Sustainable packaging solutions are challenging, but feasible
Forming tubular bags from paper is a challenge. With the newly developed „paper-ON-form“, Syntegon has succeeded in reliably packaging a wide range of product formats in paper.
15 May 2020
With mono-material films, the three sealing parameters of pressure, temperature and time must be optimised. The perfect seam can only be created if these are harmonised. (Image: Syntegon Technology)
Food packaging has to perform well - and also fulfil all current sustainability requirements. The challenge for machine manufacturers is to reconcile the various requirements. A tricky but solvable task. Syntegon Technology takes on the task in co-operation with all those involved in the supply chain.
On the road to sustainable packaging solutions, the „Circular Economy“ pioneering. The approach aims to close energy and material cycles through the efficient use of resources, recycling and waste reduction in line with the circular economy. The Circular Economy Act defines a step-by-step sequence of waste prevention, reuse, recycling and other (including energy) recovery of waste and finally waste disposal. Priority is given to the best option from an environmental perspective.
Syntegon Technology has set itself the goal of making a contribution to sustainability with its packaging solutions. Cooperation with customers, packaging manufacturers and suppliers, which the company sees as part of the solution, is essential for this. Specifically, the aim is to make both the packaging itself and the packaging process more sustainable. This includes in particular in the recycling stage, the development and further development of machines that can process new, more environmentally friendly packaging materials.
[infotext icon] Only by involving material manufacturers, brand owners and their customers through to packaging material recyclers at an early stage can machine manufacturers develop solutions that close the raw material cycle, avoid waste and still fulfil the extensive requirements placed on packaging[/infotext].
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Recyclable monomaterials
In the area of plastic packaging, the trend is increasingly moving in this direction wherever possible, Monomaterials This means preparing the packaging material for recycling in an available recycling stream. This harbours Challenges for the composition and processing of the packaging materialMultilayer films delegate different tasks such as barrier protection, sealing or printing to individual layers made of different materials. These multilayer films are not homogeneous and cannot be separated in the recycling process as they consist of several plastics. The only option is often thermal utilisation.
A mono-material - even if the packaging also consists of several layers of the same material - has to do all the work on its own. This may mean that previous assumptions, for example with regard to shelf life, have to be reconsidered or that new, optimised processes in the supply chain have to compensate for shorter shelf lives. For recycling, however, the work becomes easier: The monomaterial can be fed directly into the recycling stream and fully utilised.
Another challenge is that consumers cannot directly recognise the difference between recyclable mono-material and multi-layer film. Food manufacturers are urged to take this into consideration when designing packaging and, if necessary, to Additional information on the packaging or make it available via QR code. Syntegon Technology offers proven track & trace solutions whose QR code can already be linked with additional consumer information.
„Together with all those involved in the supply chain, we are able to find pragmatic, innovative solutions that fulfil the complex market, customer and legal requirements and thus break new, more sustainable ground.“ Torsten Sauer, Project Manager Sustainability at Syntegon Technology
Paper packaging in vogue
Tubular bags made of paper are currently increasingly in focus as an alternative to plastic. Paper packaging also offers the advantage that consumers can recognise from the look and feel that it is a more sustainable material.
The processing of paper brings a total of several challenges The paper has to be moulded and processed in such a way that its Barrier properties remain in place. It must also be ensured that the Material not damaged during sealing becomes. A new moulding unit from Syntegon Technology forms the paper without creasing, scoring or cracking, while the customised sealing tools gently create the seams. The upgrade kit „paper-ON-form“ is available for horizontal flow-wrapping machines for both cold-sealing and heat-sealing applications.
In order to achieve the best sealing results, the manufacturer develops customised sealing jaws for each customer that are specially adapted to the desired material properties and pack sizes of the manufacturer. Firstly, the experts produce 3D-printed components in order to put the prototypes through their paces in the company's own test laboratory before the actual steel components are produced. Extensive tests and initial practical projects show that there are there are no restrictions on the application quantity and the The machinability of paper is in no way inferior to conventional packaging materials.t.
There is currently a whole range of paper suppliers offering a variety of papers with different barrier properties. The paper-ON-form„ retrofit kit“ can be used for Various types of paper and conventional materials which enables a gradual changeover to paper. The new moulding unit and the individual sealing tools can be installed on different Syntegon machines of various generations.
Forming tubular bags from paper is a challenge. With the newly developed „paper-ON-form“, Syntegon has succeeded in reliably packaging a wide range of product formats in paper. (Image: Syntegon Technology)
Circular economy hand in hand
Sustainable packaging has become a Sales argument, as they can increase both sales and customer loyalty. Modern consumers want to avoid waste as much as possible and favour recyclable packaging materials. According to a global retail study conducted by Nielsen, 55 per cent of online consumers from 60 countries are willing to pay more for products if companies are committed to positive social and environmental change.
However, the successful use of sustainable packaging can only succeed if all parties along the supply chain pool their respective competences. The aim is to test the machine capability of new packaging materials and provide assistance with packaging designs. Food producers can benefit from Syntegon Technology's international network of material suppliers.
