Recyclable PP Coffee Packaging with Integrated Processing

Flexible packaging for coffee products is shifting toward recyclable mono-material structures that maintain barrier performance while remaining compatible with high-speed production. In this context, SÜDPACK and Hesser Packaging GmbH are presenting a PP-based stand-up pouch concept for 1 kg coffee formats, combining material design with processing on dedicated vertical packaging equipment.

Mono-material structure targets recyclability and barrier requirements
The packaging concept is based on SÜDPACK’s CarbonLite^® film family, which uses polypropylene mono-material structures aligned with current PPWR design guidelines. The films are designed to achieve recyclability rates above 90% based on internal assessments, while reducing material usage compared with multilayer laminates.

For coffee packaging, barrier performance remains a primary requirement due to sensitivity to oxygen, moisture, and light exposure. The films incorporate oxygen and water vapor barriers tailored to extend shelf life and preserve aroma. Optional metallization or white pigmentation provides additional UV protection, addressing degradation risks during storage and distribution.

The structure is positioned as an alternative to conventional PET/Alu/PE laminates, which typically offer high barrier properties but are difficult to recycle due to mixed-material composition. By contrast, the PP mono-material approach supports mechanical recycling streams while maintaining functional performance required for dry food packaging.

Industrial compatibility with existing packaging lines
A key aspect of the concept is its compatibility with existing converting and packaging infrastructure. The films can be processed on established equipment, enabling integration without significant line modifications. This is relevant for manufacturers transitioning toward a more sustainable flexible packaging portfolio while maintaining throughput and operational stability.

Sealing performance is engineered to support consistent pouch integrity and integration of degassing valves, which are essential in roasted coffee packaging to release CO₂ while preventing oxygen ingress. Stable sealing also contributes to reduced product loss and improved shelf consistency.

Stand-up pouch format to be demonstrated at interpack
At interpack (May 4 to 10, 2023, Düsseldorf), the packaging concept is being shown as a 1 kg stand-up pouch for whole beans and ground coffee. The format supports retail display requirements while maintaining structural stability during handling and transport.

Printing options include rotogravure, flexographic, digital, and 7-color processes, allowing adaptation to branding and product-specific requirements without altering the base material structure.

Vertical packaging system supports high-throughput production
The pouch concept is being demonstrated in combination with Hesser’s PMX 4001 vertical flow pack machine, designed for dry food applications such as coffee, flour, and sugar. The system reaches outputs of up to 65 pouches per minute under continuous operation, based on 500 g whole bean coffee packs.

The machine supports multiple pouch formats and sealing configurations while maintaining seam consistency. Extended evacuation times enable deep vacuum conditions, which help preserve aroma and reduce oxidation. High filling accuracy at elevated speeds ensures consistent pack weights, a critical parameter for both regulatory compliance and cost control.

Integrated IO-Link connectivity and Synexio compatibility enable real-time data acquisition for process monitoring and predictive maintenance within a broader digital supply chain environment. The open machine design allows access from all sides, simplifying cleaning and reducing changeover times between production runs.

Combined material and machinery approach
The joint presentation reflects a coordinated approach between material development and machine design, addressing both sustainability and production efficiency. By aligning recyclable film structures with compatible processing equipment, the concept targets industrial scalability without compromising barrier performance or throughput.

Edited by Aishwarya Mambet, Induportals Editor, with AI assistance.

www.suedpack.com