Greiner Packaging produces thermoformed IML cups for decorative carbon cuts

16 Feb 2022 --- Greiner Packaging is using its thermoforming technology to produce thermoformed in-mold labeling (T-IML) cups. The process reduces material usage as less plastic is required to produce the thermoformed cups, which also makes them 25% lighter.

As a result, fewer CO2 emissions are emitted during transportation of the cups. Both the cup and the IML label are made of polypropylene, making for a monomaterial solution that is easy to recycle.

Greiner Packaging also tries to use recycled material, although mechanically recycled material for food applications remains severely limited due to strict approval criteria, with only recycled PET currently meeting the relevant requirements.

The benefits of T-IML at a glance:

• Monomaterial solution ensures maximum recyclability.
• Lightweight packaging with a small carbon footprint.
• Highly attractive at the point of sale due to excellent print quality.
• Barrier properties can be added to reduce food waste.

Greiner Packaging asserts the new thermoformed cups with IML decoration are “just as attractive” as their injection-molded counterparts – but have the edge when it comes to environmental sustainability.

Philipp Maurer, key account manager at Greiner Packaging, emphasizes: “We are committed to a circular economy and want to take a broad-based approach to making that happen. With our new T-IML cups using less material and being readily recyclable, they encapsulate exactly what we hoped to achieve.”

The new thermoformed cups with IML decoration are “just as attractive” as their injection-molded counterparts – but have the edge when it comes to environmental sustainability. The T-IML process
The company explains that during the in-mold labeling process, a label is inserted into the thermoforming mold in which the product is shaped, thereby forming a solid bond with the finished product. With this decoration method, shaping and decoration are performed efficiently in a single process.

Having invested in a test mold, Greiner Packaging is now able to manufacture T-IML cups. The cups are available with a diameter of 95 mm and a capacity of 500 mL. Switching from injection molding to thermoforming lowers the cup’s weight in this format from 15 to 11.4 g – a 25% reduction.

Extended shelf-life
The company says another advantage of the new packaging is that the sheet used in the thermoforming process can be imbued with barrier properties. This feature extends the shelf life of the packaged food, in turn helping to prevent food waste.

Additionally, IML is an especially high-quality form of packaging decoration. Matte, rough, glossy, or soft-touch decorative effects can be applied, and the printed content is photo quality and therefore visually “outstanding.”

“IML packaging solutions are extremely effective at attracting consumers’ attention at the point of sale. On top of their [environmental] sustainability attributes, that is naturally a real plus,” adds Maurer.

Also, Greiner Packaging has partnered with LyondellBasell to produce Nescafé coffee capsules from polymers based on advanced recycled post-consumer material. These polymers, branded CirculenRevive, are made using a chemical recycling process that converts plastic waste into feedstock for new polymers using a mass balance approach.

Edited

By Natalie Schwertheim

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