Infinite circularity? Industry leaders tout metal’s efficacy in flexible packaging

26 Jul 2023 --- Metal-based packaging is suitable across industries, but especially for flexible packaging, according to experts. It is lightweight, strong and does not rust. Metal is commonly used in the aerospace, automotive, construction and packaging industries. Because it is easy to recycle, it is also an environmentally friendly choice. 

Constantia Flexibles finds aluminum to stand out as an “exceptional” material, as its value chain has embraced circular economy principles for decades. “When we recycle aluminum, we can turn it into new products without having to mine for more raw materials. Recycled aluminum can be used to make almost anything new aluminum can be used for,” a company spokesperson tells us. 

Meanwhile, Innova Market Insights finds that the use of metal in F&B packaging is increasing, featuring a 1% average annual growth (Global, CARG 2018-2022). While more than one-third of metal packaging launches are for Baby & Toddler products, the fastest-growing category in metal packaging is Meat, Fish & Eggs. 

Furthermore, the market researcher identifies BPA-free as one of the fast-growing environmental claims in metal packaging launches, while Recyclable packaging is the leading claim.

Aluminum is easily recyclable, providing environmental and financial benefits for a circular economy.Infinite recyclability 
Aluminum is easily recyclable, providing environmental and financial benefits that help create a circular economy. Unlike many other materials, aluminum does not degrade during the recycling process, which means it can be recycled repeatedly without quality or property loss.

Constantia Flexibles explains that recycling aluminum requires about 5% of the energy needed to produce primary aluminum from bauxite, resulting in energy savings and reduced GHG emissions.

“The recycling process for aluminum involves several steps. First, aluminum products, such as cans or foil, are collected and sorted into different alloy grades at recycling centers. The aluminum is then cleaned, shredded and melted to create new aluminum products. Overall, the recyclability of aluminum is one of its key advantages, making it an important material for sustainable manufacturing and consumption,” says the company spokesperson.

But discussing sustainability involves considering material recyclability and its carbon footprint. Low-carbon aluminum refers to a production process that generates fewer carbon emissions than traditional production methods.

Aluminum is typically produced through the Hall-Héroult process, which involves the electrolysis of alumina in an electrolysis cell. This process requires a lot of electricity and, if generated by burning fossil fuels, leads to significant GHG emissions.

Low-carbon applications 
Various techniques are developed and implemented to reduce aluminum production’s carbon footprint.

Constantia Flexibles launched its monomaterial fold wrap branded EcoAluLam. Due to the aluminum’s absolute barrier, EcoAluLam protects food products and allows for a premium presence on supermarket shelves.

Duplex aluminum structure with unique folding properties to replace multi-material structures.Constantia’s EcoAluLam for chocolate bars. 

Eviosys recently launched a food can with a peelable foil directly sealed on the body of the can, branded Ecopeel. The solution is said to reduce the carbon footprint of canned food items by up to 20%. 

“Ecopeel seals the can with foil via Direct Heat Seal Technology, which makes the customers’ filling process five times faster, cleaner and safer, reducing spoilage and energy usage. Having a more peelable closure means consumers have greater access to the can for full aperture, so the contents are more accessible and can all be fully removed, reducing food waste,” Tomas Lopez, CEO at Eviosys, told us.

In the alcoholic beverages segment, Amcor Capsules and Aludium marketed aluminum for use in screw caps with more than a 50% reduction in carbon footprint compared to primary aluminum sold in Europe.

“Our aluminum screw caps have been made using exclusively European-based aluminum, resulting in an average CO2 emission that is already lower than any other region. As a result, Amcor screw caps are well positioned against other screw caps on the market that use a blend of European and non-European aluminum,” Yannick Magnon, Amcor Capsules general manager, told Packaging Insights.

“The goal of low-carbon aluminum production is to minimize the environmental impact of aluminum production while still meeting the increasing demand for this versatile and widely-used material,” explains the Constantia Flexibles spokesperson.

Metal-based pack demand
The demand for more environmentally sustainable products is growing, and Constantia Flexibles says it is committed to meeting these demands. 

“We offer our customers a comprehensive 360-degree material approach, which encompasses considering the specific needs of the product in terms of protection while prioritizing minimizing its environmental impact. Our decisions are based on facts derived from LCAs, ensuring that comprehensive ecological analyses support our choices.”

In pursuing materials that balance product integrity and sustainability, aluminum has emerged as an “excellent choice,” the spokesperson says.

“With over half of our product solutions being aluminum-based, we benefit from its unique properties and recyclability. By leveraging the strengths of aluminum, we meet our customers’ requirements and contribute to a more sustainable future,” concludes the spokesperson.

By Natalie Schwertheim