Lecta innovates plastic-free paper drinking cup with aqueous dispersion layer

06 Jul 2021 --- Lecta is launching EraCup Natural, a recyclable, biodegradable and plastic-free paper-based solution for single-use cups. 

EraCup Natural is the first product in Lecta’s new range of functional papers, aligned with responsible consumption habits.

The material is ideal for hot and cold beverage cups and on-the-go disposable containers.

Manufactured under rigorous environmental and food safety certifications, EraCup Natural is based on a proprietary polyethylene (PE) and bioplastic-free process.

Moreover, the cup’s unique composition allows the paper to be recycled in standard paper recycling streams after use.

“The EraCup’s main productivity advantage is that our material needs a substantial lower temperature to seal,” Santiago Tesi, marketing and innovation director at Lecta, tells PackagingInsights.

“This means cup machines can work at around 10-20 percent lower temperature than the current solution with consequent energy savings.”

Tesi confirms the cup’s usability and durability are the same as conventional, PE-lined cups. “The product is already available and initially we are open to serve all markets,” he says.EraCup Natural is a recyclable, biodegradable and plastic-free paper-based solution for single-use cups.

Technical challenges
EraCup Natural is an SBB paperboard manufactured with pulp from certified sources, available in substances from 170-380 g/m².

The solution has an uncoated outer face, with a smooth, natural finish suitable for high-quality flexography and offset printing.

The inside is covered with a sealable aqueous dispersion, guaranteeing the manufacture of liquid-tight paper cups.

“EraCup is the result of several years of research and trials looking for the right solution to achieve all the functionalities required,” explains Tesi.

A significant challenge was finding the appropriate dispersion to apply to the paper to obtain the set of functionalities necessary to form a cup.

“Lecta has tested many different aqueous dispersions from many different suppliers and, finally, we found the appropriate material to create our new and innovative product. The dispersion is guaranteed for food contact,” Tesi continues.

“We apply an aqueous dispersion that gives our paper the adhesive functionality required for the cup formation.”

“Due to the speed of cups production machine, the paper has to be sealed by temperature in a very short time, meaning this functionally is most important to achieve.”Paper cups typically have PE barriers to hold liquid, maintain heat and prevent sogginess, but also contaminate the paper recycling stream.

“Obviously the safety in food contact is a must and the layer has also to provide this.”

Meanwhile, COVID 19 impacts and restrictions meant Lecta lost the opportunity to homologate the product with several converters and brand owners, forcing a delayed launch.

Coating considerations
Lecta manufactures EraCup at its Sant Joan Mill in Spain, a factory designed for producing graphic papers.

“The new paper has different characteristics to standard CWF, so we had to modify some parts of our coater and gain knowledge in the application of this type of dispersions using our coating technology.”

“EraCup is a PE- and PLA-free paper, totally recyclable, repulpable, biodegradable and based on a renewable raw material.”

“We understand it is an innovative product with great sustainability advantages, fully aligned with the current plastic reduction trend,” he concludes.

PackagingInsights recently discussed innovation in hot drink cups with experts from Metsä Board and Stora Enso.

By Joshua Poole