Duaa Saeed, Packaging Operations and Development Manager at DAL Group, speaks to Packaging MEA’s Ben Daniel about rebuilding Sudan’s packaging capacity, strengthening local supply, improving packaging and logistics performance, and the investment, technology and skills needed to develop a more resilient industry towards 2030.

 

 

 

Ben Daniel (BD): What drew you to packaging, and how did your experience across materials, print and converting shape your technical expertise?

Duaa Saeed (DS): I entered packaging through chemical engineering. My master’s research examined how polymer properties, processing conditions and material selection influence packaging performance. I then joined Jedian Group, working in flexible packaging quality and R&D on material evaluation, specifications, print quality, troubleshooting and trials. My responsibilities later extended to raw-material optimisation, corrugated cartons and duplex-board packaging.

 

 

Teaching polymer-resin subjects at Sudan University of Science and Technology and supervising undergraduate research strengthened my technical foundation. These experiences taught me to see packaging as an integrated discipline linking materials, machinery, product protection, quality, cost and supply-chain performance.

 

 

BD: How does your role at DAL Group span packaging operations, development and performance?

DS: I initially managed PP woven-bag operations, covering planning, material supply, machinery, quality and R&D. Lean practices and stronger controls increased productivity by 40%, reduced waste by 70% and lowered raw-material cost by 20%.

My remit later expanded across sites and countries, including films, cartons, paper bags, PET preforms, labels, aseptic cartons and rigid plastics. I lead design, specifications, supplier development, trials, troubleshooting and cost optimisation. Product protection comes first, followed by machinability, availability, total cost, logistics, shelf life, consumer expectations and environmental impact.

 

 

BD: Why is packaging strategically important across DAL Group?

DS: Packaging connects DAL’s products with manufacturing, distribution, customers and consumers. It influences food safety, shelf life, line efficiency, logistics, brand consistency, supply continuity and total cost.

An over-specified pack weakens margins; an under-performing pack creates waste, damage or complaints. We therefore connect production, quality, procurement, marketing, sales and supply-chain teams. DAL’s woven-bag, plastic-pallet, PET-preform and recycling capabilities also improve control over selected requirements and strengthen resilience when external supply is disrupted.

 

 

BD: Which project has created the clearest measurable value?

DS: We optimised PP woven bags by reviewing bag weight and raw-material formulation as one system, including tape properties, fabric construction, machine settings, conversion quality and end use. Laboratory testing, controlled trials and operational monitoring confirmed that the revised structure maintained tensile strength, dimensional consistency, machinability, filling performance and protection.

It reduced material consumption and delivered approximately US$700,000 in annual savings. The project showed that responsible cost reduction requires technical understanding and joint R&D, production, quality and commercial evaluation, rather than uncontrolled specification reduction.

 

 

BD: How do you see Sudan’s packaging and printing industry recovering to serve growing local and regional demand?

DS: Sudan has local capability in flexible packaging, corrugated cartons, PP woven bags, shrink film and labels, although capacity varies. Before the war, I estimate that flexible packaging, corrugated cartons and woven bags represented more than US$313 million combined: around 21,681 tonnes of flexible packaging, 64,000 tonnes of corrugated cartons and over 103 million woven bags.

Conflict disrupted factories, utilities, materials and logistics. Recovery is more visible in corrugated and woven bags; flexible packaging remains constrained, with one major plant recovered so far.

The market is reconnecting existing demand, capabilities and expertise, not rebuilding from zero.

 

 

BD: How is Sudan’s packaging industry responding to currency, raw-material sourcing, energy and logistics pressures?

DS: Foreign-exchange volatility can raise imported material, spare-part and freight costs between quotation and payment. Banking restrictions, sanctions and regional tensions have also affected sourcing, payments and transport. Teams now monitor exchange exposure, lead times, inventory and cash flow more closely, using shorter quotation validity, scenario costing, improved forecasting and safety stocks.

We qualify alternative sources, develop suppliers and remove unnecessary over-specification without compromising performance. Limited laboratory access has increased reliance on approved suppliers, certificates of analysis, risk-based inspection and controlled trials. Power constraints have also encouraged solar-energy investment.

 

 

BD: How can stronger local packaging production support Sudan’s food security, supply chains and industrial recovery?

DS: Almost every food, agricultural and consumer product needs packaging before storage, transport or sale. Expanding domestic capacity can shorten lead times, reduce finished- (packaging) imports, create employment and improve supply reliability.

Packaging is integral to food security because flour, sugar, dairy, edible oils, animal feed and agricultural commodities need protection from contamination, moisture, handling damage and loss. Import substitution can succeed only if manufacturers retain access to raw materials, equipment, spare parts and expertise. Sustained investment and supplier development can strengthen food supply chains and industrial recovery.

 

 

BD: Where should investment be prioritised to rebuild Sudan’s packaging manufacturing capacity?

DS: Flexible packaging is the immediate priority because demand remains strong while recovered local capacity is limited. Sudan needs modern printing, lamination, slitting, pouch-making and converting, alongside higher-barrier materials and reliable sealing. Food-grade rigid plastics, corrugated, labels, paper-based packaging, recycling and quality laboratories also offer opportunities. Investment alone is insufficient. Suppliers should combine appropriate equipment with commissioning, operator training, preventive maintenance, remote diagnostics, technology transfer, spare-parts support and long-term service.

These capabilities determine whether investment becomes sustainable industrial capacity.

 

 

BD: How can packaging optimisation reduce costs across the supply chain without compromising performance?

DS: Optimisation begins by defining performance from filling through storage, transport, retail and use. During recovery of the SKU portfolio, we reviewed specifications, qualified alternative suppliers and developed existing partners.

Packaging specification and supplier-development work delivered approximately US$1.5 million in savings, including the woven-bag project. Corrugated-carton redesign and truck-loading optimisation produced another US$1 million annually while maintaining compression, stacking and protection.

Together, packaging and logistics changes delivered about US$2.5 million. Every change underwent technical testing, production trials and supply-chain validation to reduce total cost, rather than merely purchase price.

 

 

BD: Against Sudan’s current market and infrastructure realities, what should sustainable packaging prioritise?

DS: Sustainable packaging must be practical, affordable and compatible with local realities. Packaging is not truly sustainable if it is unavailable or depends on recycling infrastructure that does not exist at scale.

Priorities are removing unnecessary material, optimising dimensions and weights, reducing production waste, improving vehicle utilisation and extending shelf life. Reducing food loss and maintaining availability are also sustainability outcomes.

DAL produces corrugated boxes using 100% recycled paper while maintaining required performance, and uses reusable rigid crates for selected distribution applications. Material choices should be based on total performance, not assumptions about a single substrate.

 

 

BD: In a traditionally male-dominated manufacturing environment, how has your experience as a woman shaped your career in packaging and technical operations?

DS: Factories, machinery and production have traditionally been male-dominated, so women may have to demonstrate technical credibility repeatedly.Preparation, process knowledge and measurable results helped me establish credibility. When a solution improves machinery, resolves a quality issue, reduces waste or delivers savings, confidence follows. I also benefited from leaders who recognised capability and provided responsibility.

Remaining barriers concern access to factory exposure, practical assignments, decision-making and leadership, rather than technical ability. Companies must give women opportunities to lead trials, troubleshoot problems and own outcomes.

 

 

BD: How can Sudan build a stronger pipeline of women and young professionals for the packaging industry?

DS: Packaging must become more visible as a career combining materials, manufacturing, food safety, quality, design, sustainability and supply chains.

Universities can add packaging modules, laboratory work, industry case studies and factory-based projects. Companies can offer internships, graduate rotations, mentoring and improvement assignments, while industry organisations provide workshops and professional networks. Women need direct exposure to machinery, trials, suppliers and technical decisions. I have developed a packaging team that includes women leading key activities; project ownership and operational responsibility have strengthened their knowledge, confidence and leadership.

 

BD: Looking to 2030, what should define the next phase of Sudan’s packaging industry?

DS: By 2030, I expect a locally supplied, diversified market serving food, agriculture, beverages, healthcare and consumer goods. Investment should prioritise flexible packaging, food-grade rigid plastics, labels and higher-performance materials, supported by technology transfer, workforce training, quality systems and laboratories. Sudan should rebuild around automation, energy efficiency, recycling, supplier localisation, export readiness and stronger competitiveness.