Resource Efficient Innovations Database (REID)

Eliminating the cardboard insert for foil sealed jars

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Eliminating the cardboard insert for foil sealed jars
In this solution the foil is stuck directly to the plastic lid, elimiating the need for a card insert
In Development – Weener claims that the new solution can be integrated into existing production lines for energetically suited plastic lids without extensive assembly work, so that the usual production process is not interrupted or slowed. The process has been developed in conjunction with a sealing foil supplier and they are currently in the testing process. Weener is actively looking for potential industry partners to trial this technology, hopefully towards the end of 2011.

Packaging Reduction, Storage and Transport efficiency

Product Categories

Relevant Materials
Plastic – rigid

Relevant Packaging Formats
Bottles and jars, Closures and dispensers (including: triggers, dosing aids, reseal and reclose devices etc.)

Supply Chain Phase
Consumer, Design, Filling


Weener have developed a new sealing system for foil sealed jars that does not require a cardboard disc insert. The characteristic popping sound that is heard when a jar of coffee or similar product is first opened is usually produced when the wax layer is broken between the foil and the cardboard disc that remains in the jar lid after opening. In existing closures, the foil is attached to the cardboard disc in order to ensure that it remains intact during delivery to the filling site. In Weener's new system, the foil is bonded directly to the plastic closure. On opening, a sound is still created on first opening, and the foil is also broken instantaneously, avoiding the need for the consumer to peel or pierce the foil to gain access to the product.

Potential Benefits

Material elimination is an obvious benefit, but the manufacturers also identify a number of other advantages:
  • Cost advantages with regard to the closure (less input, less expensive tools, less packaging waste fees)
  • No temperature-regulated transport or storage necessary, since the temperature-sensitive wax layer is no longer used.
  • No more film remnants on the opened jar.
  • Improvement of the peeling process (pull tab can be added) No additional investments on the existing assembly equipment.

Intellectual Property

The concept is currently in the patenting process in the name of Weener Plastics.

Consultant View

This is another example where package light-weighting projects can also provide enhanced consumer experience such as ease of opening. There does not have to be a compromise between environmental benefit and packaging functionality.

Contacts and Further Information

Company details:
Weener Plastik AG
Industriestraße 1
D-26826 Weener/Ems
Phone: +49 4951 306 0
Fax: +49 4951 306 150

Technology contact details:
Helge Flockenhagen, Project Manager
Tel. +49 (0) 4951/306-195

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