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Source: PackagingEurope
The primary challenge in creating a mono-material solution is preserving the barrier qualities during the retorting process, which occurs at very high temperatures. Willi Lindemann, a specialist in inline coating and New Technologies at Brückner, adds that transitioning to mono-material polypropylene poses another challenge due to the risk of shrinkage, which could adversely affect the barrier properties.
Nick Copeland, R&D director of Barrier Solutions at BOBST, notes that the goal of the companies was to develop an “ultra-thin, stretchable, heat-resistant” barrier primer combined with advanced opaque metallization. Brückner supplied the inline coating technology to stretch the primers and create very thin layers, focusing on achieving the appropriate hardness of the coating material to ensure it remains stretchable and can endure retort conditions.
The Bobst Expert K5 vacuum metallizer, featuring AluBond technology, was utilized to enhance barrier performance, adhesion, and maintain surface energy over time. Mitsui contributed its water-based Takelac polyurethane dispersion and top coating grade to further improve barrier performance and protect the AluBond layer. The company also introduced a newly developed Takelac Primer grade designed for heat resistance.
The partners have reportedly reached proof of concept for the solution and have conducted tests on the Oxygen Transmission Rate (OTR), Water Vapour Transmission Rate (WVTR), and adhesion levels before and after the retort process, yielding “excellent” results. Additional partners may be brought on board in the future to ensure the solution is robust, repeatable, and ready for production.
In other news, Siegwerk, Borouge, and TPN Food Packaging (TPN) have collaborated to create a fully recyclable, mono-material barrier stand-up pouch designed to offer robust protection and superior functionality. This solution aims to fulfill the requirements of converters, brand owners, and consumers seeking sustainable, high-performance packaging for oxygen-sensitive, dry products such as nuts and pet food.
Last month, Coveris unveiled its new resealable mono-material tray for refrigerated food applications, intended to replace non-recyclable, mixed-material packaging while ensuring extended shelf life and consumer convenience. This solution is ideally suited for processed meats, sausages, dairy products, cheese, and other chilled or refrigerated items.
Coveris has expanded its MonoFlexLite E portfolio—made with a single-layer polyethylene material—to include a recyclable solution with up to 45% post-consumer recycled (PCR) content, specifically engineered for wet wipe and cosmetics applications.
A Penteadora SA has successfully started up a complete mechanical textile recycling line and a needlepunch nonwoven line supplied by ANDRITZ at its production site in Unhais da Serra, Portugal.
The European Commission has adopted new EU-wide rules establishing the first official methodology for calculating, verifying, and reporting chemically recycled content in single-use plastic beverage bottles, primarily those made from polyethylene terephthalate (PET). Part of the Commission's broader plastics package, the initiative aims to create a transparent, level playing field and provide critical investment security for the European plastics recycling sector.