Amcor and Nestlé unveil world’s first recyclable retort pouch for pet food

29 Sep 2020 --- Amcor and Nestlé are launching the world’s first recyclable flexible retort pouch with the Purina wet cat food brand in the Netherlands in October 2020. The “recyclable packaging breakthrough” reportedly improves environmental footprint by up to 60 percent.

“Amcor and Nestlé have been able to create a unique solution that for years was thought impossible,” says Michael Zacka, president Amcor Flexibles EMEA.

“This high-barrier, high-heat resistant, packaging can be easily recycled within plastic recycling streams already existing in several European countries.”

The pouch uses Amcor’s AmLite HeatFlex Recyclable solution. Amcor launched the AmLite Ultra Recyclable high-barrier laminate pack in April 2019 – the first product made from the supplier’s new recyclable polyolefin film.

“During retort processing, the food is cooked inside the pouch at temperatures up to 130 °C. This sterilizes the product and its packaging, providing a typical shelf life of 1-2 years,” an Amcor spokesperson tells PackagingInsights.

“To withstand this process, previous generations of retort flexible packaging relied on multi-material combinations, featuring PET, aluminum foil, and PP. While high performing, this mixed-material structure is not recyclable anywhere in the world today.”Flexible retort packaging is a modern alternative to metal cans that can improve carbon footprint.

“The solution is our AmLite technology. The recyclable retort pouch was made possible by combining our AmLite high barrier coating with our most recent innovation – a PP film that delivers high-performance for heat processing.”

Amcor is working with partners to apply the AmLite HeatFlex Recyclable solution to other segments using retort packaging, including ready-meals, pre-cooked soups, sauces and baby food.

European plastic levies
The launch is timely, with the European Council approving a plastic tax starting January 1, 2021, as part of its Multiannual Financial Framework (2021-2027) and coronavirus recovery fund.

Likewise, the UK government proposes a £200 (US$263) per ton tax rate for plastic packaging with less than 30 percent recycled content that will take effect from April 2022.

Amcor and Nestlé collaborated during the product development process, testing for heat resistance, machine performance, shelf life and recyclability in real world conditions.

Flexible retort packaging is a modern alternative to metal cans that can improve the carbon footprint with lightweight, resource-efficient, ease of transportation and food waste-fighting credentials.

Adding recyclability to the pouch’s list of properties improves the environmental profile further.

CEFLEX guidelines
The new pouch meets the CEFLEX Consortium’s new packaging guidelines. CEFLEX strongly recommends the use of flexible packaging made from recyclable mono-material.

The position paper, entitled “Accelerating the circular economy for flexible packaging – a recommendation for recyclable mono-materials,” states the need to evaluate the functional requirements of packaging and, when possible, redesign existing flexible packaging to a recyclable mono-material.

Amcor is applying the AmLite HeatFlex Recyclable solution to other retort packaging segments, including ready-meals, pre-cooked soups, sauces and baby food.“This [Amcor solution] is a great example of how – through innovation – companies can solve even the biggest challenges to recyclability. Recyclable retort packaging is a revolutionary advance and will have a huge impact on pet food and beyond,” notes Graham Houlder, project coordinator and workstream consultant for CEFLEX. 

Environmental focus
The breakthrough innovation underscores Amcor’s capabilities and long-term commitment to more sustainable packaging. The company is on course to develop all of its packaging to be recyclable or reusable by 2025.

In June, Amcor joined the World Wildlife Fund-led activation hub, ReSource: Plastic, a global consortium of companies and organizations collaborating to keep waste out of the environment.

Last week, Nestlé Waters UK partnered with leading waste management business Biffa to deliver 100 percent recycled PET in a closed-loop system.

In August, German pet food company zooplus opted for Mondi’s recyclable packaging for the new flavors of its premium pet food brand Wolf of Wilderness.

The FlexiBag Recyclable and BarrierPack Recyclable form-fill-and-seal (FFS) reel material are both certified recyclable by the Institute cyclos HTP.

By Joshua Poole