Most of us will have recently held an increasing number of beverage closures in our hands that can no longer be removed from the bottle. The reason for this is an EU directive from 2019, which stipulates such tethered closures for beverage bottles from July 3, 2024.
The company corvaglia, headquartered in Thurgau, Switzerland, has played a pioneering role in the development and production of tethered caps. The development of the first tethered cap models began even before the official publication of the EU directive. Since then, corvaglia has continuously worked on innovative solutions and has been able to convince well-known brand owners of the effectiveness of its products. As one of the first suppliers of tethered caps on the continent, corvaglia has secured a firm place for itself in this product segment.
The company’s own cap production in Eschlikon was also gradually converted to tethered products as part of this process. Since 1 March 2024, more than 80 % of the closures produced in Eschlikon now meet the requirements of EU Directive 2019/904. Around 10 % of the closures produced in Eschlikon are exported to non-EU countries and will remain non-tethered for the time being. The remaining 10 % will be converted by July.
The development of lightweight closures to reduce unnecessary plastic has always been part of corvaglia’s DNA. This approach has also been consistently pursued with tethered caps. With the latest tethered caps, corvaglia is proud to make a further contribution to reducing material and energy consumption and thus lowering CO2 emissions for beverage packaging.
The new caps, introduced by BBL in Ireland, Cido Grupa in the Baltics, LY Company Group and Lactalis Puleva in Spain and Weihenstephan in Germany, have been designed to prevent litter and accelerate transition to renewable materials.
Joining forces with leading beverage producers, Tetra Pak is launching tethered caps on carton packages. Marking a significant milestone in the company’s long-term work on design for recycling, five new tethered cap solutions are currently being introduced across Ireland, the Baltics , Spain and Germany in different product categories – a market first for these geographies. As part of a wider programme, this development paves the way for Europe-based customers to stay ahead of schedule and meet the Single Use Plastics (SUP) Directive coming into force by 2024.
Julia Luscher (Photo: Tetra Pak)
Julia Luscher, Vice President Marketing, Tetra Pak, comments: “We are delighted to be supplying a number of customers with tethered cap solutions, helping them to ‘walk the talk’ towards their sustainability ambitions. Understanding our customers’ needs and having collected consumer insights through multiple pieces of research across various markets, our new tethered caps have been designed to enhance convenience. For instance, they are easy to open and re-close for subsequent consumption, while featuring carefully sized diameters for smooth pouring and drinking.”
Tethered caps play an important role in preventing litter, as the cap will stay attached to the package. They could also help reduce the carbon footprint of the carton when they are chosen by food manufacturers as plant-based options, made from polymers derived from responsibly sourced sugarcane, thereby increasing the renewable content of the package. Additionally, a majority of Tetra Pak’s tethered cap portfolio features a reduced amount of plastic. Depending on the various solutions, the company achieved a plastic content reduction ranging between 7 % and 15 %.
Marco Marchetti, Vice President Packaging Materials, Sales and Distribution Solutions, Tetra Pak, adds: “Starting with these five new introductions, we are planning to equip approximately 300 packaging lines with tethered caps in Europe by the end of 2022. Considering the scale of change required across the value chain, early collaborations like these are putting the food and beverage industry on a fast track to accelerate the transition to a low carbon circular economy.”
In May, Borrisoleigh Bottling Ltd (BBL) is set to start commercial production of the new plant-based C38 Pro tethered cap on Tetra Top® 330 and Tetra Top® 500 carton packages. Based in Ireland, BBL is an experienced and awarded water producer, who’s seeking ‘to lead the industry towards a more responsible and sustainable future’.
The new HeliCap 26™ Pro closure – on a Tetra Prisma® Aseptic 1000 Square package – is being tested since February 2022 in the Baltics with Cido Grupa, who is leading the juice segment in that region since many years and exporting its products to over 20 countries across the globe.
In Spain, LY Company Group – that is driving the growth of carton-packaged water in the country, with the mission of ‘reaching a turning point in which both society and companies are aware of the importance of choosing sustainable packaging for the conservation of the planet’ – will soon start commercial production of the new plant-based DreamCap™ 26 Pro closure on a Tetra Prisma® Aseptic 330 Square package.
In the same country, Lactalis Puleva – part of the Lactalis Group, a world leading dairy company – has chosen to test the new HeliCap™ 23 Pro closure. The cap, in its plant-based option, has been applied to Tetra Brik® Aseptic 1000 Slim packages for the brand Lauki, on shelf since March this year.
Weihenstephan, one of the oldest and most popular German dairy brands, will soon test the production of the new LightWing™ 30 closure, on a Tetra Brik® Aseptic 1000 Edge carton.
The company has also heavily invested towards an improved manufacturing experience for customers. Tetra Pak’s new high quality, automated production lines for tethered caps utilise Artificial Intelligence technology for increased efficiency.
Marco Marchetti (Foto: Tetra Pak)
Marchetti concludes: “We are on a journey towards creating the world’s most sustainable food package, a carton that is fully made from responsibly sourced renewable or recycled materials, is fully recyclable and carbon-neutral. We are ramping up investment in the development of alternative solutions across our packaging portfolio such as tethered caps and other drink-from systems, to reduce littering while increasing the renewable share of our cartons.”
“In total, we are investing around EUR 400 million in the development and roll-out of tethered cap solutions, including a EUR 100 million investment last year in our Châteaubriant plant in France to accelerate the production of tethered closures. By working seamlessly across multiple project streams and covering approximately 40 different packages with tethered caps, we expect to sell over 1.5 billion such closures by year end.”
Tetra Pak announces a project to expand its Châteaubriant plant, in France, dedicated to the design and manufacturing of caps, while ensuring increased production capacity to enable the future transition to tethered caps.
Tetra Pak announced an ambitious investment program dedicated to its factory in Châteaubriant, specialised in the production of caps. Spanning across a three-year period (late 2021-2023), this €100 million project will support the plant’s transition to the production of tethered caps by 2024. Tethered caps help to minimise litter, as the cap will stay attached to the package.
This step – that is in addition to the company’s commitment to invest approximately €100 million per year over the next 5 – 10 years to develop more sustainable packaging solutions – is key to ensuring that Tetra Pak’s customers in Europe will be ready to comply with the Single Use Plastics (SUP) Directive, an integral part of the wider approach announced in the Plastics Strategy and an important element of the EU Circular Economy Action Plan.
Charles Brand, President of Tetra Pak Europe & Central Asia, comments: “We are particularly proud of this investment project, which demonstrates how we consistently strive to provide customers with sustainable innovations and meet the rapidly changing demands of regulators and society. High-performance food packaging plays a critical role in feeding the world, but it must do so sustainably, so that food availability does not come at the cost of the planet.”
The Châteaubriant plant is a key manufacturing facility for Tetra Pak, serving food and beverage manufacturers globally, with a production capacity of approximately 5 billion caps in 2020. Awarded last year with the Roundtable on Sustainable Biomaterials (RSB) Advanced Products certification, the factory is also equipped to produce additional materials integrating attributed recycled polymers. Today, the site covers an area of over 30,000 sqm and features 19 lines dedicated to the manufacture of 6 types of caps.
The investment will be spread over two phases. The first one begins in late 2021, where the company will enlarge the industrial site to accommodate a 30 % increase in manufacturing capacity through the installation of ten additional lines that will be dedicated to the production of tethered caps. Then, between 2022 and 2023, approximately 50 % of the existing lines will be replaced, again to expand the access of F&B players to tethered caps.
Elopak is today announcing a new tethered cap solution for its iconic Pure-Pak® cartons – the Pure-TwistFlip™.
The tethered cap is the latest sustainability-focused innovation announced by Elopak. The closure remains attached to the carton throughout its entire lifetime, helping to tackle the serious problem of marine littering by ensuring that the cap is disposed of properly. It is also Elopak’s lightest screw cap to date, helping to reduce the use of plastics.
As cartons can be recycled with the tethered cap attached, the Pure-TwistFlip™ offers up an exciting new option for brands looking to meet the growing consumer demand for sustainable packaging, without compromising on convenience or product integrity.
Commenting on the announcement Elopak CMO Patrick Verhelst stated, “We are delighted to share the news that our tethered cap solution is now ready. Sustainability is a central driver of our innovation efforts at Elopak, in which we are continually seeking to raise the bar and improve on past performance.”
“We have invested heavily in developing more environmentally friendly packaging solutions that meet the same high standards our customers are used to, and at the same time offer them a way to package their products in a manner that fits with a low carbon circular economy. By combining Elopak’s Pure-Pak® carton with the Pure-TwistFlip™ cap, brands can now choose a package that both helps prevent marine littering and reduces the use of plastics.” he continued.
Beverage cartons have strong environmental credentials when compared with alternatives such as plastic bottles. Even with a regular cap studies have shown that in the case of UHT milk, cartons result in 70.7 % less CO2 emissions and in the case of fresh milk 83.6 % less CO2 emissions in comparison to disposable PET bottles .
Elopak supplies renewable, recyclable, and carbon neutral Pure-Pak® cartons. The new Pure-TwistFlip™ cap can be combined with any existing Pure-Pak® carton to provide an original Elopak packaging solution that prioritizes the environment, consumer convenience and safety. The innovation is expected to launch to the market in Autumn 2021.
Elopak already offers customers a number of sustainability-focused innovations such as Natural Brown Board cartons which are renewable, recyclable and have a lower CO2 footprint owing to reduced wood consumption and the elimination of the bleaching process.
Elopak also offers cartons without a cap. The Pure-Pak® Imagine is a modern version of the company’s original Pure-Pak® carton launched in June 2020. Designed with a new easy open feature, it contains 46 per cent less plastic and is 100 per cent forest-based.
A UN Global Compact participant, Elopak has been carbon neutral since 2016 and in 2019 was one of the first companies in the world to formally pledge to cut Greenhouse Gas (GHG) emissions in line with criteria set by the Science Based Targets initiative aimed at keeping the global average temperature increase below 1.5 C.
Tetra Pak announced it is ready to deploy its portfolio of tethered cap solutions. The portfolio brings numerous benefits to food and beverage manufacturers and consumers, as the company builds on its vision of the most sustainable food package. These benefits include minimising litter, as the cap will stay attached to the package. The carbon footprint can also be reduced because the company’s tethered caps are planned to become available as a plant-based option, therefore increasing the renewable content of the package.
U-paper straw on Tetra Pak carton package (Photo: Tetra Pak)
In tandem, the company is accelerating the expansion of its paper straws offering to ensure further renewable and low carbon materials across the range of packaging solutions. The aim of this is to address a broad range of customer sustainability needs without compromising on food safety, while still delivering on the end-user drinking experience.
Lars Holmquist, Executive Vice President Packaging Solutions and Commercial Operations, Tetra Pak, says: “These are key milestones in our journey towards the world’s most sustainable food package: a carton that is fully made from renewable or recycled materials, is fully recyclable and carbon-neutral. We consistently strive to deliver products and services that adds value to food and people while protecting the planet. Our promise, ‘PROTECTS WHAT’S GOOD™,’ allied with this strong purpose means we are providing customers with innovative products that also meet the rapidly changing demands of society.”
Tetra Pak’s tethered caps and paper straws developments mark the latest additions to its range of responsible end-to-end solutions, allowing manufacturers to achieve their ambitions in three essential areas – food safety, food waste and the environment – simultaneously.
Lars Holmquist (Photo: Tetra Pak)
Holmquist continues: “Approximately 32 % of all plastic packaging is not collected and plastic can take hundreds of years to degrade[1]. We focus on recycling by design, committing to invest approximately € 100 million per year over the next 5 – 10 years to develop more sustainable packaging solutions. This includes alternatives to replace fossil-based plastics and avoid littering, as well as maximising the use of renewable, responsibly sourced materials in our packages. Addressing people’s needs for recycling is a critical component for not only becoming more sustainable but making food more available and safer for all consumers.”
These steps are also central to ensuring that Tetra Pak’s customers in Europe will be ready to comply with the Single Use Plastics (SUP) Directive, an integral part of the wider approach announced in the Plastics Strategy and an important element of the EU Circular Economy Action Plan[2].
With this in mind, Tetra Pak has accelerated innovation in the caps domain. Holmquist adds: “The significant challenge of deploying tethered caps is the scale of the change that this brings across the value chain. If we look at Europe alone, more than 1,000 packaging lines supplied by us will be potentially transformed, translating into over 20 billion packages which are expected to be converted. All of that in three years, while minimising impact on our customers’ operations, optimising the consumer experience and contributing to both minimising litter and creating a carton package with increased plant-based and recycled content.”
Tetra Pak is progressing on this complex journey by working seamlessly across various project streams. Overall, this covers approximately 40 different packages with tethered caps. Those caps are all planned to become available as a plant-based option. The first one to be released on the market is the HeliCap™ 26 Pro closure. This product features a new screw and flip concept with a self-locking hinge, securing food protection while providing convenience for in-home consumption. Its opening and closing mechanism has proven popular with consumers, demonstrating that the solution is delivering further benefits in addition to meeting legislative requirements[3].
Holmquist concludes: “We won’t stop here. We are continuously innovating our sustainable openings offering. We envision a world where carton packages never become waste and where every carton is collected and recycled.”
[1]Source: Ellen MacArthur Foundation, https://www.ellenmacarthurfoundation.org/ [2]Main objective of Directive 2019/904 is the prevention and reduction of marine litter from single-use plastic items. The implementation of this directive into EU member states’ national legislation will lead to a ban of selected products from the market, whenever affordable alternatives are available, among other measures. While bans on plastic straws will come into force by July 2021, EU-based beverage producers, retailers and manufacturers, as well as importers, are obliged to implement tethered caps and lids – designed to remain attached to containers – by July 2024. [3]Source: consumer research conducted in Spain, Italy and Poland in November 2019, with 300 consumers through face to face interviews, focussed on HeliCap™ 26 Pro opening on Tetra Prisma® Aseptic 1000 Square package.
More and more reuse and recycling schemes for beverage packaging are seen as efficient tools for reducing the environmental impact of packaging systems and for increasing their resource efficiency.
In this scenario, AROL REVERSE is becoming a must for all those bottlers looking for an effective response to unscrew pre-threaded plastic caps and threaded aluminium caps from glass and ref-pet bottles.
Reverse main features:
Safe unscrewing of caps with a diameter from 28 to 38 mm
Speeds up to 60,000 cph (1,000 cpm)
3 to 30 heads
No cap – no decapping feature to prevent bottle neck damage
Quick format change
Special handling parts in stainless steel for ref-pet bottles to prevent scratches to bottles and give longer life to components
Decapping heads completely in stainless steel
Available with stainless steel cap discharge piping and container
Flexible design to be adapted to the local condition of any plant
Advanced inspection systems for height variance at the infeed and cap detection at the discharge.
About AROL AROL was founded in 1978 and steadily grew as a global provider of capping solutions. It designs 100 % of its capping and caps sorting machines and it produces inside + 95 % of their parts. 700+ equipment delivered every year and 24.500+ installed all over the word in a vast variety of industries, from 1.000 to 90.000 BPH, make of AROL the largest specialist of customized solutions to any capping need. The AROL technical support is available for the whole life cycle of the machine and counts on a highly skilled team of specialists operating from each of its 10 worldwide offices. AROL is part of AROL Group, together with UNIMAC-GHERRI, specialist in filling and capping of glass, metal and plastic containers with twist-off and pre-threaded caps for dense, semi dense and pasty products; TIRELLI, focused on packaging equipment for the cosmetics industry and MACA Engineering S.r.l, specialist in designing and manufacturing machines for the production, assembly and cut of aluminium and plastic caps and closures. The solutions proposed by AROL GROUP can serve therefore the beverage, beer, food, wine, spirits, personal care, chemical, household care and cosmetics industries.
MACA ENGINEERING S.r.l of San Quirino (Pordenone, Italy), specialist in designing and manufacturing machines for the production, assembly and cut of aluminium and plastic caps and closures, joined the AROL Group, world leader in capping equipment.
AROL Group thus confirms its industrial project and strategy to vertically expand its range of high-tech machines for primary packaging, in order to ensure the ever-increasing safety standards in the final customer’s interest.
“We are particularly pleased to welcome in our family the MACA ENGINEERING team, which for over 30 years has been designing and manufacturing equipment synonymous of robustness, precision and reliability, perfectly in line with our values and objectives. We are fully aware of the the growing quality expectations of the bottling lines – in every product sector and country in the world – and the possibility of adding to AROL’s know-how the technologies related to caps production, so strong and firmly rooted in MACA ENGINEERING, will result in a unique offer in the industrial landscape, which will increase the skills of both companies, bringing a sure added value to our respective clients “commented Alberto Cirio, CEO of AROL S.p.A.
“This collaboration will allow us to accelerate in the innovation and development of our products and services, relying on the experience of AROL Group companies and on an incredible R&D team that has been able to fully understand the need for integration of the equipment in the smart factories of the latest generation”, said Andrea Marchioro, CEO of MACA ENGINEERING.
Closure Systems International (CSI) and Talkin’ Things®, the leading innovator in product communication platforms, have collaborated to integrate smart packaging technology into CSI’s global platform of closures. CSI and Talkin’ Things have developed a new packaging solution named Talkin’ Cap, which uses embedded Near Field Communication (NFC) tags, for application on the inside of closures. This technology introduces a powerful platform to support a brand owner’s mobile marketing activities right from the package itself…with just a simple tap.
Brand trustworthiness and product reliability are paramount for consumer loyalty. Talkin’ Caps ensure product safety and reduce brand owners’ liability by protecting against counterfeiting and “gray market” activities throughout the distribution stream.
CSI’s Talkin’ Caps allow for real-time consumer interconnectivity at the point of consumption, giving brand owners the unique ability to have dynamic interaction and gather actionable insights based on consumer location and usage history.
With 90 % of consumers using their smartphone to help make purchase decisions in a brick and mortar setting1, Talkin’ Caps are an app-less way to drive marketing content, brand and product information, gamification, loyalty programs, awards and coupons to connected consumers.
Made from sugar cane, bio-sourced plastics offer a new level of sustainability
United Caps, an international manufacturer of caps and closures, and Braskem, a leading Brazilian petrochemical company, reported they have collaborated to deliver to the market greener bio-sourced plastic caps and closures made from sugar cane as an addition to the United Caps product portfolio.
Bio ethanol, the feedstock for I’m green™ Polyethylene, the basis for United Caps greener bioplastic caps, is derived from sugarcane, a renewable alternative to traditional fossil feedstocks. Being a renewable feedstock, sugarcane captures and fixes CO2 from the atmosphere with every growth cycle, which occurs annually. This means that the production of I’m green™ Polyethylene contributes to the reduction of greenhouse gas emissions when compared to conventional polyethylene, made from fossil materials.
“As a result, the carbon footprint of I’m green™ Polyethylene is negative, when considering our life cycle analysis. This means that every kilogram of I’m green™ Polyethylene used in United Caps products results in 3.09 kilograms of CO2 being sequestered from the atmosphere,” Brendan Hill, Sales Manager at Braskem Netherlands B.V., explained “Apart from the feedstock, I’m green™ Polyethylene follows the same production process as traditional fossil Polyethylene, ensuring that our Polyethylene has the same characteristics, quality and properties as the fossil equivalent,” he added “It goes without saying that I’m green™ Polyethylene fits all existing end-of-life scenarios and that our ethanol is sustainably sourced with clear chain of custody certification possible.”
United Caps is initially bringing to market two standard closures manufactured using bioplastic resin from Braskem, including:
The VICTORIA closure, a 30/25 screw closure designed for still drinks.
PROFLATSEAL, ideal for dairy products and still drinks, both pressurized and non-pressurized.
Innovative caps and closures for the food and drink industry are the core business of the Luxembourg-based family company United Caps. Its custom-designed caps and closures solutions have been one of the most sought-after solutions in the packaging industry for years. The company has experience growth in the high single digits since its 2015 rebranding, with a significant percentage of production being bespoke products that are uniquely designed to meet customer needs for exceptional appearance and ease of use, both in the filling line and for the consumer.
