ProAmpac envisages recycled resin as next step in recycle-ready retort pouch innovation
04 Feb 2021 --- ProAmpac has launched a patent-pending recycle-ready retort pouch for human and pet food. A next step in the product’s development is the incorporation of post-consumer recycled (PCR) and post-industrial recycled (PIR) content to create a fully circular solution, Nathan Klettlinger, market segment manager at ProAmpac, tells PackagingInsights.
“We are working through a phased approach – a lot of our customers want to move to recycle-ready as a first step and then, as more materials come on-line, add more PCR and PIC content.”
“The materials we are using are being recycled today, so there is availability, and we are starting to investigate the possibility [of PCR/PIR] in the near future.”
Klettlinger anticipates increased recycled content supply deriving from a combination of mechanical and advanced chemical recycling, depending on what’s available.
Circular economy pouches
The global flexible packaging company’s polyethylene (PE) RT-3000 pouch is a mono-material design, providing high recovery potential through mechanical and advanced recycling streams.
In the US, PE is the most widely used and recycled flexible package material, Klettlinger highlights. “Even there, we have a lot of room to grow with that type of collection,” he adds.
“I have a lot of hope for advanced recycling, where new streams are coming on-line to recycle items that aren’t currently being recycled in a way that doesn’t degrade the polymer.”
“I see this product [RT-3000] working into the recycle stream in the future, and not its own recycle stream, but piggy-backing on other, larger volumes of similar materials.”
Food waste prevention
In addition to plastic waste reduction, RT-3000 pouches fight food waste with high barrier proficiency after the retort process.
“[The RT-3000 pouch] has a very good barrier after retort – it’s the best barrier you can get when you remove the foil – using very high technology.”
Nathan Klettlinger, market segment manager at ProAmpac.
“These materials were specifically chosen to withstand the retort process. There are some materials out there that have very good barriers before retort, but then they are shocked by the retort process and don’t work very well after.”
Klettlinger says the material science behind the RT-3000 pouch was the biggest technical hurdle. Retort is one of the most challenging applications to design for due to high pressures, temperatures up to 130°C and long shelf life requirements.
ProAmpac overcame these challenges through a collaborative approach, creating a mono-material pouch with the best combination of materials with help from internal material science experts, customers and suppliers.
Shelf-stable solution
RT-3000 pouches are available in both stand-up and three-side seal configurations. The solution is EU and FDA compliant for food contact in retort applications.
“What’s unique is we can offer the pouch in a three-side seal or stand-up pouch version, with very good sealing characteristics,” continues Klettlinger.
“This is a retort product, so it’s great for various applications. Pet food is one of significant interest, as well as different types of human food, including sauces and rice, and other items that need to be ready to heat or ready to eat out of the package.”
“What retort does is provide a shelf-stable package, so you don’t need to refrigerate it or put it in your freezer, you can just put it on the shelf.”
Environmentally and economically sustainable
As a recycle-ready mono-material, RT-3000 is focused on difficult-to-recycle multi-material applications like retort. As with other ProAmpac sustainable solutions, RT-3000 is designed to run at similar filling and processing speeds as current multi-material structures that aren’t recyclable.
“[The RT-3000 pouch] runs at rate on existing equipment, which we tested with current customers who had very good results,” Klettlinger tells PackagingInsights.
“This is important to ensure there are no increased costs per pouch running through the machine and also making sure your factory capacity is still at the same level as before switching to a recycle-ready structure.”
Available in clear or opaque options, RT-3000 offers “excellent” stiffness for stand-up shelf appearance and high puncture and flex-crack resistance for safe product handling and distribution.
Klettlinger anticipates increased recycled content supply deriving from a combination of mechanical and advanced chemical recycling.
“The multi-year development included successful validation on commercial high-speed filling lines and qualification in commercial retort chambers,” reiterates Hesam Tabatabaei, vice president of product development and innovation for ProAmpac.
“RT-3000 delivers exceptional thermal stability, excellent stain and grease resistance, easy-open tear performance, and a superior oxygen and moisture barrier.”
European trendsetters
The RT-3000 launch targets Europe, ProAmpac’s primary market. The supplier also works with international customers doing business all around the world, including in North America.
“We are working with customers now in Europe and hoping to get something on shelf by the end of 2021,” Klettlinger shares.
“In North America, the regulations and interests in sustainability follow Europe, so I’d expect [the first North American RT-3000 rollouts] to be after [Europe].
“I’d love to see something at the beginning of 2022 [in North America]. We are starting negotiations with some of the largest international companies and hoping to move into those trial stages very soon,” he concludes.
The EU Plastics Strategy requires all packaging to be recyclable in an economically viable way by 2030.
By Joshua Poole
