Unilever and Mondi dish up aluminum-free paper-based packets for Colman’s Meal Makers

22 Jul 2021 --- Unilever and Mondi are unveiling a jointly-developed, recyclable, paper-based packet for Unilever’s Colman’s brand. The packet is aluminum-free and reduces plastic content to 15 percent in the form of an ultra-thin functional plastic layer. 

Innova Market Insights pinpointed the Fiber-based Frenzy as a key packaging trend for 2021 earlier in the year, documenting the rising sophistication of fiber-based solutions as viable alternatives to single-use plastics.

Innovation in plastic-replacement fiber-based solutions is booming as brands explore plastic waste escape routes and new connections with the enlarging eco-conscious consumer base.

The global market researcher found 72 percent of global consumers recognize paper-based packaging as having exceptional recyclability.

However, 32 percent of global consumers are concerned paper-based packaging does not provide adequate product protection.

Mondi’s EcoSolutions approach – based on the mantra of “paper where possible, plastic when useful” – has supported Unilever’s aim to halve the amount of plastic used in its packaging with a high-barrier, recyclable packet for Colman’s dry Meal Maker and Sauces range.

“[The EcoSolutions approach] allows us to ask the right questions and assess what technical specifications are required by the packaging. The answers to these questions help us determine the best sustainable solution for the packaged item in question,” Torsten Murra, global head of key accounts consumer flexibles at Mondi tells PackagingInsights.

“Our extensive skills in paper manufacturing and design, our coating experience and our knowledge of plastics combined with packaging application put us in a great space to supply a series of balanced solutions to a very complex marketplace.”The packet is 85% paper and has an ultra-thin functional plastic layer for and providing barrier protection.

“The challenge [for Colman’s] was to create a recyclable packaging that offers the same barrier protection as the previous solution without using aluminum. We’ve performed a wide range of tests (for example, selection of material, shelf life tests, trials on pilot lines, printing trials) to determine the best and most suitable packaging that would hit the spot between performance and most efficient use of material.”

Aluminum-free, plastic-reduced
Mondi has confirmed the packets are recyclable in existing UK paper waste streams. Moreover,  the new packet has a paper content of 85 percent and an ultra-thin functional plastic layer for sealing the packaging and providing barrier protection for the food.

Mondi and Unilever’s R&D teams identified this layer as the minimum acceptable protection needed to ensure a long shelf life while maintaining high quality and reducing food waste.

Unilever indicates it is focused on “the principle of a circular economy and the importance of creating value within it.”

Two of the company’s key targets are to transform its entire packaging portfolio into technically recyclable, reusable or biodegradable solutions, and halve the amount of plastic used by 2025, which this new packaging solution addresses.

“At Colman’s, we’re big and bold when it comes to our flavors, and we’re keen to make equally bold steps when it comes to our sustainability commitments,” comments Fikerte Woldegiorgis, foods marketing director at Unilever UK&I. 

“We are delighted to partner with Mondi to develop this recyclable paper packaging, becoming the first big brand within the category to do so.”

“The new packaging, which uses a paper-base, ensures shoppers can enjoy the same great tasting product they know and love, and now with the added benefit of being able to recycle the packs.”

COVID-19 hurdles
The two companies collaborated throughout the development process, including overcoming the challenge of limited access to production facilities during the COVID-19 pandemic.

Starting with a proof of concept, followed by extensive line trials at both Mondi and Unilever’s R&D pilot plants, provided the flexibility to quickly prototype and test the unique packaging material before scaling up.According to Innova Market Insights, 72% of global consumers recognize paper-based packaging as having exceptional recyclability.

This collaborative method goes to the heart of Mondi’s EcoSolutions customer-centric approach of working closely with its customers to ensure the best possible and most environmentally sustainable product is created while meeting the customer’s requirements.

“MAP2030, Mondi’s action plan for the next ten years to achieve our ambitious 2030 sustainability commitments, focuses on circular driven packaging and paper solutions, created by empowered people, taking action on climate,” outlines Torsten Murra, global head of key accounts consumer flexibles at Mondi. 

“By working closely with Unilever, we were able to co-create a packaging solution that will deliver on all counts and is recyclable, providing a valuable resource for the circular economy to drive real change toward a more sustainable future.”

Mondi recently struck a three-year partnership with the International Union of Forest Research Organizations to identify science-based solutions to climate-related threats to forests and forest-based industries.

PackagingInsights recently explored the key trends in soups and sauces packaging with leading flexible packaging suppliers ProAmpac, Amcor and Huhtamaki and carton pack giant SIG.

By Joshua Poole

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