Case: NEPP project

The main scope of the NEPP project is to develop and demonstrate a next generation milk carton and the process steps needed to produce it. The new milk carton will be substantially improved as regards the impact on the environment and recyclability.

Central research activities in the project are new converting methods, new use of materials, new design and development of new process steps, including adaptation of filling lines. Elopak will meet the request for more environmentally friendly cartons from regulators and consumers by developing, producing and offering a next generation milk carton with positive changes as to environmental impact and recyclability.

In the initial phase of the project the R&D partner delivered two literature studies regarding different technologies and materials which might replace plastic totally or partially as the inside and / or outside barrier of the carton and as a material for the opening device.

Laboratory testing has confirmed alternative solutions with the desired functionality in place but there is still more testing needed to achieve the total effect on the final carton. In addition to the functionality of the material, the researchers also need to work in the application steps of our value chain, with some solutions requiring more work than others. In addition, there are also material requirements when it comes to recycling and sustainability.

The carton’s opening device is being developed separately, with several solutions based on either fiber alone, or fiber with small amounts of polymers. These concepts have tested strongly in laboratory settings and give high hopes for exciting commercial solutions.

During the last year of the project, the team has focused on further investigating and testing materials containing little or no plastics. The materials have also been tested in relation to recyclability, and researchers have carried out an LCA-analysis comparing new materials to existing materials with good results. A patent application for a new opening device has been filed as a result of work carried out.

This work has shown that the targets of the NEPP project are ambitious but that potential solutions have been identified and can be introduced step by step. The first step will be to look at the outside coating, where alternative materials can both reduce the use of plastic and also make the carton better optimized for recycling. The project has provided important lessons which are valuable for our company to continue developing future sustainable packaging solutions.