After almost four years of development, Mondi and Werner & Mertz will introduce a new, patented innovation in 2019: a 100-percent recyclable pouch with detachable decorative panels. The pouch replaces conventional flexible packaging for Frosch products. The pioneering design overcomes many shortcomings of the recycling process and is the result of a joint effort by Werner & Mertz, Mondi, EPEA Switzerland (Cradle to Cradle®), Der Grüne Punkt – Duales System Deutschland and Institut cyclos-HTP.
In 2014 Werner & Mertz decided to develop packaging that is recyclable in the fullest sense. This was before most fast moving consumer goods (FMCG) companies viewed a commitment to sustainability as an indispensable building block for brand equity. Several packaging suppliers told them it could not be realised. Then they met Mondi.
The project was truly ambitious. It was not about developing flexible plastic packaging that is only theoretically recyclable – packaging likely to end up in landfill. Rather, the design aim was to “reverse-engineer” the recycling process: to create packaging fit for every stage of the recycling process.
The challenges of true recycling
A crucial and often neglected step in the recycling process is sorting. Failure to sort the collected packaging into material streams that recyclers can use leads to down-cycling – that is, the production of recycled material no longer suitable for its original application. “If you want to avoid a ‘garbage in, garbage out’ scenario,” explained Immo Sander, Head of Packaging Development, Werner & Mertz Group, “the entire value chain must be aligned – from packaging producers through players in sorting and recycling to buyers of recycled material.” This is the aim of the Recyclate Initiative that Werner & Mertz launched in 2012.
In order to develop packaging that would yield high-end recycled material, Werner & Mertz and Mondi consulted multiple recycling experts: Der Grüne Punkt – Duales System Deutschland, EPEA Switzerland as well as Institut cyclos-HTP for later certification.
The packaging needed to be made of a polyethylene mono-material, which is a prerequisite for recycling. “Our collaboration with Werner & Mertz shows, in the best possible way, how challenges can become solutions,” said Jens Kösters, Manager Technical Services, Mondi Consumer Goods Packaging, “We worked our way through an ‘innovation funnel’— testing different materials until we arrived at a designed-for-recycling concept that convinced everyone at each point of the value chain. Furthermore, the concept offers clear benefits related to sealing strength and maximum filling volume.”
A giant leap: a pouch with detachable decorative panels
A final touch was added to solve the issue of recycling printed plastic materials. The pouch has two layers. “We dress the pouch up in an eye-catching ‘outer garment’ that is printed with brand design on the front and consumer info on the back,” said Sander. “When the pouch is empty, we ‘undress’ it automatically by shredding and sorting the two components into separate recycling streams.”
The patented pouch is now 100-percent recyclable. The material is of course free of glue or adhesive. Spout and cap are also made of polyethylene – which means the recycled material will be equivalent in quality to the original material.
ChemCycling sources feedstock from post-consumer plastic waste to produce virgin grade material for food contact approved quality
Creating flexible packaging from virgin grade material derived from plastic waste is now taking a step towards reality in a pilot project called ChemCycling. Leading global packaging and paper group Mondi, in cooperation with chemical producer BASF and COROOS, have cooperated on a state-of-the-art pilot project.
Mondi, Werner & Mertz partner on fully recyclable, award-winning StripPouch that supports a circular economy
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Mondi presents its award-winning BarrierPack Recyclable plastic laminate
Mondi has developed a fully-recyclable plastic laminate for pre-made pouches and FFS roll stock that is perfect for integration into existing recycling schemes. BarrierPack Recyclable has been validated for existing industrial recycling streams.
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Mondi to showcase BarrierPack Recyclable, and a host of other packaging innovations at FachPack 2018
Mondi, the global packaging and paper group, will highlight BarrierPack Recyclable, its fully recyclable plastic laminate for pre-made pouches and FFS roll stock, along with other innovative products targeting the ice cream, pet food, and food and beverages categories at the upcoming FachPack trade fair in Germany.
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Water soluble film by Mondi reduces packaging waste and improves end consumer safety
As a result of its customer focused research and development, Mondi’s technical films business has created and introduced a water soluble film for the smart and convenient packing and dosing of powders, tabs and granulates. Dissolving completely in water, the film is ideal for single doses of dry materials, such as dishwasher and laundry tabs or bath salts.
Peter Oswald reinforces focus on growing packaging business as new Mondi Group CEO
Mondi, the international packaging and paper Group, hosted a press conference on 5 May at the interpack 2017 trade fair in Düsseldorf at which trends in the packaging industry and the focus on growing its packaging business were discussed.
Mondi shows how innovative packaging can save food
Global food waste is a serious problem – one that is being tackled by the collaborative efforts of the food and packaging industries and local and global initiatives. Mondi, the international packaging and paper Group, is playing an active role in addressing this challenge through its expertise in food safety and innovative packaging.
Mondi to show how its innovative packaging solutions respond to industry and end-user trends at interpack 2017
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Mondi attracts 30% more visitors at FachPack 2016
Mondi, the international packaging and paper Group, recorded a 30% increase in the number of visitors to its booth at this year’s FachPack trade fair in Nuremberg. Customers, prospective customers, suppliers and other interested visitors totalled nearly 900 over the three-day fair from 27-29 September. Of those, a huge number were first-time contacts for Mondi, showing the importance of trade fairs for reaching a large number of new business contacts and potential customers.
Driven by great ideas: Mondi automotive solutions to be featured at FachPack 2016
Mondi, the international packaging and paper Group, supplies the automotive and automotive parts industries not only with a variety of customised packaging and specialised paper, but also with high-tech automotive interior materials made from extrusion coated multilayer complexes. At the FachPack trade fair on 27-29 September in Nuremberg, Germany, Mondi will show its extensive range of state-of-the-art solutions for the automotive and other industries.
Perfect packaging for extreme conditions
Mondi Containerboard highlights its full range of highly functional papers for packing fruit and vegetables. Whether for high-humidity environments, hot temperatures or cold storage, the ProVantage and EcoVantage product ranges suit all these conditions perfectly. The line features ample selection, offering 12 different paper grades.
Mondi’s new anti-staining pouch offers the perfect stainless retort solution
Ready-made meals and sauces with high fat content and strong colours often have an undesired side effect on the packaging – they leave stains. As an attractive appearance and long shelf life are two key factors in convenience foods, Mondi set out to find a solution for this problem. The result is a new retort packaging that ensures highest barrier properties whilst sustaining opacity and enabling high-quality designs.
Innovation and sustainability go hand in hand with Mondi industrial bags
With the launch of numerous new industrial bag constructions over the last few years, Mondi’s innovation strength has been internationally recognized by customers and industry awards. The latest innovations, process improvements, and certifications clearly put the focus on sustainable solutions from an environmental and economic point of view.
- Elias Bittan
- Created 10 Sep 2018
- Modified 08 Feb 2019
- Hits 929