PurePac

PurePac folding box board packaging / Source: Van Genechten Packaging

EuropeFood & BeverageFood GradeOil ResistantPackagingPaperPurePacRecyclable

WHAT WE SAY:

Confectionary and plastic have had a close connection for years, with sweets and chocolate wrapped in everything from plasticised foils to cellophane wrappers and vacuum formed plastic trays. Plastic has predominantly been used to communicate a sense of luxury in this sector, but as consumers turn their back on wasteful, man-made materials, natural, renewable solutions are coming to the fore.

PurePac from Van Genechten Packaging can house slabs of chocolate without any additional protective packaging layers - it is literally cardboard on chocolate. The simplicity of the design demonstrates that a plastic-free solution sometimes lies in just taking something away.

PurePac

WHAT IS PUREPAC?

Developed by European packaging manufacturer Van Genechten Packaging (VGP), PurePac chocolate packaging is a multilayered folding box that eliminates the need for further product packaging, such as Aluminium, plastic or alu-plastic inner packets.
The Paper is coated with an anti-grease barrier on the inside, that protects chocolate from contamination and keeps aromas inside. The barrier is approved for food contact and we have contacted the company to determine exactly what it is derived from. We will update this entry upon response.
100% recyclable in the paper waste stream, the PurePac folded board carton is a GC1 or GC2 construction, meaning it is a multi-layered board product, where the middle layers are made from mechanical pulp and the outer layers bleached chemical pulp.
The carton can be printed on both the inside and the out, and VGP uses food-safe colours and varnishes to achieve the desired outcome.
The prototype of the PurePac was released in March 2022 and is awaiting commercial application.

KEY PROPERTIES:

Food Grade
Oil Resistant
Recyclable

INDUSTRY:

Food & Beverage
Packaging

AVAILABILITY:

Development Stage

DIVE DEEPER:

Blocks of chocolate are typically wrapped in either an aluminium, plastic or alu-plastic composite layer for freshness and product integrity, with any folded box carton acting as secondary packaging for added shelf appeal. While the aluminium inner wrapper can be recycled, any plastic or alu-plastic composite either cannot be conveniently recycled kerbside or cannot be recycled at all.
In contrast, paper and cardboard are easily recyclable globally. In the US, for example, the paper recycling rate hit 68% in 2021, and has met or exceeded 63% every year since 2009. The cardboard recycling rate was 91.4% in 2021. According to a study by Two Sides and Toluna, the global recycling rate of paper is 74%.
Using paper without additional plastic layers is not common in the food industry, but PurePac’s use of innovative carton folding, barrier protection and tight corner technology - that keeps the carton intact with up to 40 kilograms of pressure - allows chocolate to be packaged in one single carton, without excessive inner protection.
By removing the need for an internal aluminium packet, the company claims that PurePac can save 150,000 kilograms of aluminium per 100 million packets.
VGP claims an operational efficiency compared with traditional double packed products, with the potential for customers to save up to EUR 5 (USD 5) per 1,000 packs used. ROI is short too, with up to 200 production cycles per minute.
PurePac can be decorated extensively to facilitate brand communications. The outside can be embellished using spot UV, hot and cold foiling, and embossing.

The paper is coated with an anti-grease barrier, protecting the chocolate from contamination / Source: Van Genechten Packaging

The carton can be printed on both the inside and the out / Source: Van Genechten Packaging

KEY FACTS:

68%

The US paper recycling rate hit 68% in 2021 and has met or exceeded 63% every year since 2009.

150,000kg

PurePac saves 150,000 kilograms of aluminium per 100 million packets.

40kg

PurePac’s use of tight corner technology keeps the carton intact with up to 40 kilograms of pressure.

Key Questions to Ask:

Where do PurePac’s raw materials come from?

VGP is not transparent about where it sources its paper and card stock from, an issue for any brand wanting complete transparency throughout their supply chain. The company was, however, a recipient of a Climate Neutral certification in 2020 and has worked with BCorp brand Rituals, both of which suggest a high level of environmental and societal action. It is imperative to determine exactly how and where the paper and card feedstock is sourced, with FSC and PEFC-certified sources a priority.

Will food contaminate the board?

For food packaging to be effectively and easily recycled, it needs to be free from food residue. Chocolate is prone to melting, especially in warmer climates and during summer months. Determine if PurePac is better suited to cooler climates and whether or not it would need to be refrigerated both in-store and in the home to reduce the risk of contamination. If refrigeration is needed, clear consumer communication will be needed to encourage this behaviour change.

What sealants are used?

Purepac is a rigid cardboard carton and is glued together at multiple touch points. While the company claims the pack is 100% recyclable, this glue could contaminate the paper waste stream in the long run and when used en masse. Could the pack be held together without glue, whereby the board is folded and slotted into itself to provide structure?

What printing practices are you using?

Certain print and post-print processes impact the recyclability of paper products. Spot UV varnishes, liquid toner - such as HP Indigo Inks - and some laminations are not suitable for the paper waste stream and should be avoided.