Syntegon produces recyclable paper trays and cups for sensitive foods with EU backing
03 Jan 2022 --- Syntegon is launching a portfolio of paper-based trays and cups for sensitive food products. The barrier layer of each product is composed of 95% monomaterial and easily detachable, aiding recycling efforts.
The portfolio is designed as part of a European Institute of Innovation and Technology (EIT) Food project, titled Pack4Sense, which aims to improve the environmental sustainability impact of industry’s shift toward fiber-based materials as anti-plastic legislation comes into force throughout the world.
Innova Market Insights pegged “Fiber-based Frenzy” as a top trend for 2021, noting 72% of global consumers and 62% of US consumers recognize paper’s “exceptional” recyclability.
The Pack4Sense project (Paper packaging for Sensitive foods) brings together partners from industry and research, namely Fraunhofer Institute for Process Engineering and Packaging, Colruyt Group, Strauss Group, the University of Reading and Syntegon.
EIT Food claims to be the world’s largest and most dynamic innovation community and is supported by the European Union.
Stretchable paper can withstand wrinkling during the forming process thanks to the TPU machine.Pack4Sense
The Pack4Sense project aims to pack even sensitive products with high barrier properties in more environmentally sustainable materials. Syntegon uses a special paper, which is particularly stretchable and tearproof due to long cellulose fibers, enabling the production of sealed trays and cups with a depth of up to 30 millimeters.
A recyclable barrier layer made of 95% monomaterials provides optimal product protection. The paper, barrier layer and cover film can be easily separated, ensuring simple recyclability.
“With the paper-based trays from the Pack4Sense project, we have further developed our previous paper packaging solutions like the shaped paper pods – structured paper trays for the packaging of cosmetics and confectionery,” explains Matthias Klauser, project manager and sustainability expert at Syntegon.
However, the environmental sustainability advantage provided by easily separable and stretchable paper also poses challenges for packaging manufacturers, says Syntegon.
An example of Syntegon’s new paper-based trays.On the one hand, consumers should be able to separate all components for waste sorting. On the other hand, paper and film must not unintentionally be detached from each other.
To prevent this from happening, Syntegon’s TPU paper forming, filling and sealing machine can form a paper and barrier layer in a common process by thermoforming and pressing.
TPU to the rescue
The TPU machine, which was granted the German Packaging Award in 2020, is Syntegon’s flagship machine for paper forming.
For the PackforSense trays and cups, the paper runs directly from the roll into the feeder, while the barrier layer required for sealing is applied and joined to the paper without any further conversion step.
Alternatively, manufacturers can use a converter to connect paper and a protective layer of monomaterial without heating. A forming station presses the materials into shape before the trays are filled and sealed.
Besides using stretchable paper that can withstand wrinkling during the forming process, it is important to preserve the separability of the materials: a specially adapted geometry of the forming tools reduces the tension on the materials during the manufacturing process.
Syntegon says it is continuously working on developing its paper-forming technology. EIT Food is enabling the company to work closely with important partners and test products together with consumers and food manufacturers.
By Louis Gore-Langton
