What are the best high barrier flexible packaging materials for recyclable coffee packaging in the UK in 2023?
As a packaging buyer, you are well aware of the increasing demand for recyclable flexible packaging options for coffee packaging. Choosing the right packaging film can make all the difference in terms of shelf-life, bottom-line profitability and your brand. In this article, we will focus on three of the best recyclable high barrier flexible packaging materials for coffee packaging in the UK: mono-PE films, mono-PP films, and paper films.
Mono-PE Films
Mono-PE films are made from a single material, polyethylene (PE), which makes them easier to recycle compared to multilayer films. They are front-of-store recyclable (category 4) at major retailers in the UK and thus recognised as recyclable by OPRL, although they are not widely home recyclable yet.
With the right additives (such as EVOH) mono-PE films offer excellent oxygen barrier properties, which is essential for coffee packaging to maintain shelf-life. Mono-PE films are known for their good resistance to moisture too, ensuring the coffee stays fresh.
However it is important for you to consider that, they tend to be more challenging to run on packing machines compared to conventional or mono-PP films. That said, some experienced film suppliers have developed their mono-PE films to minimize these issues for coffee packaging, offering better runnability and making them a more viable option. This highlights the value of you working with a film supplier experienced in the coffee industry and who has good product innovation to ensure the best possible packaging solution for your coffee brand.
Another potential drawback of mono-PE films for coffee packaging is that they may not be quite as strong as multilayer films, however if you chose the correct grade then you should minimise any issues with this and on the other hand it is possible to achieve an excellent seal strength with mono-PE.
In terms of branding, mono-PE films offer you good printability, providing a great opportunity to showcase your brand. However, you do need to be careful packaging coffee as they can sometimes be slightly more translucent than conventional films. Also, with most mono-PE films you lose the ability to print good metallic colours.
Mono-PP Films
Mono-PP films are made from a single material, polypropylene (PP), which also makes them easier to recycle compared to multilayer films. They too are front-of-store recyclable (category 5) at major retailers in the UK and thus recognised as recyclable by OPRL, although they are not widely home recyclable yet.
Some of the new advanced mono-PP high barrier films offer you excellent barrier properties for both oxygen and moisture, providing you the best recyclable option for keeping coffee fresh. By way of example, tests by independent coffee roasters on SPP’s ultra-high barrier mono-PP material, alongside of a range of mono-PE materials from other suppliers has proven the superior shelf-life this material can offer you as a recyclable coffee packaging solution.
When it comes to packing machines, mono-PP films are known for their good runnability, making them easy to handle and efficient in packing processes. We have found that given the choice, coffee roasters usually prefer the mono-PP high barrier films over against mono-PE as a recyclable coffee packaging solution, as they are easy to run. You can use them in both vertical and horizontal packing machines, providing flexibility. Additionally, they have good seal strength, and they can provide you with a good shelf presence due to their mechanical properties.
Regarding branding, mono-PP films offer you excellent printability and have a natural gloss, providing a premium look and feel. You can also achieve a cost-efficient matt effect. You can achieve a good level of opacity and depth of colour if you use a metalised coating, which helps you avoid some of the challenges coffee roasters have found with mono-PE coffee packaging.
Paper Films
Recyclable paper films are another option for a recyclable coffee packaging. These films are made by applying a very thin advanced heat-seal and barrier coating to paper. Providing the coating is no more than 10% then the paper film is considered widely home recyclable or kerbside recyclable in the UK under OPRL guidelines. This is the most recyclable option available to you for coffee packaging currently.
It is possible for you to achieve a good level of oxygen and moisture barrier with the right paper. However, paper is not the best option for shelf-life when it comes to coffee packaging, and as a result you will not be able to achieve the same life as you would with conventional or recyclable plastic films.
When it comes to packing machines, recyclable paper films can be more challenging to handle compared to other films. They are more delicate to run on packing lines, and it is not possible to apply a de-gassing valve. Additionally, paper films have a much lower level of puncture resistance compared to other films, which will impact durability during transportation and storage. Therefore recyclable paper films are much more limited in their potential as a recyclable coffee packaging solution. They tend to be better suited to small formats such as sachets, with lower shelf-life requirement.
With branding however, paper films offer a unique and natural aesthetic that appeals to eco-conscious consumers. Like other films, you can also print them with a full range of printing methods: rotogravure, HD flexographic and digital. However, they may not provide you with the same level of gloss and colour saturation as other films.
In conclusion, when it comes to recyclable flexible packaging options for sustainable coffee packaging in the UK, mono-PE films, mono-PP films, and paper films are all options that that you can consider albeit there are some important limitations to remember. Mono-PP films can offer you excellent barrier properties, machine efficiencies and branding and overall may provide you the best solution recyclable coffee packaging. Mono-PE films offer good shelf-life, seal strength and branding, however the packaging machine efficiencies tend to be challenging. Paper films offer the most widely recyclable solution and a sustainable and unique aesthetic but are much more limited in their strength and in the shelf-life they provide.
It is very important for you to remember that this article covers the main materials from a general overview, but you must be careful to choose the correct grade with any of these options, and to work with a partner who is experienced providing recyclable coffee packaging solutions. If you have any further questions, one of our sustainable packaging specialists would be glad to help.