Recycling with co-injection

Superfos has refined the co-injection method for manufacturing plastic packaging. Now, we can manufacture a container from different types of plastic: plant based, virgin material and post consumer recycled material. The result is a reduced carbon footprint of the packaging.

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Superfos is committed to inventing and producing environmentally sustainable packaging solutions that help our customers reduce their carbon footprint. The refined co-injection method is a tool to reach this objective.

By using our pioneering co-injection process, we are able to recycle a lot more post consumer material than before. One of the goals of our carbon strategy is to introduce bio-plastic; this material may also be used in the co-injection methods.

As long as the different types of plastic are compatible with polypropylene (PP), we can use them for manufacturing packaging with the co-injection methods. The plastic material could be bio-plastic, plant-based, virgin, post consumer recycled (PCR) or even post industrial recycled (PIR).

In the production of conventional packaging solutions, Superfos uses nothing but polypropylene (PP) or polyethylene (PE) plastics. Both ensure a high level of hygiene and none of them give off unwanted substances to the packaged contents. After usage, PP and PE can be incinerated with energy recovery, so it becomes disposed of in an environmentally friendly way. Or it may very well be used as filling in a packaging made with the co-injection method.

Recycled material inside
Thanks to the co-injection method we can inject recycled materials between layers of virgin material. Only the raw material virgin PP is visible or in contact with the packaged content. A picture of a sandwich illustrates the concept and the share of post consumer material, the filling, is around 30 per cent. Applying the method means a significant reduction in the carbon footprint of the packaging and is a brilliant way to apply recycled material.

No need for extra white
This innovation allows packaging to keep external aspects very similar to virgin PP. Also, all technical properties and qualities remain the same as conventionally manufactured packaging. The packaging may be decorated with offset technology without any alterations. In other words, you get the advantage of using PCR but without having to add extra white - which would otherwise be necessary with pure PCR due to dark colour of PCR.

Packaging solutions made with the co-injection method are suitable for the non-food segment only; for products like building material, all sorts of adhesives and paint.

Applicable, practicable and award winning
The first co-injection method was awarded a Coup de Coeur in 2010 at Salon Emballage Pack Experts Committee as one of the best innovations of the year in our industry. Also, it was honoured with an iF packaging award in 2011.

The awards underline that co-injection is an applicable, practicable and recognized solution.