TC Transcontinental Packaging launches 100 percent recyclable pouch on US market
28 Jan 2019 --- TC Transcontinental Packaging has launched a 100 percent recyclable, multilayer barrier stand-up pouch for loose tea, in collaboration with American tea company Harney & Sons. The pouch is designed to protect the flavor and freshness of the product while improving sustainability levels. It has been available in stores since November 2018.
“We worked to develop a product that is 100 percent recyclable and ready for in-store drop-off. Harney & Sons connected with our R&D team to create a solution that would support its mission of giving back to the environment that grows the tea of the world,” Rebecca Casey, Vice President Marketing & Consumer Market Development tells PackagingInsights.
The company partnered with Dow and Charter NEX Films to develop the sustainable pouch that claims to be 100 percent recycle-ready. It also boasts an EVOH (Ethylene vinyl alcohol) barrier for product preservation, seal strength, and durability.
“The film pouches can be recycled in almost any collection program that accepts plastic shopping bags. Most of the time, those collection systems are dedicated receptacles at retail stores. In the US, 74 percent of consumers live within ten miles of a drop-off receptacle at a retail location that will accept a recyclable pouch,” Adam Gendell, Associate Director, Sustainable Packaging Coalition (SPC) tells PackagingInsights.
“By promoting and supporting innovation in flexible packaging, we encourage more businesses to develop better eco-responsible solutions,” says Todd Addison, Vice President, Business Development at TC Transcontinental Packaging.
Chris Gandy, North America Market Manager for Dow Packaging and Specialty Plastics Adhesives business says that Dow’s comprehensive total pouch portfolio of resins, adhesives, and specialty products, combined with TC Transcontinental Packaging’s sustainability mindset and pouching expertise has allowed Harney & Sons to provide its customers with a more sustainable product.
Fine tea packaging requires a multilayer, co-extruded package to protect the product’s natural oils that give tea leaves a smooth flavor and finish. EVOH delivers a barrier to gases, organic vapors and moisture, preventing the deterioration of the product, thereby extending its shelf-life.
Barrier films are not easy to break down and recycle, rendering them an unsustainable choice. Dow’s RETAIN resin technology provides the solution to this concern by “compatibilizing” the barrier, thus allowing for a multilayer film to be fully recyclable, according to the company.
“Harney & Sons has always desired to use more friendly materials for our planet. Our goal is to move towards more recyclable and compostable components in our packaging,” states Emeric Harney, Harney & Sons Marketing Director.
Gendell explains that pouches tend to be very material efficient, lightweight, and with relatively low life cycle impacts like carbon footprint. However, there is still room for improvement when it comes to applying circular economy principles, he says.
“Designing pouches for recyclability is certainly a step forward. It helps capitalize on the environmental efficiency while improving the fit in the circular economy,” he notes.
Flexible packaging offers a number of sustainability benefits throughout its entire life cycle when compared to other package formats. Some of the benefits include:
- material/resource efficiency.
- lightweight/source reduction.
- transportation benefits due to inbound format and lightweight nature.
- shelf-life extension.
- reduced materials to landfill.
- high product-to-package ratio.
- beneficial life cycle metrics.
Challenging aspects in the development of the pouch
Despite the benefits, there are still challenges to overcome, says Casey. This includes significant hurdles during the development stage.
“Although the PE/EVOH combination is outstanding when it comes to preserving food and maintaining freshness, until now, barrier films could not be recycled because of the durability of the polymers involved, and the incompatibility of the polymers in the structure,” she notes.
Other challenges to consider were that the newly developed structure required the additional attributes of durability, while maintaining high production speeds and ensuring seal strength and package integrity and a great design, Casey explains.
Cost-effectiveness was also a significant challenge in the development of the new pouch. This is because flexible packaging film requiring these characteristics typically comes at a premium over traditional barrier film for food protection.
“Harney & Sons’ commitment to its environmental values which had them pursue the project despite the incremental cost. TC Transcontinental Packaging engineered a custom structure that would meet the needs of the customer and keep the premium to a minimum,” Casey concludes.
By Kristiana Lalou
