Reelbrands reels out plastic-free water-resistant fiber-based boards range

18 Nov 2020 --- UK-based Reelbrands is launching a fiber-based boards range aimed at replacing plastic food packaging with recyclable alternatives.

Created in collaboration with paper material suppliers Swanline and SPP Labs, the line fiber-based boards – dubbed Cygnus Reelboards – are touted as a “huge win for the planet.”

“What makes our products unique is how we make them. Where barrier coatings are needed, our partner SPP Labs uses a pioneering method to coat the board or liner paper for our laminated board,” Chris McNeill, co-founder of Reelbrands, tells PackagingInsights.

“The method is top secret, but what I can say is we use significantly less coating than other conventional coaters and gain better results from what is used.”

Cygnus Reelboard's benefits
The Cygnus Reelboard range is certified plastic-free, recyclable, repulpable, and importantly a viable alternative for polyethylene-based (PE) laminated materials.

The range is also 100 percent biodegradable, compostable and highly grease-resistant with high water barrier properties.

The fiber-based boards are also bisphenol A (BPA) and Perfluoroalkoxy alkanes (PFA)-free, making it suitable for frozen, chilled and ambient conditions.

The products offer both premium and low-cost options, including functional products designed to meet most commercial needs, says Reelbrand. Previously, most of these applications were only possible in plastic.

“There are many thousands of tons of plastic being used where it could be switched to a barrier coated board, and we are still early in the journey. However, we have a smattering of brands excited about the prospect of this project,” asserts McNeill.

The Cygnus Reelboard range is recyclable, repulpable, compostable and biodegradable.Versatile plastic replacements
One of the Cygnus Reelboard range’s primary benefits is its wide range of potential applications, says McNeill.

“Our range grades suit many applications, including a Kraft, a GC1 and a GC2 type board, and one of the world’s first food-safe, plastic-free grease and water-resistant black boards.”

“We then also have a range of specialist and performance grades that are multi-ply laminates.”

The Cygnus Reelboard range also achieves recyclability while being water and greaseproof.

“Many packaging converters often turn to PE coated boards when needing to source a board which has high water and grease barrier resistance properties,” says McNeill.

“These grades of board often have plastic extruded onto it, which makes it difficult to recycle, and subject to scrutiny and future taxes.”

“The lead-times of this board are also often lengthy, and plastic-laminated board often has a shelf life to contend with, something our range doesn’t suffer with.”

Cygnus Reelboard trials
The material has already been trialed in the UK, producing a considerable drop in plastic usage.

“One case study I can talk about was one of our pilot projects for our Cygnus Reelboard range. We helped Hull-based fish brand ‘Three Oceans Fish’ to remove plastic from its packaging using one of our performance grades,” explains McNeill.

“The packaging previously consisted of a plastic bag in a corrugated box, with a carton sleeve. After successful trials, the range moved into a mono-material box, plastic-free, recyclable and compostable. This move removed over 100,000 plastic bags per month.”

Future developments
Reelbrands is currently working on developing the fiber-based board range for broader uses.

“We have more grades to announce imminently, including a highly commercially competitive grade designed specifically for food trays and punnets, which we believe will be a game-changer.”

“We are also working on some flexible materials that can be used for vertical form fill and seal as well as pouch making, to be announced soon.”

By Louis Gore-Langton

To contact our editorial team please email us at editorial@cnsmedia.com