Zotefoams, a world leader in cellular materials, announced that ReZorce, its sustainable mono-material barrier packaging range, has been named winner in the Product Innovation category at the 2024 Reuters Sustainability Awards.
This year, 700 entries from 50 countries contested 17 categories judged by an international panel of business leaders, academics, designers and changemakers in the field of sustainability. ReZorce won the Product Innovation category ahead of 13 other shortlisted entrants including other aseptic liquid packaging board (LPB) beverage cartons and packaging innovations.
Currently available aseptic beverage cartons – used for products such as fruit juices which are not refrigerated – are produced from composite layers of wood fibre, aluminium and polymer bonded together (LPB). Unlike ReZorce, these composite materials cannot be recycled through mainstream processes. ReZorce on the other hand has a mono-material design which leads to excellent performance in standard Material Recovery Facilities (MRFs). The resulting recyclate can be reused, including in the core of ReZorce cartons, bringing the prospect of circularity to the 250 billion unit-per-annum beverage carton market for the first time.
Zotefoams is currently in the latter stages of developing ReZorce for beverage carton applications and is preparing for trials with a north European supermarket chain.
During the Awards ceremony on October 1, judge Danielle Holly, Associate Director of the Aspen Institute, commented, “The judges thought [ReZorce] was an excellent and practical step towards fully recyclable packaging for widely used food and beverage formats. It’s exciting, it’s disruptive and it will really deliver an immense impact in everyday lives. Well done for pioneering it!”
Ronan Cox, Zotefoams Group CEO, comments, “We are delighted that ReZorce has been recognised on the global stage in this way. Entrants to the Reuters Sustainability Awards include some of the world’s best-known and most-admired companies and it is an honour for Zotefoams to stand alongside them.
“It is also telling that the judges recognised the need for wholesale change rather than incremental improvement in pack formats such as aseptic beverage cartons.
“This award which follows recent success in the Deutsche Verpackungsinstitut’s German Packaging Awards, serves as further confirmation that ReZorce is a much-needed product with a bright future. We are 100 % focussed on translating these award achievements into on-shelf success, as ReZorce looks to finally bring a truly sustainable solution to the aseptic carton industry and beyond.”
Following successful commercial consumer testing in 2022, Tetra Pak and Lactogal have now launched an aseptic beverage carton featuring a paper-based barrier. This is part of a large-scale technology validation, involving around 25 million packages and currently ongoing in Portugal. Made of approximately 80 % paperboard, the package increases the renewable content to 90 %, reduces its carbon footprint by one third (33 %1) and has been certified as Carbon Neutral by the Carbon Trust™.2
Greenhouse gas emissions, food waste and plastic littering are cited as the top three environmental sustainability concerns facing food and beverage (F&B) businesses today, and this is expected to remain the case over the next five years.3 Packaging solutions like these, that expand the amount of paper and lower the carbon footprint, while ensuring food safety, can help the industry overcome these challenges.
In 2015, Tetra Pak was the first in the industry to introduce a package made fully from plant-based renewable materials – paperboard and sugarcane-based plastic. The Tetra Rex® Plant-based package, suitable for cold chain distribution, is fully renewable, and the company has delivered approximately 6.5 billion of these packages to customers around the world to date.
Now, the launch of the Tetra Brik® Aseptic 200 Slim Leaf carton with paper-based barrier, together with Lactogal, provides a package that can be distributed under ambient conditions, while hitting the 90% renewable content mark. This brings Tetra Pak one step closer to its ambition of a beverage carton made solely from responsibly sourced renewable or recycled materials, fully recyclable and carbon neutral. The company is aiming for industrial scale production of the solution by 2025.
1Certified by the Carbon Trust™ – benchmark: Tetra Brik® Aseptic 200 Slim Leaf carton package with aluminium foil layer.
2“Carbon neutral” means that, after reducing the CO2 emissions by converting the package’s fossil-based polymers into plant-based polymers to the highest possible extent, the residual CO2 emissions associated with the packaging manufacture are offset by funding Gold Standard-certified climate projects around the world.
3Tetra Pak B2B research on Planetary Challenges and their impact on F&B manufacturers’ operations (2023).
SIG announced the launch of SIGNATURE EVO, the world’s first aluminium-free full barrier packaging materials for aseptic carton packs. SIGNATURE EVO extends SIG’s lower-carbon aluminium-free packaging materials – already available for plain white milk – for wider use with oxygen-sensitive products such as fruit juices, nectars, flavoured milk or plant-based beverages.
SIGNATURE EVO is the latest evolution in the SIGNATURE portfolio – SIG’s innovative offering of the most sustainable packaging materials available for aseptic carton packs.
SIG led the industry with the first ever aluminium-free solutions for aseptic cartons. By eliminating the need for an aluminium foil barrier layer, combibloc ECOPLUS cut the carbon footprint of SIG’s standard packaging material by 27 % when launched in 2010. SIGNATURE 100 cut this further in 2017, offering a 58 % lower carbon footprint than SIG’s standard packaging material by linking the polymers to 100 % renewable forest-based materials via a certified mass-balance system1.
With more than 1.9 billion packs now sold with these aluminium-free long-life packaging solutions for liquid dairy products, SIG has built on this success to create the first full barrier aluminium-free solutions for aseptic cartons.
SIGNATURE EVO packaging materials are expected to offer a similar carbon footprint reduction to combibloc ECOPLUS, to be confirmed through an independent, critically-reviewed life-cycle assessment. Like all SIG packs, SIGNATURE EVO is fully recyclable in existing recycling streams.
With barrier properties comparable to standard aseptic cartons that include an aluminium foil barrier layer, SIGNATURE EVO packaging materials ensure that even oxygen-sensitive products are protected over long periods of time without the need for refrigeration. This enables customers to bring the environmental benefits to many more food and beverage categories.
SIGNATURE EVO will initially be launched in the combiblocMini portion-sized format before being extended to other formats. It is suitable for both oxygen-insensitive products like plain white UHT milk and oxygen-sensitive products like fruit juices, nectars, flavoured milk or plant-based beverages.
SIGNATURE EVO enhances opportunities for customers to differentiate their products with an aluminium-free pack that offers both on-shelf appeal and stand-out environmental credentials.
In the future, it will also be available in more options such as SIGNATURE EVO 100 – SIG’s full barrier solution for aseptic carton packs linked to 100% renewable forest-based materials.
1Results based on ISO-compliant life-cycle assessment CB-100732c for Europe.
Downgauging innovations yield thinner, more sustainable BIB films
One word, more than any other, is guiding Bag-in-Box (BIB) film purchasing decisions today: sustainability. Whether for wine, fruit juice or dairy products, the people in the buyer center – product and packaging managers, technical engineers and purchasing agents – are tasked with finding sustainable packaging solutions.
Fortunately for them, the Mondi Styria plant in Austria, has racked up more than 60 years of experience as market leader and technology innovator. When it comes to multilayer technical films that are thinner, lighter and more sustainable – and do not sacrifice any performance properties – the Mondi experts are always extending the boundaries of technological advancement. Now, they are launching a pair of next-generation films developed for multilayer BIB products used to package liquid food products and more.
Introducing … Styria Form Bar 50
“We have now determined it is possible to replace the usual 66- or 70-micron polyethylene film with a 50-micron film, and we are the first company to be able to offer such a product,” explains Günter Leitner, Managing Director at Mondi Styria. “Downgauging in this manner results in the use of about 25 % less material while also reducing transport weight and hence the overall carbon footprint.”
A current customer is already running trials of this new product, and says it has experienced no negative impact on machine performance and that no equipment changes have been needed to successfully run the film, Leitner notes.
… and Styria Form Bar 90 DW
Separately, Mondi now has also found a way to combine what is the industry-standard, two-ply film comprising a 70-micron polyethylene layer plus a 40-micron barrier layer into a mono-layer film that measures only 90 microns thick –– a reduction of nearly 20 %. Currently, Mondi provides its 70-micron film to customers who combine it with a barrier layer provided by another supplier to get the desired end result.
“Mondi, once again, is the first and only supplier of technical BIB films able to offer this type of mono-layer product,” says Leitner. “Since this thinner film also yields more running metres per reel this leads to enhanced efficiency and productivity for our customers.”
In addition to the previously noted sustainability advantages, this latest innovation greatly simplifies matters for customers, eliminating a step from the converting process, and allowing users to buy and store only one type of film instead of two.
Customers also will benefit from reduced machine setup time due to having to change out only two reels instead of four, and having to change two reels less frequently. All of this translates into greater productivity for the converter.
Additionally, both new films are suitable for both hot-fill (up to 85 ºC) and cold-fill applications, again offering increased convenience and flexibility to the users.
