When Mark Helfrich joined Nestlé in 1995 as a Project Engineer, the world of sustainable packaging looked vastly different. Now on the cusp of retirement, Mark, who has served for three decades as Nestlé ESAR’s Packaging Engineering Manager, has become one of the driving forces behind our transformation into a packaging sustainability leader across Africa.
Mark’s journey from problem-solver to pioneer perfectly embodies the innovation showcased when Technical Director Louis Van Wyk recently presented From Packaging to Purpose at the Sustainability and ESG Africa Conference & Expo, demonstrating how individual expertise drives industry-wide change.
Mark at the Sustainability and ESG Africa Conference & Expo
Sustainability at the heart
Mark’s approach to engineering has always been guided by a simple principle: eliminate waste wherever possible. “I’ve always been someone who doesn’t like to see waste,” he reflects. This philosophy proved prophetic as we evolved our sustainability strategy toward ambitious 2025 targets of 95% recyclable plastic packaging and a one-third reduction in virgin plastic use.
Beginning in maintenance engineering and production management, Mark’s mechanical engineering background led him naturally into packaging engineering, where he would balance product protection, cost efficiency and environmental responsibility.
”I’ve always been someone who doesn’t like to see waste” – Mark Helfrich, Packaging Engineering Manager, Nestlé East and Southern Africa Region
Pioneering packaging innovation
Mark’s most transformative work began with seemingly straightforward projects that would ultimately reshape how Nestlé approaches packaging globally. The conversion of KitKat’s packaging from traditional foil and band to flow wrap introduced Nestlé South Africa’s first automated robotic end-of-line packaging system, revolutionising efficiency whilst improving food safety standards.
His leadership on the global Smarties chocolate bar packaging transition to paper demonstrated how local innovation keeps pace with worldwide change. Completed ahead of many competitors globally, this project exemplified our approach, at Nestlé: technical excellence combined with environmental responsibility.
“What really drove me was seeing how these changes aligned with my personal values of reducing waste and improving outcomes,” Mark explains, embodying the authentic connection between personal conviction and professional purpose that defines Nestlé’s approach to sustainability.
Through Mark’s Design for Recycling (D4R) initiatives, we achieved remarkable results. His work delivered a 30% reduction in virgin plastic usage over four years through optimised material density, headspace management and innovative seal technologies. For secondary packaging, incorporating 40% recycled content significantly reduced environmental impact whilst maintaining product integrity.
Working with Nestlé’s Packaging Science specialists and local suppliers, Mark supported the development of local packaging laminates incorporating innovative barrier technologies that maintain food safety and shelf-life requirements whilst achieving sustainability targets. “When moving towards D4R laminates, the impact on shelf life had to be carefully assessed,” he notes, exemplifying Nestlé’s commitment to responsible practices that never compromise consumer safety.
These achievements directly contributed to our impressive 2024 sustainability metrics.
The science of sustainable solutions
Beyond individual projects, Mark championed industry transformation. As a board member of Metpack SA, he advocated for Extended Producer Responsibility legislation, whilst his energy efficiency and sustainability projects included installation of energy efficient lighting at the Nestle factories and distribution centres, water and steam usage reduction projects at the factories, and increasing the Potchefstroom Cremora plant’s capacity by 60% without energy consumption increase.
These achievements align with Nestlé’s presentations at the recent Sustainability and ESG Africa Conference & Expo, where the company highlighted progress towards net-zero emissions by 2050. The R367 million investment at the Harrismith factory for the Bag-in-a-Box format represents the integrated thinking Mark has championed throughout his career.
“When it’s all said and done, what you remember is the people you’ve worked with over the years. Not so much the things you’ve done.” – Mark Helfrich, Packaging Engineering Manager, Nestlé East and Southern Africa Region
Wisdom for the next generation
Mark enjoying his two favourite hobbies: sailing and camping.
As Mark approaches retirement, his advice for emerging engineers reflects both technical wisdom and human insight: “Adopt a mindset of creativity and openness, given the rapid pace of change in packaging innovation.” He emphasises that whilst technology transforms the industry, human creativity and critical thinking remain irreplaceable in developing solutions for complex sustainability challenges.
Mark’s collaborative approach has enriched our collective capability at Nestlé. “When it’s all said and done, what you remember is actually the people you’ve worked with over the years,” he reflects, highlighting the human connections that drive corporate transformation.
A lasting legacy
Sustainability isn’t just about environmental impact; it’s about the people who dedicate their careers to making that impact possible. For Mark, the transition to retirement isn’t an ending, it’s an evolution. “I plan to stay engaged in meaningful work,” he notes.
The packaging innovations Mark pioneered will continue protecting products and reducing waste for years to come. But perhaps his greatest contribution is proving that when personal values align with corporate purpose, extraordinary transformation becomes inevitable. For today’s emerging engineers and sustainability professionals, Mark’s journey offers a powerful blueprint: start with eliminating waste, embrace creativity in problem-solving and never underestimate the power of collaboration.
Looking toward 2026 and beyond, Mark’s combination of engineering excellence and environmental stewardship will continue to guide our sustainability transformation. His retirement marks not an ending, but the beginning of his lasting impact on our industry and our planet.
