PulPac licensee, Stora Enso, announces the opening of a groundbreaking Dry Molded Fiber Production Unit in Skene, Sweden. The facility is the largest and most advanced of its kind, marking a significant milestone in sustainable packaging technology. Production is set to begin in Q4 2024 after successful large-scale testing.
Stora Enso’s Skene Production Unit utilises PulPac’s innovative Dry Molded Fiber process to produce high-performance formed fiber products, such as cup lids, designed to replace traditional plastics in food and beverage packaging. Unlike conventional wet forming, the dry process reduces water and energy consumption significantly, thus offering an even more sustainable manufacturing method for fiber-based packaging. Additionally, any excess material is recaptured and reused, ensuring a circular process with minimal waste.
At the heart of this innovation is the advanced technology developed by PulPac, the leading company in the field. Their Dry Molded Fiber technology provides efficient production at high speeds, enabling Stora Enso to meet growing market demand for fully renewable, recyclable, and biodegradable fiber-based packaging solutions.
The products produced with Dry Molded Fiber offer a significantly lower CO2 footprint compared to single-use plastics. The dry forming process offers also flexibility in barrier additives for customised functionality as well as an excellent surface finish with the option to advanced decoration possibilities.
Sustainability is at the core of Stora Enso’s operations. Implementing Dry Molded Fiber is an example how they continue to lead the transition to circular, low-carbon solutions in the packaging industry, making a lasting impact on both the environment and the communities it serves.
With a joint investment of around EUR 29 million by Tetra Pak and Stora Enso, a new recycling line for post-consumer beverage cartons is starting operations in Poland. The line has the potential to triple the annual recycling capacity of beverage cartons in the country – from 25,000 to 75,000 tonnes – and provides scope to absorb the entire volume of beverage cartons sold in Poland, as well as additional volumes from neighbouring countries, including the Czech Republic, Hungary, Slovakia, Latvia, Estonia and Lithuania.
Featuring an annual capacity of 50,000 tonnes, the state-of-the-art line at Stora Enso’s production unit in Ostrołęka (Poland) handles solely beverage carton material separation, detaching fibres from polymers and aluminium. The fibres are then recycled into cardboard materials, effectively contributing to material circularity by turning used paper-based packaging into new paper-based packaging materials. This new paper recycling facility is complemented by Czech company Plastigram Industries, that, together with Tetra Pak, is industrialising a solution to recycle polyAl1 into new products.
The new line is set to ramp up recycling of beverage cartons throughout Central and Eastern Europe, signaling the beverage carton industry’s willingness to support the circularity goals of the proposed EU Packaging and Packaging Waste Regulation (PPWR), and showcasing the pivotal role of recycling in helping the green transition of the food packaging sector. The industry has already invested approximately EUR 200 million to increase the capacity for beverage carton recycling in the EU and plans to invest a further EUR 120 million by 2027.2
1The non-fibre component of carton packages is known as polyAl, which designates the layers of polyolefins and aluminium being used as barrier against oxygen and humidity to protect the food content in aseptic carton packages.
2https://www.beveragecarton.eu/wp-content/uploads/2022/03/ACE-Impact-assessment-study-of-an-EU-wide-collection-for-recycling-target-of-beverage-cartons-Roland-Berger.pdf
Stora Enso and Tetra Pak are jointly examining a shared beverage carton recycling solution to meet the growing recycling need in Benelux, responding to the demand for circular paper-based packaging solutions. The joint feasibility study includes a plan for a comprehensive beverage carton recycling facility at Stora Enso’s Langerbrugge site in Belgium. Processing of the fibers would take place at the Langerbrugge site, while the polymer and aluminum barrier materials would be recycled by a dedicated partner.
Approximately 75,000 tonnes of beverage cartons are put on the Benelux market annually, a growing volume of which more than 70 % is already collected for recycling. Currently, there is no existing beverage carton recycling infrastructure in Benelux. This collaboration between Stora Enso and Tetra Pak would create a complete recycling system for beverage cartons in Benelux and surrounding regions.
Within the solution, Stora Enso would process collected beverage cartons and recover the fibers. The recycled fibers would serve as source material for producing recycled containerboard within the Langerbrugge site, delivering a fully circular solution. Tetra Pak would secure a recycling solution for polymer and aluminum materials to be processed by a dedicated partner.
The recycling project is linked to Stora Enso’s recently announced feasibility study to potentially convert one of the Langerbrugge site’s paper lines into a high-volume recycled containerboard line. This feasibility study is expected to conclude in the first half of 2023. Upon on a decision to invest, the recycled containerboard line is expected to be in production during 2025. The joint study with Tetra Pak will follow the same timeline.
The proposed recycling line in Langerbrugge will initially process an estimated 50,000 tonnes of recycled cartons per year with the potential to increase.
“With this joint initiative, we underline our commitment to local recycling progress and improving infrastructure in Benelux, a region with high volumes of collected beverage cartons. Stora Enso is a trusted and important partner which has the know-how and experience we need in fiber recycling. Together with them, we have the potential to put in place a circular solution that helps us secure a world where a growing number of carton packages is collected, recycled and we can minimise litter” – Chakib Kara, Managing Director France & Benelux, Tetra Pak.
“At Stora Enso, we constantly pursue opportunities to deepen our commitment to a circular packaging future. Circularity advancement requires smart investments and collaboration with the right partners. By working jointly with Tetra Pak, we can simultaneously create value, enhance circularity, and grow our competitiveness.” – Markku Luoto, VP LPB Aseptic and CUK, Stora Enso.
Beverage cartons contain high-quality fresh fibers that are an excellent source material for producing recycled paper containerboard. The Langerbrugge site offers a strategically important location to enable a local paper-based packaging circularity solution. Further, beverage carton collection for recycling is already advanced in Benelux.
Sulapac and Stora Enso launch a renewable and microplastic-free straw to combat the global problem of plastic waste. The straw has strong usability and works just like a traditional straw. The new straws are available to brands and consumers looking for more eco-friendly solutions.
The first customers include Finnair’s lounges in Helsinki replacing their plastic and paper straws, food delivery platform Wolt, the alcoholic beverage brand company Altia, Hotel St. George, and vegan café Kippo, among the others. The first customers represent different business sectors but have one common interest: to be in the forefront of sustainability. For end-consumers, the straws will be available in January via Biofutura.com, an online store specialised in compostable tableware and packaging, and an online retailer Verkkokauppa.com.
“There’s clearly a large demand for our product that both fulfills the sustainability criteria and has superior usability. Like all Sulapac materials, the straw is 100 % microplastic-free. It is designed to mimic nature; if the straw accidentally ends up in the ocean, it acts like a birch leaf and does not harm the ecosystem,” says Sulapac CEO Suvi Haimi.
The straws are based on Sulapac’s patent pending material innovation. The main components are renewable materials such as wood and plant-based binders. The straw is microplastic-free, meaning that it is designed to be fully biodegradable in different environments. The straw complies with existing waste systems and is designed to be recycled via industrial composting.
“Billions of plastic straws are produced and used every week, creating harmful waste that often end up in the sea. This renewable and biodegradable material can replace fossil-based materials and help combat plastic waste. Our cooperation with Sulapac allows us to explore new types of innovative and scalable materials and widen our offering of renewable solutions”, says Marcus Dehlin, Head of Business Alliances, Stora Enso.
In the first phase the straws will be available in Europe and a global roll out will follow. The straws are produced with machinery originally designed to produce plastic straws.
Stora Enso and Sulapac continue to combat the global problem of plastic waste by introducing a demo of a sustainable straw at Slush 2018, a global leading startup event gathering of 20,000 tech enthusiasts. The demo, targeting industrial scale production, is designed to replace traditional plastic straws with renewable ones. The straws are based on Sulapac’s biocomposite material – made of wood and natural binders – designed to be recycled via industrial composting and biodegrade in marine environment.
“This is an important step for Stora Enso and showcases our long-term commitment to gradually replacing fossil-based materials with renewable solutions. Our collaboration with Sulapac is a great example of what we can achieve through partnership in terms of driving innovation to create sustainable solutions within the bioeconomy,” says Annica Bresky, EVP, Consumer Board division.
Stora Enso signed a joint development agreement with Sulapac in May 2018 to license its materials and technology. The development of the demo straw is a joint collaboration between Stora Enso and Sulapac – a cooperation which complements Stora Enso’s extensive biocomposite portfolio.
“Eco-awareness is a strong driver for consumer demand, and our customers want help in replacing non-renewable materials. Different biocomposite solutions, such as renewable caps and closures and straws will be add-ons and a complement to our own consumer board portfolio, bringing additional value to our customers,” says Hannu Kasurinen, SVP Head of Liquid Packaging and Carton Board.
Sulapac’s material works in existing extrusion lines and the target is to have the straws commercially available in Q2 2019.
“Today, we proudly announce that we are launching a demo for a recyclable, microplastic-free and marine biodegradable straw. This is the world’s most sustainable straw that can be produced on an industrial scale and we have jointly developed it with Stora Enso. Billions of plastic straws are produced and used every week. This straw has the potential to be a true game changer,” says Sulapac’s founder and CEO Suvi Haimi.
The collaboration between Elopak and Stora Enso has resulted in the launch of the first gable top carton made from natural brown unbleached paperboard, creating the Naturally Pure-Pak® carton with a highly distinctive, natural look and feel.
The new paperboard, Natura Life by Stora Enso, retains the natural brown colour of the wood fibres and has a visible fibre structure. This creates a naturally different, sustainable and authentic package that meets demands from growing trends in ethical, ecological and organic products. The natural look and feel of the new Pure-Pak® carton supports the values of organic products and brings outstanding presence on shelf.
This week Arla Foods in Sweden announced the launch of several products in its organic EKO brand range using Pure-Pak® cartons made of natural brown paperboard.
“We believe that the new Pure-Pak® carton will grab attention as it communicates organic values and is totally different to anything else in the increasingly complex chilled dairy segment,” says Anna-Karin Modin Edman, Sustainability Manager at Arla.
The Pure-Pak® carton with the new natural brown paperboard is available in 1 litre and 500 ml sizes. It runs on existing filling lines for both fresh and ESL products without modifications or changes in machine settings. The new Pure-Pak® cartons are 100 % recyclable and can be recycled through existing channels.
Ivar Jevne, Elopak’s Executive Vice President Board and Blanks Supply says: “All liquid packaging board sourced from well-managed forests is environmentally friendly, however this paperboard reaches new levels in climate responsible packaging. The innovation is the result of bringing together the best of expertise, competence and experience from our collaboration with Stora Enso. This is not just another paperboard for our Pure-Pak® cartons, but a totally new concept.”
The new paperboard is produced by Stora Enso, with the majority of fibres sourced from Swedish and Norwegian forests.
“We are happy about the cooperation with Elopak and excited to introduce the new unbleached liquid packaging board Natura Life by Stora Enso. What makes this paperboard unique is that it is brown on the inside as well as on the outside. This will enhance the organic appearance of carton packaging and make it stand out on the shelves,” says Annica Bresky EVP Stora Enso Consumer Board division.
