment, and preventive measures are in place to mitigate risks.   

Apart from managing risks, control procedures ensure effective quality assurance to achieve optimum yield, while minimising waste, in order to manufacture products in the most cost-effective way.   

And last word goes to Adrian Jackson:    

‘The 100% commitment, dedication and passion of the entire staff is evident within our walls. This is the key and is essential in driving product safety, quality and continuous improvement. With BRC in place, and the support of my highly-skilled and dedicated team – offering many years’ experience and unparalleled understanding of the flexible packing industry – we’re now completely geared to serve this market with passion and fire!’