What are some of the challenges you've faced in developing recyclable packaging for retort, and how have you overcome them?
The biggest challenge was and still is to find or develop new raw materials that will provide sufficient mechanical and barrier properties, while providing recyclability. The standard structure suitable for retort would be PET/ALU/PP* in the case of wet pet food or PET-alox/OPA/PP* in the case of ready meals for human consumption.
The history of retort laminates and pouches goes back to the 1960s when the military used them to replace ALU (aluminum) cans to save high transportation and logistical costs. After 60 years of continuous improvement retort pouches are used for packing various food items. A shelf life* of 18 months (PET-alox/OPA/PP structure) or 24 months (PET/ALU/PP) structure is possible.
I started the development of recyclable structures for retort started by benchmarking available PP-based raw materials. The best materials in terms of mechanical properties and thermal stability were identified and chosen for proper production trials. The positive result was achieved after several runs.
From today’s point of view, it is possible to produce recyclable flexible packaging for hot filling and pasteurization. The “retort version” will be available as soon as new barrier layers are commercially available (they are still in the development phase).
Can you discuss any specific innovations or breakthroughs you've had in the field of recyclable flexible packaging?
My biggest breakthrough was the first positive internal production trial. After the initial phase of laboratory pre-tests, there was a time for validation under full industrial conditions. After several runs the positive result was achieved. It was a great feeling.
What role do you see recyclable flexible packaging playing in the future of the packaging industry?
Recyclable packaging will push flexible packaging forward in terms of innovation. In 2018, we were confronted with the new challenge of developing new packaging solutions, following new regulations from the European Commission. To achieve this, close cooperation with various suppliers and partners was necessary.
After five years the biggest players have their solutions or are at the end of the development stage.
What are some of the trends or emerging technologies you're excited about in the field of flexible packaging?
Recyclable packaging in general is the trend that I am most excited about. Being a packaging engineer became interesting and challenging after 2018. New raw materials are being developed.
On top of that, there are new barrier layers that can be recyclable. Today, everybody awaits OPP-siox suitable* for the retort process and is commercially available. An OPP-siox suitable material will provide barrier properties when using recyclable packaging, and it is currently in the development phase. Indeed, suitability for thermal treatment like sterilization makes the challenge even harder.
How does your background in flexible packaging contribute to your work in developing plant-based alternatives to animal leather?
I can work on new concepts of plant-based alternatives to animal leather thanks to my previous work on flexible packaging. My main area of responsibility was material development. My idea involves the application of bio-polymers and modification of their mechanical properties (for example E-modulus*, tear resistance, coefficient of friction) to match the properties of animal leather. Plant-based food waste from cafes and restaurants will be used as well.
Can you describe the process of developing a plant-based leather alternative, and what makes it different from traditional animal leather?
I test various bio-polymers (for example agar, cellulose) and their blends (various mixing ratios) and use them as binding substances. Plant-based food waste like fruit peels, coffee or grass, and dry leaves will be used to create the final product.
Benchmarking various additives influencing mechanical properties is a big part of my activities. For example, my newest “discovery” is the fact that copper sulfate improves the stiffness of agar.
My goal is to have material that will exhibit mechanical properties on the level of animal leather. The final product will not contain any petroleum-based raw materials. Dyes and adhesives will be plant-based as well.
How do you see the future of flexible packaging and leather production evolving, and what role do you hope your work will play in that evolution?
Both flexible packaging and leather will evolve in a more sustainable and environmentally friendly direction. There is no other way. I already proved that recyclable packaging can be used under full industrial conditions. I am going to prove the same with plant-based-leather alternatives.
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Glossary of terms
- PET - Polyester
- ALU - Aluminum foil
- PP - Polypropylene
- PET-alox - Polyester coated with aluminum oxide layer
- OPA - oriented polyamide
- Shelf life - the period within which a product may be stored without becoming unsuitable for consumption
- OPP-siox -Oriented Polypropylene covered with a thin layer of silicium oxides.
- E-modulus - Elastic modulus. It is a mechanical property of a material. It measures measures their stiffness or resistance to elastic deformation under stress.
