Cadios breathes new life into household coffee cups with reusable lid innovation

22 Apr 2021 --- German start-up Cadios has developed a cone-shaped reusable lid for coffee mugs and cups. Called Udo, the lid fits onto most common household cups, enabling consumers to create new use out of existing beverage cups.

“A disposable cup is used for an average of 15 minutes before it ends up in the trash, so a reusable cup is definitely a more sustainable alternative,” Carina Frings, head of public relations, marketing and design at Cadios, tells PackagingInsights.

“But the best product is the one that doesn’t have to be produced in the first place.”

In addition to a wide variety of B2C customers, Udo has garnered B2B attraction as well. “Our customers here include cafes, retailers and companies that even have their own logo printed on our lids. For example, we have already printed lids for XING, E-ON and RTL2.”

Udo is made of Thermolast K, a multifunctional, halogen-free thermoplastic elastomer (TPE) solution from TPE compounder Kraiburg. 

Also speaking with PackagingInsights, Dr. Thomas Wagner, product management EMEA at Kraiburg, says Udo’s sealing properties are “excellent” and the surface feel as well as the organoleptics are “also outstanding.”

Thermolast K is available in varying degrees of hardness, from super soft (<10 shore A) up to 66 shore D.“Compared to silicone, TPE offers a better recyclability and processability in injection molding with polypropylene (PP) and polyethylene (PE),” he shares.

TPE’s adhesive bonding can further improve the reusable lid’s hygiene and health factors as there is no gap in the molded valves or seals.

Material considerations
Choosing Thermolast K for Udo was not by chance. “We deliberately decided against a bioplastics material,” says Cadios. 

“The material is not recognized by our current waste sorting facilities in Germany and cannot be recycled.” TPE, in contrast, can be “perfectly recycled” and returned to the technical cycle. 

Meanwhile, natural rubber is in increasing demand in Germany. However, Cadios is concerned natural rubber’s expansion is threatening forest population and biodiversity. 

“Due to the high demand, rainforests are being cleared. The long transport route to Germany hurts the value chain and the ecological ‘rucksack’ of our product.”

Neither does Cadios use PE or PP as those material properties do not compare in terms of hardness. Compared to conventional PP or PE, TPE is “undoubtedly more expensive,” admits Wagner.

“That’s why we chose the TPE from Kraiburg. It not only has the ideal smoothness for our product, but it is also the most environmentally friendly on the market,” says Frings.

TPE’s eco-friendly rep
TPE performs similarly to PE and PP in terms of durability and eco-friendliness, Wagner explains, but TPE is “a lot more flexible.” 

“It can be processed by multi-component injection molding together with a multitude of rigid thermoplastics, including PE and PP. This reduces the efforts to assemble products significantly,” he details.

“Less material is required for the parts’ flexible and durable connection, such as the base and closure of a food packaging item.”

In terms of consumer usability, the compound has a soft-touch surface, making it very comfortable to hold but still providing a non-slip grip. The TPE can be custom-colored and personalized with company logos using laser technology.

The product is also dishwasher-safe, high-temperature resistant and suitable for multi-component injection molding.

Keeping it local, but going international
One of Cadios’ wider goals is to develop Udo internationally. 

Udo arrives in a range of customizable colors and company logos can be printed using laser tech.“In this way, we can do our part to integrate sustainability into everyday life and make it easier for customers to act so. Many small changes achieve a big effect,” says Frings.

The majority of Kraiburg’s TPE compounds can be produced locally – in Germany, the US or Malaysia. This provides regional customers with a product of consistent quality labeled “Made in …” 

“What adds to that is we are always close to our customers, worldwide,” says Wagner. “Whether our customer is located in Helsinki, Cape Town, Shanghai or Santa Fe, we always offer a great technical diversity that suits local requirements.” 

Further ensuring its global usability, the compound used for the Udo reusable lid covers a wide range of legal frameworks, including regulation (EU) No. 10/2011, as well as FDA – 21 CFR and GB 4806-2016. 

“These approvals enable a nearly worldwide processing and distribution of the compounds,” Wagner concludes.

By Anni Schleicher