Netstal, a leading name in the manufacturing industry, has introduced a groundbreaking thin-wall cup designed with a strong emphasis on recyclability. The key feature of this product is its composition, made entirely from polypropylene (PP), making it highly suitable for recycling, and its development is aimed at contributing to a sustainable circular economy.
This lightweight yogurt cup, weighing a mere 5.4 grams, with a 200-gram filling capacity and a wall thickness of just 0.3 mm, is a testament to Netstal’s commitment to sustainable packaging. Unlike traditional in-mold labels, the label on this cup is designed to be easily removed during mechanical recycling, ensuring the purity of the PP stream by effectively separating printing ink particles. The application of Injection Compression Molding (ICM) in the manufacturing process has resulted in an impressive 34% reduction in the cup’s weight. Furthermore, the combination of ICM and product optimization has led to a 27% reduction in packaging volume, enhancing its sustainability.
The development of this recyclable packaging was a collaborative effort, involving high-end system partners like Glaroform, Beck Automation, SABIC, IPB Printing, motan, Regloplas, and Uniform Color. Emmi AG, a prominent dairy product bottler, provided essential input from the food industry, ensuring that the packaging’s specifications were optimized while preserving its original design.
The manufacturing process for this sustainable thin-wall packaging, specially designed for dairy products, is carried out with efficiency and reliability. The product is produced in four cavities at a cycle time of 2.7 seconds using an Elion 1750 machine equipped with a hybrid injection unit. Netstal’s machines have long been known for their leading energy efficiency, and the optional adaptive system pressure reduction further enhances their performance. By determining the optimal point and adjusting hydraulic system pressure, energy consumption is significantly reduced.