Sustainability is a key consideration in the development of modern packaging. Our joint project with the DMK Group demonstrates how ecological requirements can be combined with product safety, quality, machinability, transport stability, convenience, and an appealing appearance. We are using T-IML technology to redesign the packaging for the MILRAM herb and spice quark range. This is a combination of thermoforming and In-Mould-Labelling. This results in high-quality, decorated packaging made from monomaterials that meet all the requirements of a branded product. At the same time, the packaging is recyclable and resource-efficient.
When developing a new packaging solution, packaging developers must combine product protection, functionality, and environmental friendliness. This was also the case when revising the packaging concept for the MILRAM herb and spice quark range. The existing MILRAM quark packaging no longer met the DMK Group's current requirements. The redesign aimed to create a packaging solution that would meet ecological and economic requirements. Specifically, the aim was to maximise the recyclability of the cup and significantly reduce the amount of material used. At the same time, current design trends from the packaging industry were incorporated to modernise the cup's appearance without compromising its functionality.
The original packaging weighed 11.52 g and comprised a PET cup with a paper sleeve, an ALU-PET lidding film, and a PET snap-on lid. Thanks to the new, optimised packaging solution, the total weight has been reduced to 8.4 g and it now consists of a PP cup with IML, an ALU lidding film and a PP snap-on lid. This 27% reduction equates to more than 200,000 kg per year. Using fewer materials and a mono-material approach reduces GHG emissions by around 20 per cent compared to the old packaging (18.4 kg CO₂eq instead of 23.09 kg CO₂eq per 1,000 cups).
The previous packaging consisted of a PET cup with a paper sleeve, an ALU-PET lidding film and a PET snap-on lid. Now the MILRAM packaging consists of a PP cup with IML, an ALU lidding film and a PP snap-on lid. The printing inks previously used have been reduced to a minimum to reduce the amount of impurities in the recycling stream and as a basis for higher recyclate quality. The mono-material approach has improved the recyclability of the overall packaging XY% to 98.3%.
T-IML combines the well-known processes of thermoforming and In-Mould-Labelling. During this process, a heated film is formed using compressed air. At the same time, a pre-printed plastic label made of the same material as the container is bonded to it. This enables the production of extremely lightweight packaging from mono-materials. The improved recyclability and low weight of these mono-material solutions significantly reduce greenhouse gas emissions.
The larger opening flap on the sealing plate makes it easier for the consumer to grip and open the flap. The optimized tear-open behavior allows for better separation of the lid and cup, which is also conducive to recyclability.
The design relaunch was accompanied by a conscious decision in favor of the snap-on lid. The improved product protection keeps food waste to a minimum.
There are numerous potential savings along the value chain. We would be happy to present these to you in a personal meeting:
The choice of materials and the mono-material approach reduce the overall weight of the packaging
Recyclable thanks to monomaterial and design adaptations
MARCO VON DÖLLEN
The EU Packaging & Packaging Waste Regulation (PPWR) sets out the framework conditions for how packaging should be designed in the future. Unnecessary packaging and packaging waste should be reduced and reusable systems and recycling should be promoted. In our opinion, plastic packaging meets precisely these requirements, as plastic is more efficient than alternative materials.
Plastic is more efficient than alternative materials.
PPWR is driving deforestation and the growth of mountains of waste.
100% in unregulated sectors (e.g. nonfood) creates incentives for investment in mechanical recycling.
Recyclability and the use of recyclates are the basis for a functioning circular economy.
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