Syntegon, Taghleef and Polifilm brew up “aroma-proof” packaging for coffee

17 Aug 2020 --- Syntegon, Taghleef Industries and Polifilm have joined forces to develop an aroma-proof polypropylene (PP) monomaterial solution for coffee packaging. The cooperative project yields the “best aroma and product protection combined with 100 percent recyclability,” film extrusion specialist Polifilm declares. The joint move provides a closed-loop solution to conventional coffee packaging that uses aluminum-containing composite, which is a “classic example of poorly recyclable solutions.”

“It is Syntegon’s target to build a wide network with material suppliers to validate materials in terms of machinability and package quality, and as a result be able to offer whole packaging solutions to our customers,” Torsten Sauer, Head of Sustainability at Syntegon, tells PackagingInsights.

“By doing so, we strive to establish Syntegon’s reputation as a strong player in the industry when it comes to sustainable packaging solutions. Polifilm is one of our partners who approached us with its high barrier Mono-PP material solution which was successfully validated and offered on our virtual interpack show,” he continues.

Although mixing different coffee beans can provide a coveted flavor blend, mixing different plastic materials results rather in structures that do not meet recyclers’ approval. Circumventing this issue, Taghleef Industries’ printable biaxially oriented PP (BOPP) film Extendo goes “hand-in-hand” with Polifilm’s PP sealing film, the company states. Extendo barriers are currently used in Corny snack bars, for example.

Extendo barrier films help propel oxygen, moisture and mineral oils in food packaging, while protecting aroma (Credit: Taghleef Industries).The Polifilm PP film has a wide sealing window that allows larger tolerances in machine settings and thus stabilizes the packaging process. To ensure that the solution can be processed on common packaging machines, Polifilm focused on minimizing the early seal initiation temperature of the PP sealing film.

This is necessary when using BOPP as an outer layer to achieve a sufficiently wide sealing window in the common heat-sealing process despite the lower temperature stability compared to conventional PET.

Sealing the deal
The right sealing starting point and the appropriate sealing temperature are “decisive in the processing and beyond,” adds Jens Kölble, Head of Packaging & Performance Films at Polifilm. “They determine the subsequent functionality, as well as the resilience of the solution. The crucial product protection provided by the stability of the packaging solution is also a key criterion for Syntegon who is the supplier of process and packaging technology.”

As a final step, Syntegon processed both films into flow packs and reclosable stand-up pouches sealed with a zipper. By avoiding the use of a further group of materials in addition to the PP used, the resulting packaging can be recognized by recycling machines as PP monomaterial and can be materially recycled without further separation.

Returning to the cycle of materials, the resulting recyclate can be used again in other plastic applications. Outside of coffee applications, this concept is applicable for other food and non-food packaging, such as for detergent or hygiene products.

When asked whether Syntegon was presented with any particular challenges within its partnership role, Sauer replies: “We have a long history of packaging coffee at Syntegon and offer numerous technologies specifically designed for this industry, from vertical bagging, vacuum packaging up to aroma protection valves, so we already have insight in the packaging challenges of coffee producers and are happy to support them on their journey to more sustainable packaging.”

“Our goal is to ensure a consistently good packaging quality with high machine efficiency and availability, also with new sustainable packaging materials,” says Sauer. “In addition, it is important for us to support our customers in the changeover to sustainable packaging material. In doing so, we are pleased to accompany our customers all the way to the finished product on the shelf,” he concludes.

By Anni Schleicher

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