Case Study: Leading Beverage Manufacturing Company achieves plastic-free tea packaging with PA Consulting

Leading Beverage Manufacturing Company - Customer Case Study

PA Consulting worked with a leading beverage manufacturing company that wanted to address the environmental impact of traditional tea bags, which typically contain plastic webbing that contributes to landfill and ocean waste. The customer needed a more sustainable tea packaging format that would meet consumer demand, reduce plastic use, and align with growing regulatory pressure.

PA Consulting developed a plastic-free “tea sheet” made from lokta pulp and pressed tea leaves, creating a home compostable alternative that held up in boiling water without additives. PA Consulting delivered a working MVP in three months, produced a proof of concept in six weeks, and filed two international patents, while helping enable a solution that could reduce the 6.5 million kilograms of tea bag plastic disposed of each year in the UK alone.