“Huge potential in hot-fill”: UFlex, Mespack and Hoffer Plastics team up on recyclable mono-PP pouches

08 Oct 2021 --- UFlex is joining forces with flexible packaging manufacturer Mespack and custom injection molding innovator Hoffer Plastics to develop easily recyclable polypropylene (PP)-based hot-fill pouches with material-reducing spout caps. 

“There is huge potential in hot fill pouches,” a UFlex spokesperson tells PackagingInsights. “The global retort pouch market has reached US$1.5 billion as of 2020 and continues to grow at a CAGR of 8.1% between 2021-2026. To address this great potential, we see opportunities in creating more closure options – other than spouts – to reduce plastic waste.” 

The new pouch combines the strength of UFlex’s oriented PP and cast unoriented PP-layered laminate structure, offering enhanced barrier properties, easy heat sealability and longer shelf life for unrefrigerated food storage.

The pouches are sealed with patented tamper-evident spout caps from Hoffer Plastics, and produced with the Mespack HF-series fill-and-seal machine, enabling efficient fill through the spout of premade pouches. Due to the continuous spout filling, up to 15% of the headspace is reduced by eliminating the wave effect.

UFlex affirms many brands have been showing interest in the mono-polymer hot-fill pouches and it has already found a taker in a “leading environmentally conscious US-based baby food brand.”

Applications galore
The pouches, manufactured at the UFlex India plant, will be exported to North American markets and predominately used for packing edible products, such as baby food, food puree and pet food.

The new pouch has already found a taker in a “leading environmentally conscious US-based baby food brand.”Hot-fill pouches have established themselves as an industry alternative to traditional industrial canning methods in the ready-to-eat food segment. 

Targeting fresh, cooked or semi-cooked food, juices and drinks, hot-fill pouches are particularly functional for easy storage and food consumption from the heated pack.

However, hot-fill pouches continue to struggle with full recyclability given their poly-material structure. In this arena, developing fully recyclable solutions remains a key objective.

Maintaining barriers 
While UFlex has experienced a “very smooth collaboration,” the key challenge the company faced was ensuring the barrier to humidity and oxygen remained intact.

“From a technical point of view, the transition from non-recyclable to recyclable laminates requires addressing some key challenges of pressure, temperature and speed to ensure a successful hermetic seal,” says the spokesperson.

“As part of the R&D process, it takes a few trials to perfect the laminate and post-production trials at the co-packers end. This means calibrating the machines for mono-materials to achieve the desired seal strength and barrier.” 

UFlex in the news
Following its membership to the Alliance to End Plastic Waste, UFlex recently spoke with PackagingInsights about its views on the new Indian plastic pact.

In August, the company highlighted a range of innovative launches from its flexible packaging, chemicals and holography businesses.

Earlier this year, FlexFilms International revealed its global expansion plans in a video interview. The film manufacturing arm of UFlex, India’s largest multinational flexible packaging solutions company, has newly commissioned BOPET lines in Poland and Russia.

By Anni Schleicher