How Imperial Cartons Helped Sonora Foods Scale From Start-Up to National Supplier

The TLDR (Too Long Didn’t Read) Version 

Sonora Foods needed packaging that could support the growing distribution of their Australian-made corn chips and tortillas. They partnered with Imperial Cartons to develop flexible carton solutions that protected their products, fit their production workflow, and scaled with demand.

• Client: Sonora Foods – Bendigo-based manufacturer of locally made corn chips, tortillas, wraps, and flatbreads.

• Problem: 14 years ago, Sonora Foods required an Australian packaging manufacturer capable of delivering flexible volume cartons to support the expansion of their business into the future.

• Solution: Imperial Cartons provided custom corrugated cardboard packaging with no minimum order quantities, responsive service, and quick turnarounds. As a local manufacturer, Imperial Cartons was able to easily adapt to the changing carton volume requirements as Sonora Foods continued to grow.

• Outcome: Over 14 years, Sonora Foods grew from a regional start-up to a national food supplier, supported by reliable, food-grade carton packaging made in Melbourne.

  
  

Prefer the details? Read the full story here. 

About the Client: Sonora Foods

Sonora Foods is a proudly Australian food manufacturer based in Bendigo, Victoria. Through its partner brands, Eureka Chip Company and Eagle Foods Australia, the business produces a growing range of locally made corn chips, tortillas, wraps, and flatbreads, all using 100% Australian-grown ingredients.

What began as a small startup operation has evolved into a national supplier. Their products are now stocked in major supermarkets and used by food service and private label clients across the country. With over 85 years of combined industry experience, the Sonora team brings deep product knowledge, consistency, and a practical approach to every part of their operation. Their long-term growth has been supported by supply partnerships with businesses that understand the requirements of food manufacturing, including their packaging.

In 2010, Sonora was just getting started. They needed a packaging partner who could keep pace with their goals, offer small runs without rigid systems or MOQs, and deliver cartons suited to their product lines. They sought a supplier that understood their business, fostered a trusted relationship, and provided support. That’s where Imperial Cartons came in.

The Challenge: Finding a supplier who would prioritise their start-up business and partner with them for long-term growth.

At the time, Sonora Foods needed a reliable packaging supplier who could work closely with a start-up business, offering the flexibility and speed that larger manufacturers often can’t, or are unwilling to, provide. They required packaging that was functional, scalable, and tailored to their specific product lines.

Here’s what General Manager Steve Mallia had to say about why they chose Imperial Cartons over larger competitors:

"We wanted someone to grow with. I didn’t want to go with the bigger companies because I didn’t want to get brushed aside. And obviously, I contacted you, and you’re easy to get along with. You’re not just the owner. You’re my relationship manager, which is something different. We hit it off. You were down to earth. It wasn’t just a sale with you. You work with us. We were a start-up company. We’ve got measurements, we’ve got sizes, we’ve got samples straight away. We understood where we were coming from, so it was good."

This early need for responsiveness, guidance, and custom packaging was the starting point of a long-term collaboration.

The Solution: Custom Carton Packaging Designed to Grow With the Business

From day one, Imperial Cartons provided custom corrugated cardboard packaging solutions with the speed and flexibility Sonora Foods needed. Our Melbourne-based production team delivered small-volume orders quickly, with ongoing support as the business grew.

Packaging solution highlights:

1. Flexible order volumes - supporting start-up and growth phases

2. Custom carton design - tailored for tortilla and chip packaging

3. Prototyping and sampling - to test packaging before full production

4. Direct consultation - eliminating delays from automated systems

5. Australian-made corrugated cartons, manufactured locally with fast turnaround

Our team worked closely with Sonora Foods to deliver fit-for-purpose cartons that adapted as they grew, ensuring their products were safely packed, efficiently stored, and ready for shelves from local deliveries to national distribution.

The Result: A Packaging Partnership Built for Long-Term Growth

Over more than a decade, Sonora Foods and Imperial Cartons have built a trusted working relationship shaped by responsiveness, consistency, and shared growth. What began as a single order has developed into a packaging partnership that continues to evolve with their expanding product lines and distribution footprint.

Key outcomes include:

1. A 14-year relationship and ongoing collaboration

2. Sonora Foods is now one of Imperial Cartons’ top two customers

3. Our cartons support their full product range, from wraps to corn chips

4. Packaging evolved alongside new SKUs, lines, and logistics needs

5. Flexible, responsive service that continues to support their national growth

From their first box to today’s national footprint, we’ve been proud to help Sonora Foods scale with confidence.

Need Packaging That Supports Your Business Growth from Start-Up to Scale?

We understand the demands of food production. Whether you're launching your first product or expanding nationally, we deliver custom cartons that protect, present, and move your goods, without rigid systems or unnecessary delays.

Just practical solutions, made to fit your business.

Let’s talk: www.imperialcartons.com.au/contact