Elopak Unveils Groundbreaking Recyclable Carton Technology, Accelerating the Shift from Plastics

This is an AI generated illustration and does not represent actual product or service.

In a significant stride toward a more sustainable packaging future, Elopak, a company in carton packaging solutions, has unveiled a novel paperboard-based container technology. Detailed in the recently published international patent WO2025133300A1, this innovation centers on a new multilayer barrier coating that enhances recyclability without compromising the protective qualities essential for liquid food products like milk, juices, and yoghurt.

This development is a cornerstone of Elopak's mission to lead "the shift away from plastics," a vision prominently featured on their website. The company highlights that cartons can reduce plastic use by up to 85% and lower emissions by 73% compared to plastic alternatives. This new patent provides the technological backbone to make these sustainable packages even more circular.

The Innovation: A Smarter Barrier

The core of the invention is a multilayer barrier coating that replaces or augments traditional, hard-to-recycle layers. The key layers in the sequence are:

1. A Polyvinyl Alcohol (PVOH) Layer: This layer provides crucial gas barrier properties. The patent specifies a PVOH with a high degree of hydrolysis (70% or greater), which is key to its performance and processability.

2. A Bonding Layer: Typically a modified polyethylene, this layer ensures strong adhesion between the PVOH and the moisture barrier.

3. A Moisture Barrier Layer: Made of materials like Low-Density Polyethylene (LDPE), this layer protects the paperboard from liquid.

The most significant advancement lies not just in the materials, but in the manufacturing process. The layers are co-extruded simultaneously from a melt, rather than being applied in separate, energy-intensive steps using water-based dispersions. This method is faster, reduces energy consumption by eliminating extensive drying, and critically, results in a more uniform, pinhole-free barrier.

A Leap in Recyclability

The primary challenge with multi-material packaging has always been the difficulty of separating the components for recycling. Elopak's new laminate structure directly addresses this issue.

The patent demonstrates through repulping tests that containers using this new barrier coating disintegrate in a fraction of the time compared to traditional materials. A reference laminate took 30-35 minutes to separate, while the new material achieved complete fiber disintegration in just 5-10 minutes.

Furthermore, the separated polymer fractions from the new material form larger, cleaner pieces, making them easier to sort and recycle. This translates to a more efficient recycling process with lower energy consumption and a higher yield of pure paper fibers.

Synergy with Sustainability Goals

This technological breakthrough aligns perfectly with Elopak's public commitments. The company’s "Packaging by Nature®" philosophy and "Naturally Circular" initiatives emphasize creating packaging that is renewable, recyclable, and leaves the world unharmed. By designing for end-of-life from the start, this patent exemplifies their strategy of "Repackaging Tomorrow."

Elopak's new patent represents more than just an incremental improvement; it is a fundamental rethinking of carton lamination. By creating a high-performance barrier that is also highly recyclable, Elopak is strengthening the carton's position as the most sustainable choice for liquid packaging.

This invention not only reinforces the environmental credentials of their iconic Pure-Pak® cartons but also provides a tangible solution for brands under increasing regulatory pressure to improve packaging sustainability. As the world seeks to reduce plastic waste and carbon emissions, Elopak's latest innovation proves that the future of packaging is not only paper-based but also intelligently designed for a circular economy.

Trending Stories

Latest Stories