Recyclable sachets take the heat

08 February 2021

FFP Packaging Solutions has worked closely with JDM Food Group to produce 100% recyclable sachets that can withstand hot fill processes.

JDM Food Group uses a high volume of sachets in its production and was using a PET/PE mixed polymer material for hot and cold fill applications that could not currently be recycled. The company was keen to move to a recyclable material which would not compromise functionality.

Katie Smith, category manager at JDM, explains: “Our environmental responsibility is a core value for JDM and we were committed to finding a sustainable solution for our sachets. We were acutely aware that it was a tall order with a hot fill process, not to mention the requirement for a barrier film so that the functionality of the pack would not be impacted”.

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 a 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.

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.