An innovative, energy-efficient two-step manufacturing process, EcoForm, to produce CPET (Crystalline Polyethylene Terephthalate) trays for use in the food packaging industry.

Información del proyecto

EcoForm

Identificador del acuerdo de subvención: 683891

DOI

10.3030/683891

Proyecto cerrado

Fecha de la firma de la CE 29 Mayo 2015

Fecha de inicio 1 Junio 2015

Fecha de finalización 31 Octubre 2015

Financiado con arreglo a

• INDUSTRIAL LEADERSHIP - Leadership in enabling and industrial technologies – Nanotechnologies

Coste total

€ 71 429,00

Aportación de la UE

€ 50 000,00

Coordinado por

GR8 ENGINEERING LTD
United Kingdom

Periodic Reporting for period 1 - EcoForm (An innovative, energy-efficient two-step manufacturing process, EcoForm, to produce CPET (Crystalline Polyethylene Terephthalate) trays for use in the food packaging industry.)

Período documentado: 2015-06-01 hasta 2015-10-31

Resumen del contexto y de los objetivos generales del proyecto

The incumbent thermoforming process used to produce rigid packaging for the food industry dates back over 60 years, has very high energy use, a very large footprint and relatively low output. The UK ready meal market currently uses 1.3 billion containers, yet CPET tray design and manufacture has not changed in over 30 years. Packaging is dominated by one main supplier in Europe. Therefore, consumers, retailers, brand companies and food processors have limited choice of both suppliers and tray designs, with prices and availability dictated by suppliers.

Trabajo realizado desde el comienzo del proyecto hasta el final del período abarcado por el informe y los principales resultados hasta la fecha

GR8 has created a better solution. We have proven that injection moulded preforms, produced at one site and transported to another, can be converted into containers. All major packaging materials, aPET, CPET and PP, have been successfully tested on our prototype EcoForm machine. Results clearly demonstrate that considerable energy savings are achieved, at all stages of the process. For example, EcoForm is 50+% more energy efficient than traditional thermoforming and saves approx. 10-20% in material wastage, resulting in lower material, transport and storage costs; a compelling case for the food processing industry. The containers are enhanced by biaxial orientation, unique to EcoForm, increasing mechanical strength by up to 20% allowing still further reductions in materials. The process does not compromise recyclability at all.

Transporting preforms to food processors allows manufacture of containers on-site, significantly reducing transport and warehousing costs and improving speed to market. Additionally, EcoForm allows the production of new, innovative shapes for packaging, currently uneconomic to transport.

Avances que van más allá del estado de la técnica e impacto potencial esperado (incluida la repercusión socioeconómica y las implicaciones sociales más amplias del proyecto hasta la fecha)

Further development is now required to build a full production machine, to be tested both inhouse and at a food processor’s site. The route to market has been clearly identified as through major retailers influencing their food processors to adopt EcoForm machines on site. Already a major British supermarket chain, the leader in ready meals, have declared their intention to work with EcoForm and have an agreement with their ready meals supplier to install an EcoForm machine at their food processing site.

When complete, this project will significantly alter the plastic packaging supply chain of processed and prepacked foods: reducing material quantities, energy, transport and warehousing costs. EcoForm shortens the supply chain, making it more responsive to consumer demands, enabling less waste.

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