A longstanding packaging challenge – the environmental impact of small plastic sachets – has found a promising solution through a new industry collaboration.
Compostable film producer Futamura, flexible packaging converter Repaq, and machinery specialist GK Sondermaschinenbau have teamed up to develop a fully compostable sachet for liquids such as condiments, sauces and creams.
These small-format packs, used globally in the hundreds of billions, have traditionally been made from complex multi-layer structures that are difficult, if not impossible, to recycle. Their size, contamination with food, and mixed-material construction mean they typically end up in landfill or as litter.
Now, after two years of development, the trio of companies has launched a certified home- and industrial-compostable alternative using Futamura’s NatureFlex cellulose-based film as the barrier layer. The laminate includes an additional biofilm that enables hermetic sealing, delivering the product protection and shelf life demanded by brands – with no compromise in production efficiency.
Sven Seevers, technology manager at Repaq, said the solution achieves an oxygen transmission rate (OTR) of 0.5 at 23°C and 50 per cent relative humidity, with a shelf life of up to 12 months. “It was very important for us to replace this non-recyclable packaging, which can pollute the environment, with a compostable solution. We succeeded after two years of development work with our great co-operation partners,” he said.
GK Sondermaschinenbau adapted its equipment to ensure reliable machinability of the new laminate, confirming performance across a range of machinery sizes. “Almost no adjustments were required to use the solution supplied by Repaq,” said sales director Nico Merkel. “The packs can withstand pressure and perform at scale.”
Futamura’s regional sales manager Joachim Janz described the launch as a breakthrough. “Small-portion sachets have always been the tricky ones for recycling, so this success in compostability is good news to be shared.”
The first commercial compostable sachets using the new structure are set to enter the market shortly.
