30 Sep 2024 Innovations in caps and closures
On 3 July 2024, the EU’s new legislation mandating tethered caps for single-use plastic beverage containers officially came into effect – it has lead to a raft of innovation….
The official implementation of this new EU legislation is a significant milestone in the fight against plastic pollution.
Proposed in 2018 and adopted in 2019 as part of the EU’s Single-Use Plastics Directive, this law requires that plastic caps and lids on beverage containers of three litres or less remain attached during use and storage.
Initially met with resistance from major companies like Coca-Cola, Danone, Nestlé and PepsiCo – who cited the substantial time, effort and investment needed for redesigning packaging and retooling production – the industry has since adapted. Coca-Cola, for example, rolled out tethered caps a year and a half ahead of the deadline.
To ensure compliance, the Commission tasked the European standardisation body CEN with developing robust standards for tethered cap design. These standards consider factors such as strength, reliability, safety and compatibility with existing production equipment, leading to diverse solutions like hinged tops and lasso closures.
However, the transition has not been without its challenges. Some consumers have expressed frustration on social media, complaining about fiddly elements and caps hitting their faces while drinking.
Some of the latest innovations
Fibre-based caps
Recyclable as paper, and with an estimated 135 billion carton board packages using plastic caps globally each year, this cap offers a drop-in solution, making it easy for producers to integrate into existing systems.
Blue Ocean Closures released a new fibre-based cap designed for aseptically packaged products like long-life dairy, juices, plant-based drinks and soups.
No-spill beverage closure
Alpla launched a no-spill beverage closure, designed for practical and child-friendly use. This closure dispenses liquid only when suction or pressure is applied to the mouthpiece, effectively preventing leaks and splashes.
Developed in partnership with Norwegian company SmartSeal, this closure maintains a secure seal even under high bottle pressures of up to 2.7 bar.
ET caps for beverages
Origin Materials launched a new sustainable PET cap designed for carbonated soft drinks. This cap is lightweight and compatible with the widely used PCO 1881 neck finish, making it suitable for a range of beverages, including juices and sparkling water.
Claimed to be the first commercially produced cap made entirely from PET, it uses either virgin or rPET. The design includes a user-friendly tamper-evident feature.
100% recyclable ketchup cap
Kraft Heinz introduced its first 100% recyclable cap for squeezy ketchup bottles, developed in collaboration with Berry Global.
Made from polypropylene, it replaces the previous silicone valve, improving recyclability while maintaining functionality. The cap design project, which spanned eight years and included 45 prototypes, focused on optimising both sustainability and user experience.
Extensive testing ensured the new cap dispenses the same portion of sauce without compromising squeezability. The redesign is expected to prevent around 300 million plastic lids from reaching landfills annually. The caps were rolled out across 400ml and larger bottles of Heinz Tomato Ketchup, with plans for further expansion into other sauces.
Reducing food waste
In 2023, United Caps, in collaboration with UK-based start-up Mimica, launched the Bump Cap, a recyclable plastic closure designed to combat food waste.
Using innovative plant-based gel technology, this cap activates upon opening, measuring spoilage based on time and temperature without direct contact with the beverage.
As beverages degrade, tactile bumps appear on the cap, providing a clear freshness indicator. In consumer trials with orange juice, 97% of participants extended their use beyond traditional expiry dates, with some enjoying their juice five to six days longer.
100% post-consumer recycled resin
PolyCycle Innovation, in partnership with Closure Systems International, introduced PolyCycle PCR closures made from 100% post-consumer recycled (PCR) resin.
The resin’s proprietary process ensures high quality and performance, making it suitable for various applications, including carbonated soft drinks.
PolyCycle closures are fully recyclable and reduce energy consumption by 79% and greenhouse gas emissions by 67% compared to virgin resin.
Sustainable screw caps
Amcor Capsules announced a sustainability advancement for its Stelvin aluminium screw caps, reducing carbon emissions by up to 35%. It is the first low-carbon aluminium screw cap on the market, leveraging up to 46% recycled aluminium and low-carbon primary aluminium.
The improvements apply to all Stelvin and 30H60 screw caps produced in Europe, North America and South America.
Read the full article here: Foodbev.com