At FACHPACK 2024, Constantia Flexibles will display its ‘industry-first’ print service for aluminium and PET die-cut dairy lids, alongside its range of sustainability-minded packaging solutions from a paper twist-wrap to a compostable coffee capsule lid.
Constantia Flexibles claims to be the only flexible packaging company able to digitally print full-surface and water-based onto aluminium without compromising its sealing conditions. Currently, its technology is able to print on aluminium and PE, although it is set to be extended to all substrates in the future.
Its digital print service will be showcased at FACHPACK. Constantia believes that its ‘competitive’ speed will fast-track product development, approval, and shipping in ‘unprecedented’ time.
Unlike conventional printing solutions, this service intends to negate the need for printing clichés, plates, or cylinders. Furthermore, it is set to reduce costs by requiring less artwork preparation at the repro house.
It pursues consistent print quality by covering 93% of all Pantone colours and supporting short-runs, reducing working capital, and allowing for multiple customization within a batch – all while keeping material waste at a minimum, Constantia says. It also claims to utilize water-based inks in line with food safety and sustainability standards.
With the company claiming that a recyclable alternative is available for over 90% of its portfolio, it is set to display its ‘360-degree materials approach’ of aluminium, film, and paper solutions the trade fair. This will include its Ecolutions packaging range, encompassing a range of food and beverage applications.
EcoPeelCover is a thinned lidding solution for polypropylene and polyethylene cups. Having received a German Packaging Award in 2024 under the Sustainability – Material Reduction category, it is said to reduce aluminium thickness by 25% and the coating layer by 50%.
Apparently, it offers various high-barrier properties to extend the shelf life of dairy products, alongside an easy-peel coating to facilitate smooth, consistent opening. It is also reported to provide reliable sealing and high corrosion resistance, and to operate at temperatures between 180°C and 230°C.
EcoPeelCover comes with solvent-free UV-Flexo printing, Constantia says, with its reduced material consumption and lighter transport weight expected to lower its carbon footprint. Customers can also request the solution in Low Carbon Aluminium (Lowcarbalu) with ASI-certified quality.
In line with global sustainability goals, Lowercarbalu is believed to ‘significantly’ cut down on carbon emissions compared to traditional aluminium solutions without compromising on performance or durability.
The material is apparently suitable for a range of packaging lines.
Another solution on display is PPCover, a mono-polypropylene die-cut lid. Because it does not contain any metal, it is anticipated to be appropriately sorted in the metal detection stage at end-of-life.
Constantia highlights the lid’s ‘great’ opacity and ‘excellent’ resistance to both punctures and tearing. Heat resistance is listed as another benefit, as is sealability with standard flat sealing tools.
Designed to be used with polypropylene cups, it is envisioned for such applications as non-retort ready meals, non-carbonated beverages, and dairy products such as yoghurts.
The EcoLam family of polyethylene laminates are designed to replace PET/PE and other multi-material, and therefore non-recyclable, laminate options. Among the different barrier levels are the standard EcoLam laminate, EcoLamPlus, and EcoLamHighPlus, the latter of which is said to achieve similar barrier values to PET/Alu/PE laminates.
Apparently, the EcoLam range is lighter than conventional options, utilizing less barrier polymer to achieve ‘excellent’ thermal resistance. Constantia emphasizes that every grade is RecyClass-certified and complies with Europe’s standard sorting and recycling technologies.
A similar product family comes in the form of EcoVer – again offering the EcoVer, EcoVerPlus, and EcoVerHighPlus barrier grades. These mono-polypropylene laminates are highly transparent and are set to provide low initial sealing temperatures and heat resistance in various product applications.
Compatible with VFFS and HFFS lines, the solutions have been designed in line with contemporary ‘Design for Recycling’ guidelines.
For preserved food packaging, Constantia will showcase its lightweight, recyclable aluminium packaging, EcoAluTainer. It is set to package both human and pet food in stackable containers that are reportedly free from harmful substances, e.g. epoxy resins containing BPA.
As it is retortable, EcoAluTainer packaging is expected to serve as a safe and environmentally conscious packaging option while also adhering to strict standards of performance and quality. Among its potential applications are sausages, dry pet food, and drink pouches.
Like EcoPeelCover, EcoAluTainer is available in Lowcarbalu with ASI-certified aluminium.
Unveiled earlier this summer, EcoTwistPaper is a paper-based, wax-free twist-wrap solution for confectionary products. The Confederation of European Paper Industries (CEPI) has given the product a score of 90/100 points in repulpability testing, and the wrapper’s plastic-free composition is thought to exempt it from the Single-Use Plastics Directive.
Constantia adds that advanced treatments improves the softness of the solution, and that EcoTwistPaper is compatible with existing machinery.
Last but not least, EcoPressoLid is a biobased capsule-lidding material for home-compostable coffee capsules. Designed for compostability in collaboration with Greiner Packaging, it apparently comes with a high oxygen barrier to maintain the freshness of the coffee and perform ‘excellently’ while the beverage is being brewed.
“Digital printing is our latest technical advancement, a unique printing technology for aluminum die-cut lids,” said Marc Rademacher, executive vice president Consumer Commercial of Constantia Flexibles. “We also strive to offer a wide range of products designed for recycling across all segments, including our product innovation, EcoTwistPaper and compostable EcoPressoLid.”
FACHPACK attendees are also invited to attend a presentation by Dr. Dietmar Lenko, head of Group Innovation & Product Sustainability Consumer at Constantia Flexibles, on 24th September 2024. ‘Innovative packaging solutions designed for recycling in various recycling streams (Aluminum, PE, PP, Paper)’ will dive deeper into the Constantia Flexibles 360° approach as part of Ausstellerforum INNOVATIONBOX, and will take place in Hall 4, opposite Booth 4-302.
Also on display at this year’s FACHPACK is Henkel’s ‘anti-slip’ palletizing and end-of-life adhesives. These will include hot melt adhesives from the Technomelt Supra PS range, designed to cut down on excess consumption of plastic film by securing stacked goods on pallets in transit.
Moreover, BEUMER Group’s ‘maintenance-friendly’ stretch hood technology will be showcased. It seeks to ‘safely and reliably’ process films containing 30% recycled material or higher, cutting down on film consumption and packaging costs while targeting safety, efficiency, and ergonomic performance.
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