Sustainability, Simplified

Many brands are adopting substrates that prioritize recyclability and post-consumer recycled content, and this is driving a shift from Form-Fill-Seal (FFS) to Fill-Seal (FS) platforms.
© Deyan Georgiev – stock.adobe.com

Alleviating PET’s manufacturing pain points will expedite mono-material packaging’s proliferation.

By Dan Margherio is Director of Sales for IMA Food North America

In response to evolving regulatory mandates and growing consumer demand for environmentally conscious solutions, major brands in dairy, snack and other segments are moving away from conventional virgin plastics like polystyrene, adopting substrates that prioritize recyclability, post-consumer recycled content, or both. However, as the food industry embraces sustainability on an ever-broadening scale, packaging materials must be reimagined and reshaped every bit as much as they must be recycled and repurposed. Despite their obvious promise in reducing the sector’s carbon footprint, such newer, more eco-friendly materials often come with their own unique challenges for packaging manufacturers and brand owners.

Of course, these obstacles are well worth overcoming. For starters, the shift away from traditional plastics is not solely driven by environmental concerns. Among other issues is increasing awareness and alarm concerning conventional plastic resins’ high levels of polyfluoroalkyl substances (PFAS). Commonly (and ominously) known as “forever chemicals,” PFAS can pose long-term health and environmental risks – well-founded fears that have influenced and expedited the push toward next-gen, ideally PFAS-free mono-material packaging.

For this reason and others, against this backdrop one substrate in particular, PET, has emerged as a particularly promising option for its blend of recyclability, functional benefits and consumer appeal. PET’s widespread recyclability is a defining advantage, with many regions in the United States offering curbside PET recycling programs. Such broad recycling accessibility makes PET a practical choice for both manufacturers and consumers, directly supporting efforts toward a circular economy.

That said, sustainable packaging is only truly sustainable if it admirably serves its primary purpose: product protection. Beyond recyclability, PET excels in safeguarding products from oxygen and moisture, both critical to preventing premature spoilage; few things erode brand loyalty like a food item that goes bad before its labeled expiration date. Additionally, PET’s transparency provides a distinct edge in competitive retail environments. The ability to showcase the product within the packaging builds trust among consumers and enhances shelf appeal, both key to standing out in crowded supermarket aisles.

Innovations in cutting equipment, such as IMA Food North America’s Zero Technology process, are making it easier to separate multipacks into individual units. Image courtesy of IMA Food North America.

PET Peeves

Considering the myriad benefits PET enjoys compared with other resins – including traditional plastics and several sustainability-minded ones – the hesitance and graduality behind PET’s adoption largely boils down to one issue: manufacturability. Despite its outstanding attributes, there’s simply no denying that PET is fickle and carries production challenges both upstream and downstream.

One prominent pain point has been “cut-ability,” meaning the ability to separate formed cups into individual cups. PET’s density and ruggedness make it harder to cut and form compared with other substrates. Moreover, PET does not “snap” as easily as most other resins, necessitating enhanced measures for cups that require protective layers above and beyond sealing liners. This issue becomes especially evident with resealable cups – for example, quart-sized containers of yogurt.

Fill-Seal Operations

To address these challenges, many manufacturers are shifting from traditional form-fill-seal (FFS) processes to fill-seal (FS) operations. By outsourcing the cup formation step, manufacturers can simplify production and better manage PET’s unique characteristics. FS systems provide greater flexibility, enabling manufacturers to adjust component sizes, graphics, and other design elements with greater ease. Notably, such flexibility is especially valuable amid fluctuating substrate availability.

FS processes involve loading preformed cups into stackers, sterilizing them with vaporized peroxide or sterile air/steam, and sealing them with film, foil or paper. These “snap-on” lids provide an added layer of protection, ensuring product integrity. Advanced filling systems further enhance the consumer experience by preventing residue from collecting on the seals, maintaining a clean appearance upon initial product opening.

In focusing solely on filling and sealing preformed cups, FS operations offer an attractive, streamlined alternative. For one, the FS approach eliminates some of the more labor-intensive and technically demanding aspects of FFS, such as controlling timing and temperature during thermoforming. Modern FS equipment, designed for user-friendly operation, addresses the ongoing shortage of skilled packaging equipment operators, making it an increasingly compelling option for manufacturers seeking to optimize manpower.

To simplify substrate-specific challenges, many manufacturers are shifting from Form-Fill-Seal (FFS) to Fill-Seal (FS platforms, such as the Hamba Flexline FS line. Image courtesy of IMA Food North America.

Form, Fill & Seal Systems

But of course, FFS systems still have their place and, like FS setups, are evolving along with the packaging substrates they handle. For instance, innovations in cutting equipment and simpler FFS equipment retrofits are making it easier to separate multipacks into individual units, overcoming one of the primary obstacles posed by PET’s density. One such technology features an innovative extractable central cutting unit design, and utilizes a patented punch process to deliver precise cutting and pre-cutting of eco-friendly materials like PET, PP, and PLA.

As sustainability continues to redefine the food packaging industry, PET emerges as a standout choice for its versatility and environmental benefits. With its recyclability, superior product protection and established consumer appeal, PET offers manufacturers a compelling eco-conscious packaging solution. While manufacturability challenges remain, advancements in production technologies and equipment are paving the way for broader adoption. By leveraging these innovations, food manufacturers can achieve their sustainability objectives while delivering the quality and convenience consumers expect.

About the Author

Dan Margherio is Director of Sales for IMA Food North America, which serves the dairy and food industries with several brands of the IMA group. The company’s portfolio comprises a wide range of packaging equipment, including filling and sealing machines (FS); forming, filling and sealing machines (FFS) for various volumes, including multipacks; filling systems for flexible stand-up pouches; wrapping machines; and aseptic vertical and horizontal FFS systems for stick packs and pouches. www.imadairyfood.com.