NatureWorks and IMA fast-track compostable coffee pod commercialization in North America

23 Feb 2022 --- NatureWorks and IMA are fast-tracking commercialization of compostable coffee pods for distribution to coffee brands and roasters. The partners have instigated a first trial phase for the K-Cup compatible pods. 

“With the promising results we’ve seen so far, we have already begun the next phase of development by partnering with converters in North America to bring these new compostable pod designs to commercial scale,” says Flavio Di Marcotullio, global industry manager for single-serve beverages at NatureWorks.

Tests are carried out under the supervision of the IMA Coffee R&D team in cooperation with NatureWorks. First, the filters and top lid film sealing phases are simulated. Then the parameters are adjusted based on the testing results.

In April 2021, NatureWorks entered a strategic partnership with IMA Coffee to accelerate the North American market for compostable single-serve coffee pods.

Coffee extraction testing
Microleakage detection testing performed at IMA Coffee Lab has produced “promising” results, leapfrogging the process toward the coffee extraction testing phase.

The pods will soon be available to brands and roasters focused on meeting consumer demands for environmentally sustainable packaging and circular economy directives that specify compostable packaging as a key enabler of recovering food waste for compost, explains Di Marcotullio.The trial version of K-Cup coffee capsule stacks.

At NatureWorks, the development of new single-stage thermoforming processes and capsule designs continue to produce clear capsules that meet IMA’s specifications for filling and sealing on their packaging machines.

Currently, NatureWorks is building a US$600 million polylactic acid (PLA) complex in Thailand. According to the company, the plant, which will produce lactic acid, lactide, and polymers, will also be the world’s first PLA facility designed to be fully integrated. 

Data acquisition for capsule design
NatureWorks has constructed a custom Data Acquisition System for K-Cup compatible pods to understand and benchmark how different capsule designs perform under various brewing conditions.

Coffee capsules are complex structures where the capsule body, lidding, and filter must be designed to deliver consistent quality brewing. The components must perform well during assembly, filling, on the shelf and during brewing. All these parameters have to be met before the capsules reach consumers. 

In 2019 IMA launched IMA NoP – No Plastic Program to direct its production chain toward increased environmental sustainability.

“NOP (No-Plastic Program) means we promote eco-friendly plastic substitutes for the packages manufactured on IMA machines. Through the research and testing of alternative processes and materials, together with customers, material suppliers and partners, we foster plastic-free and sustainable, compostable packaging solutions,” says Nicola Panzani, IMA coffee sales manager and IMA Coffee Petroncini CEO.K-Cup coffee capsules undergo testing at the IMA Coffee Lab.

IMA also established the Open Lab, where material technologists study, develop, and test compostable and recyclable materials to be used in its packaging equipment.

NatureWorks is an advanced materials company with an extensive portfolio of renewably sourced polymers and chemicals. It is jointly owned by Thailand’s largest Association of Southeast Asian Nations (ASEAN) integrated petrochemical and refining company, PTT Global Chemical, and Cargill, which provides food, financial and industrial products and services worldwide.

NatureWorks and IMA will share more about the latest innovations in single-serve compostable coffee capsules and developments from the partnership at AMI’s Single-Serve Capsules Global Virtual Summit from 29 March 29- to 31 March 2022.

By Inga de Jong