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Coveris develops manufacturing technology for thin wall thermoformed containers

Coveris Rigid´s Center of Development & Innovation together with its partners Kiefel and Bosch-Sprang have developed a new manufacturing technology for thin wall thermoformed containers.

The three companies have partnered during the industry fair K 2016 to develop an alternate to the single serve Barrier PS-Cups with a sustainable PP solution for the Northern American market. 

Replicating the same performance of PS-cups, ensuring the puncture during the brewing process and material distribution of the multi-layer barrier PP-Cup are the main challenges of the de velopment.

The partnership led to the development of a new technology and has been ramped-up on 91-cavity thermoforming system with in-mold calibration with an annual capacity of 750 million single serve Barrier PP-Cups.

The calibration technology enables for control of the material distribution in the most critical areas of the cups and achieve better side wall stability and uniform bottom thickness.

Kiefel, Bosch-Sprang and Coveris Rigid, have signed an exclusivity agreement to use the In-mold Calibration Technology.

By using this technology beneficial material distribution can be achieved resulting in product performance when compared to the already existing PS solutions.

With minimum efforts these products can be modified to different decoration requirements like coloring, embossing etc.

The development is completely sustainable and recyclable solution with all in-line process waste returning to the multi-layer structure.

The cup can be recovered in the post-consumer recycling process with the selected composition.

Coveris said that it has a capability to provide PP-lid replacement for the Aluminum lids and produce a single material solution to the market.

The packaging company has seen number of requests to develop sustainable thermoforming solutions in Polypropylene.

It is aiming to reduce the in-process waste and the use of post-consumer material thereby limiting the need of raw material.