Packaging and production method for same

Abstract

The invention relates to a packaging (1) having a moulded fibre part (2) and a film (3) which is moulded onto the moulded fibre part (2). The moulded fibre part (2) is compostable and the film (3) is also compostable. The entire packaging (1) can be compostable. The film (3) can be two-layered or three-layered and constitute both a water vapour diffusion barrier and an oxygen diffusion barrier. The packaging (1) can be an outer packaging for a plurality of portion packages (4), each containing an extraction product (42), and which are compostable. The film (3) can be a multi-layer film having a first layer (31) made of PBS or PHBH and a second layer (32) made of a vinyl alcohol copolymer. For production, the film (3) can be thermoformed.

Description

[0001] PACKAGING AND MANUFACTURING PROCESSES THEREFOR

[0002] The invention relates to packaging and methods for its production. It relates to devices and methods according to the generic terms of the patent claims. In particular, the invention relates to packaging (outer packaging) for single-portion packs such as coffee capsules.

[0003] For ecological reasons, it can be beneficial for packaging intended for single use to be compostable. For example, there are known types of molded fiber packaging that can be composted. However, molded fiber packaging is generally unsuitable for packaging products that require protection from moisture and / or oxygen.

[0004] One way to protect such a product from moisture and / or oxygen would be to laminate a polyethylene film onto a fiber molding. Depending on the shape of the fiber molding, however, this process can be difficult, especially if the fiber molding has steep recesses. Furthermore, polyethylene is not compostable, so such packaging is not compostable and must be disposed of as a whole either by thermal recycling or by dismantling it into its components (fiber molding and film), which are then disposed of separately. If disposed of improperly, the polyethylene can enter the environment as microplastics.

[0005] For portion packs for extraction products such as ground coffee (coffee capsules), the trend is toward compostable portion packs, allowing the coffee capsules to be disposed of whole in the compost after use. However, it is not always possible to design the portion packs in such a way that they adequately protect the extraction product (e.g., coffee grounds) from moisture, water vapor, and oxygen. Therefore, it may be advisable to provide outer packaging for portion packs that can ensure the portion packs are protected from moisture and oxygen, ultimately providing adequate protection for the extraction product. Such outer packaging should ideally also be compostable.

[0006] It is an object of the invention to create a packaging that is particularly ecological.

[0007] A further object of the invention is to provide a packaging that is compostable as a whole.

[0008] A further object of the invention is to provide a packaging which can enable a long shelf life of a product packaged therein, in particular if the product is to be particularly well protected from moisture and / or oxygen in order to maintain high product quality.

[0009] A further object of the invention is to create a packaging that is easy to manufacture. A further object of the invention is to create a packaging that is relatively lightweight or consists of a small amount of material, particularly a small amount of polymer material.

[0010] Another object of the invention is to provide a package that is well suited for packaging dry products.

[0011] Another object of the invention is to provide a package that is well suited for packaging moist products.

[0012] Another object of the invention is to create a packaging that does not produce microplastics when it enters the environment.

[0013] Another object of the invention is to provide a packaging that does not exhibit biotoxicity when released into the environment.

[0014] A further object of the invention is to provide a new manufacturing method for producing a packaging.

[0015] A further object of the invention is to provide a method for producing a package with which a variety of packaging shapes can be produced.

[0016] At least one of these objects is at least partially achieved by devices or methods according to the patent claims.

[0017] The packaging comprises a molded fiber part and a film, with the film being molded onto the molded fiber part. The molded fiber part is compostable, and the film is also compostable. This creates a material composite that can, on the one hand, protect the product packaged therein, for example, mechanically. On the other hand, the two components, the molded fiber part and the film, are compostable, which is advantageous from an ecological perspective. In particular, the packaging can be compostable. For example, the packaging can essentially consist of the molded fiber part and the film.

[0018] By being molded onto the fiber, the composite material can be perceived by the consumer as a single part. The film can adhere to the fiber-molded part. For example, it can adhere to the fiber-molded part essentially over its entire surface or, alternatively, in places.

[0019] The fiber-cast part can be manufactured using one of the known fiber-casting processes, for example from waste paper fibers and / or other cellulose fibers; of course, with conventional additives if necessary.

[0020] The fibre-moulded part can, as usual, be a moulded part, for example it can have a recess for each of several products to be packed in the packaging (for example) portion packs.

[0021] The packaging can be produced efficiently using the process described below.

[0022] In the present disclosure, “compostable” may in particular also mean “home compostable”.

[0023] In the present disclosure, the terms "compostable" and "home compostable" may in particular mean: "compostable" or "home compostable" according to the European standard EN 13432 (in particular: EN 13432:2004) for packaging and / or according to the European standard EN 14995 (in particular: EN 14995:2006) for plastics.

[0024] The film can be a polymer film, particularly made of a thermoplastic material. If the film is thermoplastic, it can be easily adapted to the fiber-molded part, particularly through the application of heat.

[0025] In embodiments, the film has a layer which consists of at least 90 percent by weight, in particular essentially, of a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate), also known as PHBH. In particular, the layer can consist of at least 90 percent by weight, in particular essentially, of a PHBH filled with a filler material. The filler material makes it easier or even possible to form the PHBH into a film and, in particular, to mold this film to a fiber part by thermoforming. Thermoforming for films is sometimes also referred to as "deep drawing." Suitable filler materials include, for example, inorganic materials, in particular in powder form, such as talc.

[0026] In embodiments, the film consists essentially of this layer.

[0027] PHBH is well-suited to forming a water vapor diffusion barrier. Depending on the formulation, PHBH can also form an oxygen diffusion barrier.

[0028] To meet the high barrier requirements of coffee products, for example, the film can be a multi-layer film. For example, one layer can form a particularly strong water vapor diffusion barrier, while another layer can form a particularly strong oxygen diffusion barrier.

[0029] In embodiments, the film comprises a first layer made of a first polymer material and a second layer made of a second polymer material. The first layer can be arranged between the fiber-molded part and the second layer. In particular, the first layer can be adjacent to the fiber-molded part. If necessary, an adhesion promoter can also be provided between them to improve the adhesion of the first layer (or the first polymer material) to the fiber-molded part. Furthermore, the first layer can be adjacent to the second layer. As will be explained further below, such a two-layer structure can already be sufficient, i.e., satisfy the requirements of the product, particularly when the products to be packaged are dry; or, particularly when the products to be packaged are moist, a third layer (made of a third polymer) can be provided, which is adjacent to the second layer.

[0030] In embodiments, the first polymer material is a water-insoluble polymer material. Such materials can be well suited to forming a water vapor diffusion barrier; for example, PHBH (optionally filled) and polybutylene succinate (PBS). This allows the film to be relatively thin or lightweight.

[0031] In embodiments, the first layer forms a water vapor diffusion barrier.

[0032] For example, their water vapor transmission rate (WVTR) at 23°C and a relative humidity of 85% can be a maximum of 25 g / m 2 per day, in particular a maximum of 10 g / m 2 per day or even only a maximum of 5 g / m 2 per day. This ensures good protection of the products being packaged from moisture.

[0033] In some embodiments, the film forms a water vapor diffusion barrier. Its water vapor transmission rate at 23°C and a relative humidity of 85% can, for example, be a maximum of 10 g / m 2 per day, especially a maximum of 5 g / m 2 per day or even only a maximum of 2 g / m 2 per day. This ensures good protection of the products being packaged from moisture.

[0034] The water vapor transmission rates (WVTR) in the present disclosure can be determined in particular according to ISO 15106-2 (in particular: ISO 15106-2:2015).

[0035] In embodiments, the first polymer material consists of at least 90 percent by weight, in particular essentially, of a polybutylene succinate (PBS). This material is easy to shape, for example, by thermoforming, and is well suited to forming a strong water vapor diffusion barrier.

[0036] In embodiments, the first polymer material consists of at least 90 percent by weight, in particular essentially, of a PHBH; in particular of a PHBH filled with a filler material. This material, in particular with the filler material, is easy to shape, for example by thermoforming, and is well suited to forming a strong water vapor diffusion barrier. Furthermore, it can form an oxygen diffusion barrier.

[0037] In some embodiments, the second layer forms an oxygen diffusion barrier. Its oxygen transmission rate at 23 °C and a relative humidity of 50% can, for example, be a maximum of 3 cm 3 / m 2 per day, especially a maximum of 1 cm 3 / m 2 per day, or even only 0.2 cm 3 / m 2 per day. This ensures that the products being packaged are well protected from oxygen.

[0038] In some embodiments, the film forms an oxygen diffusion barrier. Its oxygen transmission rate (OTR) at 23°C and a relative humidity of 50% can, for example, be a maximum of 1 cm 3 / m 2 per day, especially a maximum of 0.2 cm 3 / m 2 per day. This ensures that the products being packaged are well protected from oxygen.

[0039] The oxygen transmission rates (OTR) in the present disclosure can be determined in particular according to ISO 15105-2 (April 2022).

[0040] In embodiments, the second polymer material consists of at least 90 percent by weight, in particular essentially, of a vinyl alcohol copolymer. These materials can form strong oxygen diffusion barriers. As a result, the film can be relatively thin or lightweight.

[0041] In embodiments, the second polymer material consists of at least 90% by weight, in particular essentially, of one of the following:

[0042] - Poly(vinyl alcohol) copolymer (PVOH);

[0043] - Butenediol-vinyl alcohol copolymer (BVOH);

[0044] - Ethylene-vinyl alcohol copolymer (EVOH); or a mixture of at least two of the following:

[0045] - Poly(vinyl alcohol) copolymer;

[0046] - Butenediol-vinyl alcohol copolymer;

[0047] - Ethylene-vinyl alcohol copolymer.

[0048] These materials exhibit good oxygen diffusion barrier properties and can be processed into films that are easily conformable, for example by thermoforming.

[0049] PVOH also exhibits excellent biodegradability. PVOH is highly compostable.

[0050] BVOH can be particularly water-soluble, especially at high degrees of hydrolysis.

[0051] EVOH can form a particularly strong oxygen diffusion barrier, especially at high ethylene contents, especially in relatively high humidity conditions. In some embodiments, the packaging can enclose an interior space for accommodating a product to be packaged, particularly one that can be sealed hermetically.

[0052] In some embodiments, the second layer is adjacent to the interior. Especially for dry products, a corresponding packaging structure with the following layer sequence can be used:

[0053] (i) Fiber casting

[0054] (ii) first layer forming a water vapor diffusion barrier as mentioned, in particular made of PHBH or PBS as mentioned;

[0055] (iii) second layer, oxygen diffusion barrier-forming as mentioned, in particular made of a vinyl alcohol copolymer as mentioned; be advantageous because it is very simple (two-layer film), and the first layer prevents moisture absorbed by the fiber molding from reaching the second layer, so that the barrier formed by the second layer

[0056] Oxygen diffusion barrier is not reduced or destroyed by moisture.

[0057] When moist products are to be packaged, the above-mentioned layer structure can be used, supplemented by a third layer, which protects the second layer from the moisture of the product so that its oxygen diffusion barrier functionality is not reduced or destroyed.

[0058] In embodiments, therefore, the film has a third layer made of a third polymer material, wherein the second layer is arranged between the first layer and the third layer, and wherein an interior space for receiving a product to be packaged can be enclosed by the packaging, wherein the third layer is adjacent to the interior space.

[0059] In particular, the second layer may be adjacent to the first layer and to the third layer.

[0060] The same applies to the choice of material for the third layer as for the first layer. In some embodiments, the packaging is an outer packaging for several portion packs (or "capsules") for an extraction product, for example, coffee (especially ground coffee) or tea. Such portion packs are well known, for example, as "coffee capsules."

[0061] Among the systems for preparing beverages, the so-called coffee capsule systems (there are also versions for preparing tea) are well known. In these systems, hot water is usually introduced into such a capsule under pressure to prepare a coffee or tea beverage through extraction. To introduce the hot water, the capsule is often pierced on one side (the injection side). Various options are known for expelling the brewed beverage, generally from the other side of the capsule (the extraction side).

[0062] The most common capsules are made from materials that are neither biodegradable nor made from renewable raw materials. These capsules consist largely of aluminum or polypropylene (PP), for example. Such capsules can offer advantageous properties both for storage (e.g., tightness, particularly impermeability to air and oxygen) and for application (e.g., heat resistance, puncturing behavior, etc.).

[0063] Accordingly, compostable capsules represent a significant ecological advance. Improved protection of the extracted product can be achieved if it is protected from oxygen and / or moisture not only by the portion packaging, but also by packaging or outer packaging of the type described here, which then typically contains several compostable capsules (portion packs).

[0064] The method for producing a package can in particular be a method for producing a package of the type described herein.

[0065] The procedure includes

[0066] Providing a compostable fiber molded part; Providing a compostable film;

[0067] — Molding the film onto the fiber-molded part.

[0068] In some embodiments, the forming process involves thermoforming the film. This process involves heating the film. This heating makes the film slightly stretchable and allows it to adapt to the shape of the fiber-molded part. In addition to elevated temperatures, compressed air and / or vacuum and / or molding tools can also be used during the forming process.

[0069] In some embodiments, the molding process creates a positive connection between the fiber-cast part and the film. This can be particularly the case if the fiber-cast part has a sufficiently high surface roughness.

[0070] In embodiments, an adhesion promoter is introduced between the fiber casting and the film before molding in order to achieve sufficient adhesion between the fiber casting and the film.

[0071] In principle, other processes are also possible, for example the film can also be laminated.

[0072] The subject matter of the invention is explained in more detail below using exemplary embodiments and the accompanying drawings. They show, in highly schematic form:

[0073] Fig. 1 shows a section through a package designed as an outer package, containing portion packs;

[0074] Fig. 2 shows a section through a wall of the packaging from Fig. 1.

[0075] Parts not essential to understanding the invention are partly omitted. The described embodiments are exemplary of the subject matter of the invention or serve to explain it and have no limiting effect. Fig. 1 shows, highly schematically, a package 1 containing several products 4. The package 1 forms an outer packaging for the products 4, which are hermetically sealed within the package 1. The products 4 are designed as compostable portion packs (for example, coffee capsules), each of which is designed as a portion pack 41 filled with an extraction material 42 (for example, coffee powder or tea).

[0076] The packaging 1 essentially consists of a fiber-molded part 2 and a film 3 facing an interior 5 enclosed by the fiber-molded part 2. The film 3 also encloses the interior 5. The products 4 are arranged in the interior 5.

[0077] Fiber casting 2 and film 3 are compostable.

[0078] The film 3 forms an oxygen diffusion barrier and a water vapor diffusion barrier that protects the extraction material 42, in addition to the protection that the extraction material 42 enjoys from the portion packaging 41.

[0079] Details on the barrier effects have already been mentioned above. Therefore, they will not be repeated here.

[0080] As symbolized by the thick dashed lines in Fig. 1, the packaging 1 can be opened at designated locations, for example, the packaging can be in two parts or can be opened up.

[0081] Fig. 2 shows, also highly schematically, a section through a wall of the packaging 1 from Fig. 1. The film 3 is two-layered or optionally three-layered (then referred to as film 3'). It has a first layer 31 and a second layer 32, as well as optionally a third layer 33.

[0082] The first layer 31 is adjacent to the fiber molded part 2 and to the second layer 32. The third layer 33 (if present) is also adjacent to the second layer 32.

[0083] An adhesion promoter can optionally be provided between the film 3 or 3' and the fiber-molded part 2. Advantageous materials have already been specified above. Accordingly, the film 3 or 3' can be constructed in particular as follows:

[0084] - first layer 1 made of PHBH, second layer 32 made of PVOH; or

[0085] - first layer 1 of PBS, second layer 32 of PVOH; or - first layer 1 of PHBH, second layer 32 of PVOH, third layer of PHBH; or

[0086] - first layer 1 of PHBH, second layer 32 of PVOH, third layer of PBS; or

[0087] - first layer 1 of PBS, second layer 32 of PVOH, third layer of PBS; or

[0088] - first layer 1 made of PBS, second layer 32 made of PVOH, third layer made of PHBH.

[0089] Instead of PVOH, another vinyl alcohol copolymer can be used, in particular one of those mentioned above (B VOH, EVOH).

[0090] The two-layer versions can be used well for dry products such as the portion packs described.

[0091] The three-layer variants allow for the packaging of moist products. The third layer 33 protects the second layer from moisture, which can reduce or destroy the oxygen diffusion barrier effect of the second layer. Furthermore, due to the water solubility of the proposed polymer, the second layer could be partially dissolved by moisture.

Claims

PATENT CLAIMS 1. Packaging comprising a fiber-molded part and a film which is molded onto the fiber-molded part, wherein the fiber-molded part is compostable and the film is compostable, in particular wherein the packaging is compostable.

2. Packaging according to claim 1, wherein the film is a multi-layer film comprising a first layer of a first polymer material and a second layer of a second polymer material, wherein the first layer is arranged between the fiber molding and the second layer, in particular wherein the first layer is adjacent to the fiber molding.

3. Packaging according to claim 2, wherein the first polymer material is a water-insoluble polymer material.

4. Packaging according to claim 2 or claim 3, wherein the first layer forms a water vapor diffusion barrier, with a water vapor transmission rate at 23°C and a relative humidity of 85% of maximum 25 g / m 2per day, especially a maximum of 10 g / m 2 per day; in particular wherein the film forms a water vapor diffusion barrier, with a water vapor transmission rate at 23°C and a relative humidity of 85% of not more than 10 g / m 2 per day, especially a maximum of 5 g / m 2 per day.

5. Packaging according to one of claims 2 to 4, wherein the first polymer material comprises at least 90% by weight, in particular substantially, — consists of a polybutylene succinate; or consists of a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate), in particular of a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) filled with a filler material.

6. Packaging according to one of claims 2 to 5, wherein the second layer forms an oxygen diffusion barrier, with an oxygen transmission rate at 23°C and a relative humidity of 50% of a maximum of 3 cm 3 / m 2per day, especially a maximum of 1 cm 3 / m 2 per day; in particular wherein the film forms an oxygen diffusion barrier, with an oxygen transmission rate at 23 °C and a relative humidity of 50% of not more than 1 cm 3 / m 2 per day, especially a maximum of 0.2 cm 3 / m 2 per day.

7. Packaging according to one of claims 2 to 6, wherein the second polymer material consists of at least 90% by weight, in particular essentially, of a vinyl alcohol copolymer.

8. Packaging according to one of claims 2 to 7, wherein the second polymer material consists of at least 90% by weight, in particular essentially, of one of the following: - Poly(vinyl alcohol) copolymer; - Butenediol-vinyl alcohol copolymer; - ethylene-vinyl alcohol copolymer; or a mixture of at least two of the following: - Poly(vinyl alcohol) copolymer; - Butenediol-vinyl alcohol copolymer; - Ethylene-vinyl alcohol copolymer.

9. Packaging according to one of claims 1 to 8, wherein the film has a layer which consists of at least 90% by weight, in particular substantially, of a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate), in particular of a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) filled with a filling material; wherein the layer — forms a water vapor diffusion barrier, with a water vapor transmission rate at 23 °C and a relative humidity of 85% of maximum 25 g / m 2 per day, especially a maximum of 10 g / m 2 per day; and — forms an oxygen diffusion barrier, with an oxygen transmission rate at 23 °C and a relative humidity of 50% of maximum 3 cm 3 / m 2 per day, especially a maximum of 1 cm 3 / m 2 per day.

10. Packaging according to one of claims 2 to 9, wherein the packaging can enclose an interior space for receiving a product to be packaged, and wherein the second layer is adjacent to the interior space.

11. Packaging according to one of claims 2 to 9, wherein the film has a third layer made of a third polymer material, wherein the second layer is arranged between the first layer and the third layer, and wherein an interior space for receiving a product to be packaged can be enclosed by the packaging, wherein the third layer is adjacent to the interior space, in particular wherein the second layer is adjacent to the first layer and to the third.

12. Packaging according to claim 11, wherein the third polymer material is a water-insoluble polymer material, in particular wherein the third polymer material comprises at least 90% by weight, in particular substantially, — consists of a polybutylene succinate; or — consists of a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate), in particular of a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) filled with a filler material.

13. Packaging according to one of claims 1 to 12, wherein the packaging is an outer packaging for several portion packs, each containing an extraction material, and which are compostable.

14. A method for producing a packaging, in particular a packaging according to one of claims 1 to 13, comprising — Providing a compostable fibre moulding; — Providing a compostable film; — Molding the film onto the fiber-cast part.

15. The method according to claim 14, wherein the forming step includes thermoforming the film.

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