NAME OF THE PROJECT
Packaging of polypropene foamed foil for takeaways.
PURPOSE OF THE PROJECT
Execution of a research for designing a formula of polypropene foamed foil made of recyclate, to be used in production of takeaway thermoformed packaging.
BENEFICIARY
Korporacja KGL S.A.
VALUE OF THE PROJECT
9 012 466,30 PLN
CO-FINANCING
5 084 833,11 PLN
PROJECT DESCRIPTION
The project considers industrial research, development and pre-implementation works aimed at preparation of an innovative packaging solution of polypropylene foamed foil (XPP) made of 100% recyclate, used for production of takeaway thermoformed packaging. Characteristics of this type of packaging includes exchange of polystyrene with polypropylene of post-consumer and post-production recyclate.
The project is to be completed within 30 months, divided into 4 stages. The 1st stage considers gaining new knowledge and skills on moulding foamed foil made of recycled polypropylene from post-consumer wastes and post-production recyclate, to be used in production of a model takeaway packaging e.g. menu box. This stage includes testing effectiveness of PP foaming of various melt flow indexes, with the use of chemical, psychical and mixed porophors.
Formula of foamed foil is to be prepared, including its according homogenization of ingredients, effective drying technology, processing of incompatible ingredients and method of foil modification with mineral additives, which are supposed to nucleate pores and enhance stiffness of packaging.
The research effects are to be implemented at a subsequent stage of designing new packaging, a model single cavity mould and specification of thermoforming process parameters. This stage closes with presentation and tests of the model packaging. The packaging is to be tested in respect of its endurance and thermal characteristics, thermal transmittance, migration and sensory with selected model liquids.
The third stage includes confirmation of research assumptions and enables the transition from the modelling to prototyping phase in order to verify the production technology with the use of selected formulas for production of prototype foil and packaging. This stage also provides for preparation of a few prototype tools for packaging of different takeaway requirements and testing the priorly prepared assumptions on multi cavity prototype moulds. The readymade products are to be tested again to have their endurance and thermal characteristics, thermal transmittance, migration and sensory verified.
Once the research stage is finalized and new PP foil packaging for takeaways is prepared, the Beneficiary plans to prepare for the implementation, which includes series of operations introducing the products into the market. Execution of the pre-implementation phase is to confirm the KGL potential for serial production of new takeaway packaging according to the designed parameters, with the use of its own machine park. The designed solution is to be implemented into the KGL production business and consequently placed on the market. The foamed foil packaging is addressed for restaurants, bars, diet catering businesses and producers of readymade dishes.