There were a number of challenges to overcome; firstly, the material needed to be recyclable in the UK utilising the current infrastructure. It then needed to be suitable for the demands of the hot fill process with a minimum temperature of 75°C and for the solution to be commercially viable, it had to run at the same speed as JDM’s current film. The material also needed to have a barrier to avoid the risk of delamination due to the acidity of some of the products being packed, whilst still maintaining a recyclable status.
FFP suggested their all PE laminate called FFPE that could be supplied with an EVOH barrier. This would enable the sachets to be recycled with carrier bags at supermarkets as classified by OPRL and would also address the functionality of the pack, avoiding the risk of delamination. FFPE can be supplied printed or plain and will run efficiently on existing lines without the need for costly modifications.
Katie Smith, Category Manager at JDM comments:
FFP and JDM worked closely together, running trials to ensure the material would run effectively and efficiently in production with no drop off in throughput compared to the previous non-recyclable film that was being used. It was also stringently tested through the hot fill process to ensure no issues would arise during actual production runs. The resulting all PE sachets are now on shelves in major retailers and are 100% recyclable through current UK recycling streams.