Alpla’s thin-walled containers meet PPWR regulations
Alpla will produce thin-walled containers for dairy products using recycled PET for the first time.
The creative solution satisfies every PPWR criterion and is scheduled to begin series production in the fourth quarter of 2025.
Together with machine manufacturer Engel, mould maker Brink, label maker iPB Printing and joint venture partner Intopack, the injection moulding division ALPLAinject has succeeded in producing thin-walled PET plastic cups with recycled material via rePETec – the interplay of technology, mould, process and material treatment. A single-stage injection moulding process allows for fully recyclable packaging made of up to 100 per cent rPET. Alpla explained, by way of example, that 30 per cent recycled material content required by the PPWR for PET is easily possible.
With PPWR (Packaging and Packaging Waste Regulation) setting the direction of travel for dairy products such as yogurt, cheese spreads, pudding, cream and curd cheese are to be packaged in a more environmentally friendly way in the EU in the future, from 2030, plastic food packaging must contain a minimum percentage of recycled material – otherwise penalties may be imposed.
The problem: cups for dairy products are made of PP (polypropylene) or PS (polystyrene) – and for both there is no approved recycling material from the mechanical recycling process for contact with food. Small quantities are only available through chemical recycling, which is far more costly and energy-intensive.
“With rePETec, we create stable packaging with thin walls made of rPET, can recycle it after use and access the existing and established PET recycling stream. None of this has been feasible so far. With this solution, manufacturers of dairy products meet all legal requirements and at the same time strengthen the regional circular economy,” explained Thomas Maibohm, head of sales and product management thin-wall packaging at Alpla. Following the successful test phase, Alpla and Intopack are planning to start series production from the fourth quarter of 2025 – initially with the two standard formats of 180 and 300 millilitres. Depending on the customer’s requirements, the filling volume can be from 100 to 500 millilitres.
0.32 millimetres thin walls and integrated in-mould labelling (IML) minimise weight and material consumption. The higher specific weight of rPET is more than compensated by significantly better barrier properties. This increases the shelf life compared to conventional PP cups. ‘This opens up new opportunities for dairy products and can prevent food waste,’ said Thomas Maibohm.
The high-quality rPET is contributed by system provider Alpla from its own recycling plants in Europe.”‘Quality and availability are guaranteed in the long term,” added Thomas Maibohm, emphasising the benefits. After use, the PET yogurt pots can be included in the already established PET bottle cycle. The PP label is first removed from the packaging during mechanical recycling.
“The cups enrich the ‘bottle-to-bottle’ cycle. In the future, a bottle can become a cup and then back into a bottle and so on. This saves resources, avoids waste and is financially unbeatable,’ Maibohm stressed.
