From a small trade finisher to a leading sustainable packaging manufacturer, Platypus Print Packaging has evolved through a century of family experience, continuous investment, and a deep commitment to Australian manufacturing. Lindy Hughson reports.
In 1982, under a two-storey Brisbane home, Tom Lusch founded Platypus Graphics as a trade finishing business specialising in foiling and embossing. It was the third generation of the Lusch family’s long printing heritage, extending back almost a century. Today, under the leadership of general manager Aaron Lusch and his brother operations manager Tim Lusch, Platypus Print Packaging has evolved into a major supplier of fibre-based cartons and sleeves for Australia’s food, beverage, health, beauty and pharmaceutical sectors.
“Dad’s business started with the pretty stuff,” says Tim. “We were doing hot foil stamping and embossing for other printers. From there we grew into commercial printing, and then into packaging – that’s where the future was. But those first two stages gave us the strengths we rely on today: attention to detail, high-quality finishing and a culture of value-adding.”
Focused transformation
For many years, Platypus balanced its commercial print and packaging work. Around eight years ago, the brothers made a deliberate decision to focus fully on packaging. “It’s hard to be very good at both,” says Aaron. “So, we made packaging our game – and once we did that, everything changed. Back then packaging was half our business; now it’s close to 100 per cent.”
A key step in that transformation came with the acquisition of Ovato’s packaging division in 2022, a move that cemented Platypus’s position in the sector. “We’d been working across both markets for some time, but that acquisition really propelled us,” Tim explains. “We became intentional about meeting the standards required for food and pharmaceutical packaging, including full food safety compliance. That’s when we shifted gears from being a printer that made boxes to being a packaging manufacturer.”
The results speak for themselves. Over the past decade, the company’s packaging output has increased fivefold, while its workforce has grown to around 125 employees. Now, says Aaron, the focus is on building greater efficiency and automation into the business. “We’ve had the growth and transformation,” he says. “Now it’s about optimising the systems we’ve established.”
Investing in technology
Platypus continues to invest heavily in world-class manufacturing equipment from suppliers such as Koenig & Bauer and Bobst. “We’re fortunate to work with the best technology partners in the world,” says Tim. “The consistency across our presses, die-cutters and gluers means minimal downtime and maximum efficiency, and with most of our equipment being relatively new, our facility is kitted to optimise performance.”
While offset printing remains the company’s core process, Platypus keeps a close eye on digital technology. “Digital print has made big inroads in labels and flexible packaging, but not yet in folding cartons,” Tim says. “Offset has traditionally dominated folding carton production in Australia, but both digital and flexo have niche potential and may have growing relevance in the market.”
Automation and data integration are also becoming increasingly important, both in production and in supply chain traceability. “Digitisation is driven partly by marketing, for personalisation, but also by safety and compliance,” Aaron explains. “With the right traceability systems, we can pinpoint where every product came from, down to the forest source of the fibre. That transparency is what brand owners expect.”
Innovation and collaboration
Innovation at Platypus often begins with the team itself. One recent example is a new four-pack carton concept for the craft beer market that reduces board usage and material waste. “We look for ways to help customers save resources while maintaining strength and shelf presence,” says Tim. “In that case, we designed the concept and took it to brewers as a ready-made solution.”
The company’s design process is consultative and collaborative. “Most of the time, we’re working directly with brand owners,” Aaron says. “They know the look they want but not always how to achieve it. We help them translate that vision into a manufacturable product – for instance, suggesting when to use a metallised board instead of a foil finish.”
While much of Platypus’s work finds its way to the shelves of major retailers such as Coles and Woolworths, the business also thrives in niche markets like health and beauty, where creativity and tactile finishes still matter. “In food, cost control and compliance drive decisions,” says Tim. “In beauty, there’s more room for artistry. Having both keeps our team versatile and our plant capabilities sharp.”
Sustainability embedded
As a converter of sustainable fibre packaging, Platypus places equal emphasis on product responsibility and operational sustainability. The company is accredited to ISO 14001 and holds FSC and PEFC chain-of-custody certifications. It is also a member of the Australian Packaging Covenant Organisation (APCO).
“Our sustainability story starts with what we do internally,” says Aaron. “We measure and improve our waste reduction year on year, from pallets and shrink wrap to corrugated shippers. We track Scope 1 and 2 emissions now and will be reporting Scope 3 next – it’s becoming mandatory. Compliance frameworks help drive that discipline.”
Beyond compliance, Platypus supports its brand-owner customers in meeting their own sustainability goals. “They need accurate data on packaging tonnage and recyclability for their reporting. We can provide that, and we often help them meet their carbon and waste reduction targets,” Tim adds.
Australian-made advantage
Being Australian-owned and locally based has never mattered more, says Aaron. “Australian ownership helps, but manufacturing here is what’s important. Almost all our customers – around 95 per cent – are themselves local manufacturers. We understand their environment: the pressures of labour shortages, rising input costs, and the need for reliable supply chains. We’re close to their business, not just geographically but philosophically.”
That proximity is proving a competitive strength as brand owners look to de-risk their supply chains. “Major manufacturers in Australia want continuity of supply,” Tim notes. “When you buy locally, you know your packaging won’t get stuck offshore. That’s been a big factor in maintaining strong customer relationships.”
Culture and continuity
At the Brisbane facility, many of the team members have been with Platypus for decades – some since the 1980s. “It’s humbling,” says Tim. “We’ve got an open-door culture. Staff can walk straight into my office or Aaron’s to talk about anything. There’s no hierarchy here – it’s a flat structure, and that helps us make quick decisions and stay agile.”
The company places strong emphasis on training and apprenticeships, with around six or seven apprentices currently in its ranks – over five per cent of the workforce. “It’s hard to find experienced print and packaging operators locally,” says Aaron. “We’ve recognised that we must grow our own talent. We’ve built solid systems around onboarding and training to keep the craft alive.”
That focus on continual improvement and investment in people reflects the legacy of their late father, Tom Lusch. “Dad was always changing something – new equipment, new technology, new ideas,” Tim recalls. “That spirit of evolution is part of who we are. He used to say, the day the business stops changing is the day it stops growing.”
With its packaging business now fully established and growing, Platypus’s next phase is about refining efficiency and embracing automation. “Our business has grown a lot in a short time,” says Aaron. “Now it’s about doing what we do but doing it better – on a slightly bigger scale.”
Tim agrees: “We don’t stand still. We’ll keep investing, keep improving, and keep supporting Australian manufacturing.”
The brothers concur: “In five years, we’d like to think we’ll still be right here in Brisbane, manufacturing world-class packaging, supporting Australian brands, and staying true to what’s always defined us – quality, service and innovation.”
This article was first published in the November–December 2025 print issue of PKN Packaging News, p30
