Hoffmann Neopac has become the first tube manufacturer to sign a partnership with Saperatec. The manufacturer of barrier tubes for pharmaceuticals, cosmetics and oral care products will supply its production waste to Saperatec, the first industrial recycling plant for aluminum laminate composites, upon its opening in mid-2023.
In Europe, around 11.5 billion tons of plastic, aluminum and laminate tubes are produced annually i (based on ETMA, 2020). Of these, 38% are laminate tubes, with the majority comprising aluminum barrier laminates (ABL). Such tubes cannot currently be industrially separated and recycled in existing recycling facilities.
ABL tubes – like all other ABL packaging waste – are usually downcycled or incinerated and, depending on the country, packaging may even end up in landfills.
To further reduce aluminum waste, Neopac recently introduced innovative barrier tubes comprised of mono-material construction. These bring the advantage of being recyclable in the PE or PP material stream, and therefore reused for new applications. But of course, tube products with aluminum barriers will continue to be necessary, as these meet the most stringent requirements for barrier properties, especially for pharmaceutical ointments and creams that must go through a regulatory approval process. Such tubes represent around 10% of the laminate tubes manufactured in Europe.
In parallel with efforts to optimize tube design for improved recycling, progress is being made in the recycling of all raw materials from aluminum-containing material composites. A particularly promising technology is spearheaded by Saperatec GmbH; in a pilot plant, the company has already demonstrated the ability to break down multilayer composite materials such as PE/Al into their individual materials, thus enabling a high level of material recycling.
Utilizing a special washing technique, Saperatec separates plastic and aluminum layers without dissolving them. A laboratory study at Saperatec in spring 2021 with various ABL tubes from Neopac showed that Polyfoil tubes, for example, can be completely separated in this fashion.
Following the separation process, the materials are sorted. This produces fractions of polyethylene and aluminum, which can be recycled to high quality in commercially available plants.
In the medium term, this process will also make it possible to recycle composite materials made of aluminum and plastic with high recycling rates.
Saperatec began construction of its Dessau, Germany industrial separation facility in December 2021. The plant is scheduled to commence operation in mid-2023 and will then recycle composite packaging waste made of aluminum, plastic and paper. In a first step, Neopac plans to feed production waste generated at Saperatec in larger quantities to the special separation process in the future. In a second step, Neopac and Saperatec will examine the technical possibilities for applying recycled, materially separated production waste to the production of new tubes. In this way, the two partners are making an important contribution to reprocessing aluminum-containing packaging, such as ABL tubes, for further high-quality uses.
The process will be improved and perfected using additional technologies currently in development, which will allow intelligent sorting of ABL packaging into an ABL packaging material stream. These include HolyGrail 2.0 technology, and eddy current detection in combination with NIR PO detection.
Product safety and sustainability
"In addition to the already existing environmentally friendly and recyclable tubes from our EcoDesign portfolio, we are committed to a recycling solution for our conventional Polyfoil ABL tubes. With this new initiative, we will offer our customers the best possible balance between product safety and sustainability," says Peter Bossert, Head of Materials Development at Hoffmann Neopac AG. "As early as this year, we will make a portion of our production waste available to Saperatec to demonstrate its recyclability on an industrial scale, per the promising laboratory tests that have been performed. With the pending recycling of ABL tubes, we are closing a recycling gap in our portfolio."
High-quality plastic recyclates
Thorsten Hornung, Managing Director of Saperatec GmbH is delighted:
"We are grateful for innovative companies such as Hoffmann Neopac AG, which are actively committed to making progress on the circular economy and are prepared to make their production waste available to us for high-quality recycling. With the construction of the first recycling plant for composite materials made of plastic, paper and aluminum, we aim to produce high-quality, film-ready plastic recyclates for packaging applications while returning the recovered aluminum to the material cycle."
Neopac’s Polyfoil MMB tube approved by USA’s Association of Plastic Recyclers
Hoffmann Neopac has been granted approval for its Polyfoil MMB mono-material barrier tube by the US-based Association of Plastic Recyclers. APR’s strict recycling standards are met by the company's mono-material barrier tube, in versions both with and without thin film metallization.
Neopac’s Polyfoil MMB® tube approved by RecyClass recycling standards association
Neopac has been granted RecyClass approval for its Polyfoil® MMB mono-material barrier tube, a groundbreaking combination of product protection, user friendliness and appealing aesthetics. According to the laboratory results, the ‘Polyfoil® MMB Tube PF528’ product conforms to the current European PP container recycling stream.
Neopac wins Pharmapack sustainability award for mono-material barrier tubes designed for recyclability
Neopac has earned first place in the coveted Excellence in Sustainability category of the 2021 Pharmapack Awards. The winning solution was Neopac’s Polyfoil MMB mono-material barrier tube, a groundbreaking combination of pharma-grade product protection, user friendliness and appealing aesthetics.
Neopac showcases new mono-material barrier tubes designed for recyclability
Neopac’s Polyfoil MMB mono-material barrier tube is a forward-thinking combination of practicality and eco-consciousness, the high-performance solution offers both superior product protection and significantly enhanced recyclability. The result is a carbon footprint reduction of up to 38% compared with traditional aluminum barrier tubes.
Neopac wins Swiss packaging award for first application of novel tube procurement service
Hoffmann Neopac has won a Swiss Packaging Award in the Marketing category for the company’s initial project involving its recently launched DigitAll360° tube procurement service. Introduced earlier this year with an online marketplace, DigitAll360° offers intuitive ordering of digitally printed tubes with high-quality variable printing, precision color matching, flexible batch sizes and expedited delivery.
Hoffmann Neopac gains key sustainability designation
Hoffmann Neopac, a global provider of high-quality packaging for Pharma, Cosmetics and FMCG Industries, has successfully completed an audit conducted by the International Sustainability & Carbon Certification (ISCC) at its tube manufacturing facility in Debrecen, Hungary.
Hoffmann Neopac makes massive green energy investment at Switzerland packaging plants
Hoffmann Neopac has installed one of the largest solar power systems in Switzerland. The extensive green energy initiative, which costs more than 2 million Swiss Francs ($2.2 million), will make Hoffmann Neopac fully electricity sustainable at each of its two manufacturing sites in its home country.
Neopac develops Polyfoil dropper tube solution for vegan vitamin D product
Hoffmann Neopac has partnered with Streuli Pharma AG to launch a dropper tube for direct, precision administering of a novel vegan Vitamin D formulation. The aesthetically appealing solution for Streuli Pharma’s new food supplement Luce D3 product houses a vegan Vitamin D solution in a tube with a metered dropper for safer, more accurate dosages.
Choose the best toothpaste packaging for the environment
Finding a sustainable packaging which offers compatibility with the formula is not an easy one for anyone. Neopac's newly launched Polyfoil mono-material barrier tubes offer a solution to this problem, as these tubes can reduce tube body weight by as much as 50% as standard plastic tubes!
Neopac wins Tube Council Award for high-barrier, easy-application solution for veterinary products
Hoffmann Neopac has won gold in the “Best Pharmaceutical Tube” category in the annual Tube Council Awards. The winning entry was a convenient, high-barrier single-use tube with a simple, no-mess applicator developed for Aurora Pharmaceuticals.
Neopac introduces lightweight plastic tube with reduced wall thickness for enhanced sustainability
Hoffmann Neopac has introduced a lighter plastic tube solution comprising up to 30% less virgin materials. The latest addition to the company’s EcoDesign series of eco-friendly tubes, the new LIGHTWEIGHT TUBE aligns with packaging industry desires to minimize carbon footprint and materials waste.
Neopac launches online shop for digitally printed tubes
Hoffmann Neopac has launched a direct purchase microsite for DigitAll360°, its recently introduced digital tube decoration service. The new marketplace, accessible via shop.neopac.com, walks tube customers through an intuitive process that includes downloadable design guides and templates, an initial portfolio of stock tubes from 50-200 ml in volume, simple artwork uploads 3D renderings and a comprehensive pre-purchase artwork check.
Neopac wins WorldStar awards for two sustainability-minded tube solutions
Hoffmann Neopac has earned a pair of 2021 WorldStar Awards from the World Packaging Organization for two of its most groundbreaking recent tube solutions. For Neopac, both recognitions came in the Health & Personal Care category and exemplify the company’s commitment to sustainable packaging solutions.
Neopac develops tube solution for Aurora Pharmaceuticals
Hoffmann Neopac has developed a differentiating packaging solution for a topical antiparasitic solution produced by Aurora Pharmaceuticals. Featuring the active ingredient selamectin, the recently released Revolt Topical Solution is now available via prescription in convenient, high-barrier single-use tubes with a simple, no-mess applicator.
Neopac introduces Europe’s first mono-material barrier tubes with HDPE caps to receive full Recyclass technology & product approval
Hoffmann Neopac is launching a novel line of mono-material barrier tubes providing exemplary product protection while being fully compatible with existing HDPE recycling processes. The first tube solution in Europe to receive full RecyClass technology and product approval per the organization’s “Recyclability Evaluation Protocol for HDPE Containers” standards.
Neopac to Highlight Solutions for Sustainability, Functionality at Webpackaging LIVE Cyber-Exhibition
Global provider of high-quality tubes, Neopac, is exhibiting at the first edition of Webpackaging LIVE, a unique virtual packaging show in full 3D. Neopac will be featuring its sustainability-minded EcoDesign portfolio, as well as the innovative, shape-maintaining SpringTube at Webpackaging LIVE.
Neopac introduces market’s first recyclable PE based mono-material tube with HDPE flip-top cap
Hoffmann Neopac has introduced the market’s first fully recyclable polyethylene-based tubes with high-density polyethylene (HDPE) flip-top caps. A breakthrough in the worldwide push for packaging sustainability, the company's tubes can be viewed in the company's Webpackaging LIVE 3D showcase.
Neopac wins pair of "Tube of the Year" awards from European Tube Manufacturers Association
Neopac, a global provider of high-quality packaging for a broad array of industries and applications, earned two “Tube of the Year” awards from the European Tube Manufacturers Association (ETMA). The recognition came in two of the competitions most coveted categories: Plastic Tubes and Laminate Tubes.
Continuing sustainability efforts, Neopac moves toward mono-material barrier tubes designed for recyclability
Neopac is in the development stages of food- and pharma-grade mono-material barrier tube solutions that align with existing recycling processes. Neopac’s push for mono-material tubes will employ sound packaging science to align with current recycling practices and processes – all while providing its cosmetics, food and pharma customers with outstanding barrier properties to protect sensitive products.
At Luxepack New York, Neopac to debut direct-to-shape digital decoration service for tubes
New digital printing capabilities launch: Hoffmann Neopac, a global provider of high-quality packaging for a broad array of industries and applications, will debut DigitAll360°, its new direct-to-shape digital decoration service for tubes.
3D Neopac Debuts SpringTube for an Array of Applications in the US and India
3D Neopac, a global provider of high-quality packaging for a broad array of industries and applications, has developed SpringTube, a packaging solution for cosmetics, personal care products and other applications, including art paints. The tube is specially designed to maintain its shape while delivering a host of additional benefits for consumers, brand owners and manufacturers.
Neopac introduces Tube Design Guide for optimum recyclability at CPhI Worldwide
Hoffmann Neopac, a global provider of high-quality packaging for a broad array of industries and applications, debuted a set of best practices for tube packaging recyclability at CPhI Worldwide. The company’s Tube Design Guide for Recyclability amounts to a multi-step tutorial with comprehensive consideration of lighter, more circularity-minded materials.
Neopac wins three prestigious healthcare sector packaging awards
Hoffmann Neopac has received three high-profile awards for tube solutions in the healthcare sector. Each of the tube solutions utilizes Neopac’s high-barrier Polyfoil technology, a proprietary blend of materials providing advanced barrier properties for products requiring ample protection against potentially harmful external factors, including moisture and oxygen.
Neopac develops Polyfoil dropper tube solution for Streuli vitamin D application
Neopac has partnered with Streuli Pharma AG to launch a dropper tube for direct, precision administering of Vitamin D. Seen as a step up from standard packaging involving glass vials and pipettes, the solution houses vitamin D in a tube with a metered dropper. The result is safer, more accurate dosages.
Neopac Opens First U.S. Facility with Site Tours & Demos of High-Speed Tube Production Line
Hoffmann Neopac officially opened its first U.S. facility on Thursday, May 16 with a ceremony that included tours, demonstrations and remarks from senior executives. Focusing primarily on small-diameter tubes, the 37,000-square-foot plant in Wilson, NC boasts a high-speed tube line capable of producing some 80 million tubes annually, as well as floorspace for several additional packaging lines to come.
Neopac recognized in two competitions highlighting sustainable and innovative packaging solutions
Neopac was one of five finalists for a Green Award at LuxePack New York, where the company's PICEA tube, which houses a line of hair conditioners for Neopac's customer, Madara. Elsewhere, at the 50th Anniversary of the prestigious Swiss Packaging Awards, Neopac won one award category and was nominated in two others
Neopac Participates in Smart Green Island Makeathon Youth Education Challenge
At the event, Neopac challenged youth participants to design and develop a "smart tube" for pharmaceutical packaging applications that, when combined with the company's metered dosing tube solutions, could help patients adhere to prescription regimens via IoT connectivity.
- Bianka Cramblit
- Company News
- Created 22 Feb 2022
- Modified 23 Feb 2022
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