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The introduction of new sustainable options for food packaging is always of interest, but when it can replace polymers that the company has eliminated due to environmental reasons, the acceptance will be higher.
Proposition 65's health and safety concerns about styrene have prompted some brands to replace polystyrene (PS), which has long been the default polymer choice for form-fill-seal thermoforming in food packaging applications. Another disadvantage of PS is that the material is usually not recycled. Therefore, many brands promise to transition food packaging solutions from PS by 2025, or even before 2022.
Assuming that performance, barrier, and mechanical properties must be maintained without increasing costs or large capital expenditures to replace existing systems and processes, it is not easy to replace undesirable materials with more sustainable solutions.
This is why ICPG's XPP reinforced barrier polypropylene was created as an optimized direct substitute for yogurt multi-packaging and single cups for creamers, puddings, condiments, dips, shelf-stable beverages, etc.
ICPG’s Commercial Director Michael Moren answered our questions about this innovative new food packaging option.
Why is the timing good for XPP? Moren: The global demand for more sustainable and recyclable packaging solutions, coupled with Proposition 65 concerns about health and safety, has prompted brand owners to find alternative solutions to materials that meet these concerns. Many have committed to 2025 This was done in 2016. However, historically, they have found a solution that allows them to achieve their goals while maintaining all the positive features of current packaging solutions-processing, barrier protection, compatibility with existing systems and processes, cost , Has always been a challenge. So far, there is a lack of solutions in one or another key area, which is why the status quo is maintained. Through XPP, we have developed solutions that meet all key issues and requirements.
What are the key attributes? Moren: This material enhances the key performance attributes of FFS, which are usually not observed in traditional PP solutions, such as enhanced stiffness, "elasticity" and controlled shrinkage. This more sustainable and recyclable PP solution eliminates the health and safety issues of Proposition 65 for food packaging. This material also provides stronger barrier protection than PP and PS without the use of special barrier materials or coatings.
Please pay attention to the sustainability advantage.
Moren: In its simplest form, XPP is a single-material PP solution. Therefore, it benefits from the many sustainable properties of PP, including less solid waste by weight, less carbon dioxide equivalent by weight, and more Low fuel consumption and fewer emissions. Compared with packaging alternatives with higher weight and density.
In addition, XPP also has enhanced features that can provide additional sustainability advantages, such as inherent barrier enhancements, which provide an opportunity to extend the shelf life potential. We know it is the key to reducing food waste.
In addition, as a single-material PP solution, XPP improves the convenience of recycling compared with alternative barrier solutions such as high-impact polystyrene (HIPS)/polyvinylidene chloride (PVDC). Finally, the increase in material rigidity provides an opportunity to reduce the size of the existing structure, thereby reducing the amount of material used, increasing the output, increasing the efficiency and reducing the weight of the parts.
How is the barrier achieved? Moren: This technology is proprietary, but we can say that no traditional functional barrier materials, additives or coatings are used. This helps simplify materials and allows us to control costs for our customers. In order to meet high barrier specifications, we can add ethylene vinyl alcohol (EVOH) when needed to enhance barrier protection.
How much research and development did you participate in? Moren: ICPG has been working on this development since 2019.
In what form is the material provided? Moren: XPP is available in extruded coil form for rigid thermoforming and FFS food packaging applications. The material can be provided in custom roll sizes, with specifications ranging from 0.016 inches to 0.060 inches wide and 15 to 37 inches wide.
Does the machine need to be replaced compared to PS?
Moren: All settings adjustments were very small, did not result in throughput loss, and did not have any capital equipment modifications required to convert the production line from PS to XPP.
What is the cost premium? Moren: It is very important for us that this solution does not increase the cost of brand owners. Our case studies show that, in addition to all other sustainability and functional advantages, we can save costs for many applications compared to alternative PS or PET solutions.
The ready-to-use nature of the solution means that brand owners can also save money on capital expenditures to replace or make major modifications to existing equipment required for replacements. In addition, compared with PS and PET, due to the reduced material density, it can significantly save materials and increase production.
What is the current level of interest? Moren: We have seen many companies looking for alternative solutions for their current PS form-fill-seal food packaging. They were surprised that the performance of this material was exactly as advertised, and they were excited about the potential to revolutionize their product portfolio.
Some of us even recently said to us, "Where have you been all the time?!", which lets you know how difficult it is to find such a solution over the years. We are here now, ready to bring this solution to the market and help our customers achieve their goals.
Is there a company using or testing it? Moren: XPP is currently available for purchase from ICPG. The specific information about the customer's application is confidential, but I can say that we have successfully verified the materials on the FFS and thermoforming equipment that are usually used with PS.
In short, what should brands know about XPP? Moren: Brand owners should know that this solution can solve all their problems related to PS replacement and sustainability issues of FFS food packaging. This is indeed a complete solution, and our team is always ready to provide the support you need to help you achieve your goals.
Final thoughts? Moren: This is an extremely versatile solution that can be used in various packaging/sterilization processes, including: aseptic, hot-fill, distillation, modified atmosphere packaging, high-pressure processing (HPP), form-fill-seal and heat Forming; suitable for various markets, including: applesauce, baby food, dairy products (including yogurt and creamer), coffee and tea bags and capsules, shelf-stable beverages, single-serve fruit and vegetable cups, single-serve condiments, dips Sauces and sauces, pet food, snack packs and mobile products.
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