Bobst unveils Generation 2.0 monomaterial recyclable pouches in eight-partner collaboration

17 Sep 2021 --- Substrate processing specialist Bobst has launched “Generation 2.0” pouches, which are recyclable, mono-material alternatives replacing non-recyclable, high-barrier multi-material packaging structures.

However, swapping out non-recyclable plastic for more environmentally friendly alternatives still demands the same “like for like” performance, stresses Nick Copeland, R&D director at Bobst.

Most F&B packaging is multi-layer and multi-material for high-barrier protection against oxygen and water to prevent food waste but cannot typically be recycled.

However, the inherent properties of new generation materials, such as biodegradable and compostable alternatives, are “generally inferior to the materials we are trying to replace or substitute [in terms of barrier protection],” Copeland maintains.

“This creates a real challenge for the packaging designers,” he tells PackagingInsights. In light of these difficulties, Bobst’s Generation 2.0 pouches have reached a “key milestone.”

Copeland sheds light on the R&D process, opportunities seized when creating the pouches in collaboration with eight partners, including Dow and UFlex, and pressing stakeholder demands.

The secret recipe
Bobst’s “Generation 2.0” samples are high-barrier, full polypropylene laminated pouches, printed in gravure. They provide the option of an AluBond metalized barrier or transparent aluminum oxide barrier layer and solvent-free barrier adhesive and/or topcoat.

The pouches also include UV low migration flexo printing, providing barriers with AluBond metalization, on full low-density polyethylene laminated pouches.

CI flexo water-based printing on full MDO-PE laminated pouches with AluBond metallization are also available, providing an ultra-high-barrier using a high-barrier solventless adhesive.

Bobst says its new “hero samples” deliver state-of-the-art solutions utilizing a new generation of polymers.Three significant challenges
Bobst took a three-pronged approach to overcome recyclability limitations. First, the company combined higher density resins with orientation methods to add more mechanical stiffness and rigidity to the films. Optimized web transportation and tension control on the Bobst equipment was also required.

Then, the associated conversion platforms needed to be optimized to minimize the heat impact to the more heat-sensitive substrates via improved thermal management and cooling systems.

Finally, Bobst used additional functional barrier layers in the substrate design, wet barrier dispersion coatings, vacuum-deposited barrier layers and barrier adhesives to reinforce the barrier performance.

However, it was important to minimize the non-mono-material component of the packaging structure to achieve recyclability.

An eight-fold group effort
To support Generation 2.0’s complex R&D process, Bobst recruited an “Eco System” of stakeholders across the value chain, ranging from resin manufacturers and film producers to convertors and machine manufacturers.

Dow provided the PE resins, while UFlex supplied the biaxially oriented polypropylene (BOPP) film used in some of the tests. Indopoly supplied a BOPP film with a special skin layer for one of the pouches.

Bobst achieved good performance and processability for the BO films due to Brückner Maschienenbau’s R&D competence but also relied on Hosokawa Alpine’s expertise in blown film extrusion and machine direction orientation technology.

Sun Chemical provided the sustainable oxygen barrier solventless adhesives used in the program, while Michelman supplied the water-based barrier topcoats in parts of the project. Finally, Elba converted the finished reels into pouches.

Commenting on the challenges of working with such a versatile team, Copeland shares that one of the difficulties was aligning everyone’s availability during the pandemic. Moreover, coordinating the timing of materials and process steps through the journey from resin to finished pouch proved testing at times.

Customer interest up-and-coming
The group partnership now yields a faster time to market for customers. “This has helped to provide significant commercial interest from customers who want to future-proof their business,” notes Copeland.

He highlights this development will assist brand owners to reach their environmental sustainability commitments, as several across the FMCG industry have pledged full recyclability of packaging by 2025 – “or earlier.”

The new solutions are being experimented and further tested. When “mature enough,” they will also be developed under three pillars of sustainability: mono-material film-based solutions, fiber-based solutions, and end-of-life solutions.

“Our vision is to offer more ‘connected’ and optimized hardware solutions across our machine range together with optimized process solutions and supporting process know-how,” concludes Copeland.

“We realize this goal can’t be achieved alone and we need strong industry partnership and support from the whole value stream to reach our targets.”

By Anni Schleicher

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