Resource Efficient Innovations Database (REID)

Stretchable aluminium foil offers light weighting opportunities for confectionary wraps and lidding materials

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Stretchable aluminium foil offers light weighting opportunities for confectionary wraps and lidding materials
A laminated structure consisting of a 3 micron reverse printed BOPP film laminated with a 6.5 micron aluminium foil can be used to significantly reduce the material resources required for wrapping chocolate figurines, tablets and dairy products and for lidding materials.
In Use – This material can be used to wrap chocolate figurines, chocolate tablets and cheeses and other dairy products that require the aluminum foil wrapping or can be used as a lidding materials for yogurt or soft cheeses.

Benefits
Packaging Reduction, Product Waste Reduction, Resource efficiency (e.g. filling line efficiency), Storage and Transport efficiency

Product Categories
Food

Relevant Materials
Laminates, Metal, Plastic – Flexible

Relevant Packaging Formats
Flexible & Films

Supply Chain Phase
Packing, Production

Details

This laminated structure consists of a 3 micron reverse printed BOPP film laminated with 6.5 micron aluminum foil. The total weight of the packaging is 21 grams per metre square.
The very thin layer of BOPP film (2.7 grams per metre square in weight) is equivalent to the lacquer that is used during the printing of unsupported aluminum foil, but it brings significant strength to the aluminum foil to protect from physical damage such as scratching and tearing. The BOPP film also protects the foil from corrosion.
 
With only 2.7 grams per metre square of film in the laminated structure, there are no adverse impacts on the dead fold property of the aluminum foil. The laminated structure is equivalent in strength to 18 micron aluminum foil (or 49 grams per metre square of foil), leading to significant material savings overall.
 
Furthermore, because of the strength of the material the laminated structure runs better on the machine and results in reduced machine downtime and waste during wrapping.
 
By reverse printing the BOPP film the ink is isolated between the film and foil layers, and therefore no direct food contact with the ink is possible. This is important for bunch wrap packaging style used for confectionary figurines, where the foil is folded in such a way that sometimes the printed side can come into contact with the food.
 
The film is also offered with a heat sealable effect for chocolate tablets or yogurt/cheese lids.  In the heat sealable format, the BOPP film brings extra protection for chocolate tablets that include broken nuts or crunchie ingredients, protecting the packaging from puncture or tearing.  The heat seal starts at the low temperature of 70 C. The BOPP also provides protection of aluminum lids from corrosion by aggressive products such as soft cheese and yogurts. 
 
The material, branded as Yango AL, is produced by Moneta-S in the Slovak Republic.

Potential Benefits

The principal environmental benefits are improved resource efficiency and reduced packaging waste through use of less material. The base weight of Yango AL is 21gsm, compared to 38gsm for the 14 micron aluminium foil that is typically used for this type of packaging. As a result, 45% more candies can be wrapped per kg of Yango Al packaging material compared to alternative substrates. This also results in improved distribution efficiencies for the delivery of packaging materials to the packer/filler.

Furthermore, the improved performance of Yango AL reduces product damage (through scratching, tearing and puncture) and therefore reduces requirements for secondary packaging materials
Improved machinability results in further environmental benefits through reduced downtime and subsequently less material process waste. 

Intellectual Property

There is no patent registered for this invention, but Moneta-s believes they are the only company in the world that can print and laminate on a 3micron BOPP film.

Consultant View

Laminated materials will be more difficult to recycle than simple aluminium foil. However, this type of packaging is very unlikely to enter the material recycling stream, and will certainly not be present in large quantities. It is therefore likely to have no significant impact on recycling processes. The increased complexity of the substrate is more than justified by the subsequent material savings and improved performance delivered by the material.

Contacts and Further Information

Katarina Magyarova   - Marketing director
Masarykova 60, 07101 Michalovce, Slovak Republic
Phone: +421 917 752 890 / Mobile:+421 918 582 317
Fax: +421 56 668 42 18
E-mail: katarina@moneta-s.com

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