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Left: Yoghurt pots manufactured using Microcell technology save 20–25% plastic. |
Plastics are an integral part of the packaging industry: they provide reliable protection for products, often have a lower carbon footprint than alternative materials, and can be processed efficiently. At the same time, pressure is mounting on manufacturers to conserve resources and further reduce raw material use – without compromising on stability, functionality or recyclability. With the introduction of the EUPPWR, from 2030 onwards only packaging that is fully recyclable may be placed on the market; in addition, there are ambitious targets for the use of recycled materials. Promix Solutions offers an economically and environmentally sound solution to these challenges: Microcell technology. It typically reduces packaging weight by around 20%, fully preserves mechanical properties and, at the same time, enables true recyclability.
Lighter packaging – same performance – significant cost savings
Microcell technology involves incorporating environmentally neutral gases such as CO2 or N2 into the plastic. This creates a fine-pored, microcellular foam structure. Cell size and cell distribution are crucial: a very fine and homogeneous structure ensures that cups or trays achieve the same stability as conventionally manufactured packaging even after thermoforming – despite a significantly reduced density.
A typical extrusion line for packaging films with a throughput of 800 kg/h saves up to 3.8 tonnes of plastic per day using Microcell technology. This equates to around €3,800 per day or over €80,000 per month. Extrapolated over a year, this results in a reduction of around 1,000 tonnes of plastic per line.
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(Image: KGL S.A.) |
The lower film weight for the same film thickness not only reduces energy consumption during thermoforming but also reduces transport weight – which leads to an overall improvement in the carbon footprint. The technology is suitable for virtually all polymers and can be seamlessly integrated into both existing and new production lines.
Environmentally friendly and fully recyclable
As Microcell uses environmentally neutral blowing agents and contains no environmentally harmful additives, the packaging remains fully recyclable. Even production waste, such as that generated during thermoforming, can be easily recycled, as the additive does not accumulate in the material as is the case with chemical blowing agents.
Microcell technology is suitable for a wide range of packaging applications produced using extrusion and thermoforming processes: food packaging such as pots or trays, boxes and technical packaging, as well as form-fill-seal (FFS) applications.
Case study: The ‘lightweight’ yoghurt pot
In the case of yoghurt pots, which are often produced using the FFS process, Microcell enables a 20 to 25% reduction in material usage without compromising on shelf life or product protection. Whilst polystyrene is traditionally used, polypropylene and polyester are becoming increasingly important.
Case study: PP clamshell tray
In a 3-layer PP clamshell tray, the Microcell core layer forms the heart of the design. Sandwiched between two solid outer layers, it significantly improves insulation and withstands temperatures of up to 100°C. The foam structure reduces the material density considerably – in this example by 40%.
Microcell PP is a sustainable alternative to polystyrene or paper-coated solutions. As a mono-material, it fully complies with the requirements of the European Packaging and Packaging Waste Regulation (PPWR) and is fully recyclable. Furthermore, the process enables high-quality, cost-effective products for hot-fill applications, including disposable coffee cups.
Environmentally friendly, cost-effective, future-proof
Microcell combines environmental benefits with economic efficiency. Through the use of environmentally neutral propellants, significant material savings and full recyclability, the technology paves the way for sustainable, cost-effective and regulatory-compliant packaging solutions – today and in the future.
Promix at interpack in Düsseldorf from 7 to 13 May: Hall 7a, Stand C15, Swiss Pavilion.
