Sustainability is a key consideration in the development of modern packaging. Our joint project with the DMK Group demonstrates how ecological requirements can be combined with product safety, quality, machinability, transport stability, convenience, and an appealing appearance. We are using T-IML technology to redesign the packaging for the MILRAM herb and spice quark range. This is a combination of thermoforming and In-Mould-Labelling. This results in high-quality, decorated packaging made from monomaterials that meet all the requirements of a branded product. At the same time, the packaging is recyclable and resource-efficient.
When developing a new packaging solution, packaging developers must combine product protection, functionality, and environmental friendliness. This was also the case when revising the packaging concept for the MILRAM herb and spice quark range. The existing MILRAM quark packaging no longer met the DMK Group's current requirements. The redesign aimed to create a packaging solution that would meet ecological and economic requirements. Specifically, the aim was to maximise the recyclability of the cup and significantly reduce the amount of material used. At the same time, current design trends from the packaging industry were incorporated to modernise the cup's appearance without compromising its functionality.
The original packaging weighed 11.52 g and consisted of a PET cup with a paper sleeve, an ALU-PET lid film, and a PET snap-on lid. The new, optimized packaging solution reduced the total weight to 8.4 g. It now consists of a PP cup with IML, an ALU lid film, and a PP snap-on lid. This 27 percent reduction represents an absolute value of more than 200,000 kg per year. The reduction in material and the use of a single material reduce GHG emissions by approximately 20 percent compared to the old packaging (18.4 instead of 23.09 kg CO₂eq/1,000 cups).
The previous packaging consisted of a PET cup with a paper sleeve, an aluminum-PET lid film, and a PET slip lid. Now, MILRAM packaging consists of a PP cup with IML, an aluminum lid film, and a PP slip lid. The printing inks used previously have been reduced to a minimum in order to reduce the amount of contaminants in the recycling stream and as a basis for higher recyclate quality. The monomaterial approach has improved the recyclability of the overall packaging to 98.3%.
T-IML combines the familiar processes of thermoforming and in-mold labeling. A heated film is shaped using compressed air. A pre-printed plastic label made from the same material as the container is inseparably bonded to it during the process. This allows extremely lightweight packaging to be produced from monomaterials. The improved recyclability of single-material solutions and their low weight significantly reduce greenhouse gas emissions (GHG emissions).
The larger opening tab on the seal plate makes it easier for consumers to grip and open. The optimized tear-off behavior allows for better separation of the plate and cup, which also improves recyclability. The design relaunch was accompanied by a conscious decision in favor of a slip lid. Improved product protection keeps food waste to a minimum.
marco von Döllen
Sales Manager
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The EU Packaging & Packaging Waste Regulation (PPWR) sets out the framework conditions for how packaging should be designed in the future. Unnecessary packaging and packaging waste should be reduced and reusable systems and recycling should be promoted. In our opinion, plastic packaging meets precisely these requirements, as plastic is more efficient than alternative materials.
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