Papkot has unveiled its new Papkot PA category of mineral-based Processing Aids, said to enable up to 20% reduction in material usage while achieving performance equivalent to traditional fibre-based containers.
Papkot says the new aids underwent ‘rigorous industrial trials’ conducted with Fedrigoni at their Cordenons and Fabriano facilities. Adding just 1% of the Papkot PA to the fibre mix is said to result an estimated $12.6 million in annual gross savings for a standard 280,000-tonne mill, according to CEO Manuel Milliery.
The company states the processing aids aim to bypass the limitations of traditional additives with proprietary plastic-free and inorganic nanostructures which apparently bond fibres at the molecular level. A 30% stiffness increase allows manufacturers to optimize the usage of the fibre composition, reducing hard wood fibres and increasing the filler contents for a 20% fibre reduction.
Papkot adds that faster dewatering and reduced refining demand significantly decrease the primary energy consumption for paper making or molded fibre production lines, and lighter-weight finished products - such as egg cartons that weigh 20% less - lead to fewer trucks and lower shipping costs.
In partnership with Fedrigoni, Papkot states it has achieved a ‘world first’ in fibre circularity: under industrial conditions with 1% Papkot PA, the companies used 100% siliconized glassine waste together with standard fibres to make a high-performance moulded fibre container. Papkot also says Papkot PA has been validated at Technology Readiness Level 7 (TRL 7), signifying that the system prototype has been demonstrated in a real-world, operational industrial environment.
In related news, in September Metsä Spring announced that it is now preparing the Muoto Laminated Fibre series, a new solution that combines moulded fibre products with barrier films, for industrial testing. The laminated range is designed for more demanding food industry applications, such as meat, poultry, and ready meals.
As part of our Sustainability Awards Finalist interview series, we recently heard from PAPACKS about its moulded Fiber Bottle, said to be recyclable and aiming to offer a scalable, patented alternative to plastic bottles for products such as dietary supplements. The bottle also has optional plant-based barrier coating and is suitable for liquids and non-liquids.
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