Sonoco Europe expands its product line with plastic packaging based on in-mould labelling (IML) technology, a high-quality packaging solution for perishable foods like sausages, fish and milk products. Some well-known examples are Monte desserts from Zott, Rügenwalder Teewurst, Goldsteig Bambini Mozzarella and ice cream by major brands. Sonoco produces plastic packaging using thin-walled injection techniques. Polypropylene (PP) granules are used almost exclusively as raw material and packaging is decorated with IML. 2007 saw the launch of PermaSafe, the world’s first plastic packaging solution for sterilized and pasteurized food products. As a "reinvention of the can", it offers a creative alternative for marketing durable foods.
Sonoco plastic packages are made at the Sonoco plant in Zwenkau near Leipzig, Germany. Production focuses on cups, cans and oval containers with volumes from 100 ml. Sonoco utilizes high-performance equipment, the latest technology and robotics. The IML process mentioned above is a relatively new packaging technology – the main advantage being that manufacturing and decorating are now combined in a single production step. Another benefit is that labels applied during the injection process are usually made of the same raw material as the actual packaging, so there is no need to separate materials for recycling. Adhesives are not necessary because both components are melted together during processing.
More design freedom with IML
In-mould labelling opens up a wide range of design possibilities for decorating packages and producing outstanding tactile and visual effects, and even highly realistic photographic images. Labels are available with a matt or glossy surface, and provide additional product protection against UV rays and light. They can be printed using either offset or gravure printing.
The PP that is used as packaging material has a myriad of potential applications. It will not crack when it freezes and can be used in microwave ovens. If required, it can offer a high level of transparency, enabling consumers to view the packaged product. There is almost no limit to the shapes that are possible with plastic packaging, which allows for unique, tailor-made packaging solutions.
In addition, the thin-walled injection process used by Sonoco ensures a high degree of hygiene. Prior to injection, the granular base material is melted at approximately 250° Celsius, which makes it ideal for food packaging. A further advantage of the production process is that freshness seals can now be created in a single step because opening tabs are integrated into the body of the can. Another common alternative is to seal the package with a plate made from aluminium or plastics such as PET film.
“PermaSafe – reinvention of the can”
With Permasafe, Sonoco brings the advantages of plastic packaging to the canned food industry. Perishable products, including sterilized and pasteurized foods, retain their freshness and aroma thanks to the PermaSafe technology. The innovative solution is as robust as a conventional metal cans, but lighter and much easier to handle. It also offers a variety of new options for packaging shape and design. The new injection-moulded plastic packaging provides high stability and excellent barrier properties for guaranteed hygiene and longer shelf life for sensitive products. IML technology offers practically unlimited design options along with a variety of shapes and packaging formats – from round to oval and rectangular shapes. This enables a highly individualized brand appearance at the point of sale.
The solution offers consumers a number of benefits when it comes to convenience. PermaSafe packaging is handy, easy-to-open and resealable – in line with today's trends toward single-serve dishes that are quick and easy to prepare. Products packaged in PermaSafe containers can be easily heated in the microwave or a water bath.
Food manufacturers benefit from the PermaSafe technology when it comes to cost efficiency, production and logistics. It is thin-walled and up to 90% lighter than conventional glass jars. Moreover, the packaging is stackable and requires up to 80% less storage space than for example metal cans. Containers are available with many different sealing options such as Ring Pull or peelable films which means that in many cases, food manufacturers can continue to use capping machines designed for metal cans.
Sonoco offers a broad range of rigid packaging solutions. The company produces both plastic and cardboard packaging solutions. Composite cans, composite drums and luxury tubes in different forms and designs are part of the versatile portfolio.
