Weekly Roundup: Unilever’s Hellmann’s transitions to rPET, Amcor invests in ePac Flexible Packaging

23 Apr 2021 --- In packaging news this week, Unilever brand Hellmann’s transitioned its “squeezy” condiment range to 100 percent recycled PET (rPET) bottles in the UK. Amcor announced a US$10-15 million strategic investment in ePac Flexible Packaging. Taco Bell revealed a pilot program to recycle sauce packets with TerraCycle. Also, BASF, Quantafuel and Remondis signed a Memorandum of Understanding (MoU) to jointly evaluate a cooperation in chemical recycling.

In brief: Recycled PET
Unilever condiment brand Hellmann’s transitioned its UK “squeezy” range to bottles made from 100 percent rPET. The transition is expected to complete by the end of 2022, with 40 percent of the products already hitting shelves in rPET. “With our new 100 percent recycled plastic bottles, which are also fully recyclable, we’re providing shoppers with an accessible and simple way to help make their households and mealtimes more sustainable,” commented Andre Burger, vice president of foods and refreshment for Unilever UK&I. “Our Hellmann’s bottles are our first food brand in the UK to use 100 percent post-consumer recycled plastic, and while making the switch has not been without its challenges, these learnings will enable us to accelerate the move of other Unilever food brands to using more recycled plastic too.”

Avient launched ColorMatrix Optica PET blue toners and colorants for the enhanced recyclability of PET packaging. Variations in the aesthetic appearance of rPET are caused by multiple heat cycles as the material is recovered and reused, including yellowing and other color variations. Also, processing efficiencies are reduced as the material is recycled. Formulated for addition to virgin PET and rPET, heat-stable ColorMatrix Optica blue toners work to correct and reduce the yellowing or color variation typically occurring during the recycling process.

Cocofloss unveiled a new dental floss composed of 85 percent recycled polyester, sourced from post-consumer PET water bottles. The company aims to divert more than 500,000 water bottles from landfills over the next 12 months. The new material requires fewer processing stages and takes 64 percent less energy to make than virgin polyester, resulting in 32 percent less CO2 emissions and 94 percent less water consumption, Cocofloss shares.Avient’s ColorMatrix Optica PET blue toners and colorants.

In brief: Acquisitions and investments
Amcor announced a strategic investment in ePac Flexible Packaging, a leader in the high-quality, short-run length digital printing segment for flexible packaging. The investment will range between approximately US$10-15 million, including a minority ownership interest in ePac Holdings LLC and funding for one or more ePac sites. ePac has a fast-growing international footprint and is focused on servicing the needs of small and medium-sized consumer goods customers through a digitally-enabled and scalable business model. With 18 sites fully operational and five more currently underway, ePac serves thousands of customers around the globe and generates annual revenues of approximately US$100 million.

ProAmpac acquired El Dorado Packaging, a leading US producer of consumer and industrial multi-wall packaging solutions. The terms of the transaction were undisclosed. El Dorado manufactures customized paper-based packaging and printing solutions for retail and industrial markets. With three plant locations in Arkansas, Minnesota and Nebraska, El Dorado produces paper self-opening sacks, rollstock for consumer packaging and industrial multi-wall bags for foodservice, seed, animal health and chemical markets.

Smurfit Kappa invested a further €35 million (US$42 million) in its Hoya paper mill and board manufacturing plant in northwest Germany. It is the latest phase of an investment program commencing in 2011. This final phase will see production output increase by 70 kt to 450 kt per annum. The investment will replace the complete press section of the PM2 paper machine with new state-of-the-art technology, increasing the overall efficiency of the manufacturing process.

In brief: Recycling partnerships
BASF, Quantafuel and Remondis signed an MoU to jointly evaluate a cooperation in chemical recycling, including a joint investment into a pyrolysis plant for plastic waste. Remondis, one of the world’s leading waste and water management companies, intends to supply suitable plastic waste to the plant while BASF will use the resulting pyrolysis oil as feedstock in its production Verbund as part of its ChemCycling project. Quantafuel intends to provide the technology and to operate the plant. The company is a specialist for the pyrolysis of mixed plastic waste and the purification of the resulting pyrolysis oil. The technology is jointly developed and being held with BASF. The location of the pyrolysis plant is to be confirmed.Cocofloss’ dental floss made of 85% recycled PET bottles.

Taco Bell announced it will be launching a pilot program to recycle sauce packets with international recycler TerraCycle later this year. The fast-food restaurant will become the first QSR brand to partner with TerraCycle to tackle recycling flexible film packets. Taco Bell sells around 8.2 billion sauce packets in the US annually. TerraCycle is renowned for collecting traditionally non-recyclable materials, cleaning, melting and remolding them into hard plastic to mark recycled products. Taco Bell has pledged to make all consumer packaging recyclable, compostable or reusable by 2025 worldwide.

TerraCycle also partnered with Sanofi Consumer Healthcare, makers of the Gold Bond, Cortizone-10 and Selsun Blue brands, launching two national recycling programs for its personal care product packaging and aerosol containers. Consumers are invited to recycle their empty packaging using free shipping labels. Once collected, the waste is cleaned and melted into hard plastic that can be remolded to make new recycled products, such as park benches and picnic tables.

In brief: Fiber-based launches
Sappi expanded its product range for corrugated board applications with Fusion Nature Plus, an uncoated, fully bleached and fully recyclable virgin fiber liner. Fusion Nature Plus offers “excellent” printing results in flexographic, digital and offset printing processes. The virgin fiber liner is based on the concept of the successful Fusion Topliner. In contrast to the double-coated Fusion Topliner, Fusion Nature Plus has a natural, uncoated surface with a more tactile feel in response to the growing market for this product, Sappi says. The liner is also provided in very low grammages.

BillerudKorsnäs introduced the latest development in White Top Kraftliner. Pure DecorX is a 3-ply construction made of 100 percent primary wood fibers for a strong and stiff liner, providing lightweighting opportunities, high runnability in converting machines, reduced risk of washboarding and enhanced packaging performance. Pure DecorX is also renewable, recyclable and biodegradable, while the fibers can be traced back to responsibly managed forestry.BillerudKorsnäs’ Pure DecorX White Top Kraftliner.

In brief: Plastic film launch
Wipak introduced the newest member of its sustainable range: SC ECO XX XPP, a recyclable PP-based thermoformable film with a high barrier. The films are designed for thermoforming applications and vacuum packaging. “Our new SC ECO XX range shows excellent results on the packaging machines,” says Wipak’s manager for application service and R&D, Kai Nieber. “With this thermoformable mono-PP solution, common PA/PE films, such as those used in vacuum applications, can be replaced. Due to the special manufacturing process and the use of high-performance raw materials, these films offer exemplary mechanical properties, high puncture resistance, excellent forming behavior, and great transparency.”

In brief: Climate pledge
Greif, a leading industrial packaging and services provider, set a goal to reduce its absolute Scope 1 and 2 Greenhouse Gas (GHG) emissions by 28 percent by 2030. This target aligns with the prevailing climate science limit of keeping global warming below 2 °C. The company will also further investigate its Scope 3 GHG emissions and decide about pursuing a net-zero carbon aspiration by the end of 2023. Greif’s new goal builds on its near 15-year commitment to sustainability and an 11 percent emissions reduction per unit of production achieved in 2019.

In brief: Plant-based production
Avantium and sugar beet processor Cosun Beet Company, part of Royal Cosun, revealed plans to jointly construct and operate the first commercial plant to produce plant-based glycols using Avantium’s Ray Technology. Cosun Beet Company and Avantium entered into a Term Sheet to establish a joint venture in which Cosun Beet Company will take a substantial share. The companies plan to form the joint venture in 2021 to make an investment decision for the foreseen commercial plant in the first half of 2023 and commercial operations commencing in 2025. The joint venture is envisioned as a world-class producer of plant-based glycols, actively contributing to a fossil-free future.

By Joshua Poole

Smurfit Kappa invested a further €35 million (US$42 million) in its Hoya paper mill and board manufacturing plant in northwest Germany.