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PROCESSING & PACKAGING
Paper-based Syntegon packaging for ‘SENSitive foods’
As part of an EIT-funded project, Syntegon has developed paper- based trays and cups for sensitive food products. Together with partners from industry and research, namely Fraunhofer Institute for Process En- gineering and Packaging in Dresden, Colruyt Group, Strauss Group and the University of Reading, Syntegon is implementing the EIT project “PACK- 4SENSE” (Paper packaging for SENSi- tive foods) to develop a sustainable packaging concept. EIT Food, the world’s largest and most dynamic in- novation community, is supported by the European Institute of Innovation and Technology (EIT), a body of the Eu- ropean Union.
Stretchable, sustainable & tearproof
The aim of the project is to pack even sensitive products with high bar- rier properties in more sustainable ma- terials. Syntegon uses a special paper, which is particularly stretchable and tearproof thanks to long cellulose fi- bers, thus enabling the production of sealed trays and cups with a depth of up to 30 millimeters.
A recycable barrier layer made of 95% mono-materials provides optimal product protection. The paper and the barrier layer, as well as the cover film can be easily separated, ensuring full utilization of its recyclability.
This sustainability advantage,
EIT Food combines industry and research for environmentally friendly packaging solutions
however, also poses challenges for packaging manufacturers. On the one hand, consumers should be able to separate all components for waste sort- ing. On the other hand, paper and film must not be detached from each other unintentionally. To prevent this from happening, the TPU paper forming, filling and sealing machine from Syn- tegon forms paper and barrier layer in a common process by thermoforming and pressing. “With the paper-based trays from the “PACK4SENSE” project, we have further developed our previ- ous paper packaging solutions like the shaped paper pods – structured paper trays for the packaging of cosmetics and confectionery,” explains Matthias Klauser, Project Manager and Sustain- ability Expert at Syntegon.
Paper and barrier layer
The TPU has already been honored with the German Packaging Award in 2020 and is Syntegon’s flagship ma- chine for paper forming. For the PACK- 4SENSE trays and cups, the paper runs directly from the roll into the feeder – the barrier layer required for seal- ing is applied and joined to the paper without any further conversion step. Alternatively, manufacturers can use a converter to connect paper and pro- tective layer of mono-material without heating. A forming station presses the materials into shape before the trays are filled and sealed. In addition to using a particularly stretchable paper that can withstand wrinkling during the forming process, it is important to preserve the separability of the mate- rials: a specially adapted geometry of the forming tools reduces the tension on the materials during the manufac- turing process.
Syntegon is continuously working on further developing its paper-forming technology. EIT Food enables the com- pany to work closely with important partners and to test products together with consumers and food manufactur- ers. This cooperation makes it possible to develop prototypes and solutions that meet product requirements and optimize the sustainability of packag- ing step by step.
Using a particularly stretchable paper that can withstand wrinkling during the forming process on the Syntegon TPU machine, allows to form individual shapes for optimal product presentation. (Source: Syntegon)
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