Paper Flexible packaging
(Eco-friendly instant noodle packaging)
As a Solutions Enhancement provider in packaging company
Introduction
The global focus on sustainability has increased awareness of environmental issues. Many countries have introduced laws and regulations to mitigate environmental impacts, including restrictions on packaging materials used in imported goods. Traditionally, flexible packaging for instant noodles cannot be recycled because it combines multiple types of plastic. This is necessary to achieve the high barrier properties required for long shelf life. In this challenge, my team collaborated with the customer to develop a new packaging specification that uses a single type of plastic while maintaining the necessary barrier properties.
My customer exports their products to the EU, a region with strict packaging regulations, including bans on single-use plastics and non-recyclable materials. Moreover, consumers in this region are highly focused on sustainability and environmental responsibility. As a result, my customer aims to make their products more eco-friendly and give them a sustainable appearance to meet consumer expectations and support environmental conservation efforts.
1. Explore the EU regulation about single-use plastics
2. Study and Exploration of Flexible Packaging in the Market:
Research how other brands are approaching sustainable solutions in flexible packaging. Most of them are transitioning from multi-material to mono-material designs, which are recyclable. Some are also attempting to replace plastic with paper.
Instant noodle packaging comes in various forms, but for this project, we are focusing on flexible packaging. This type of packaging requires high barrier properties to ensure a long shelf life. To achieve this, it typically consists of multiple layers made from different types of plastic, which provide the necessary barrier properties.
However, for the packaging to be recyclable, it must be made from a single type of material. My team explored replacing some plastic layers with paper, as it is recyclable. Unfortunately, paper does not offer the same barrier properties as plastic. To overcome this challenge, I collaborated with my R&D team to identify a coating that enhances the barrier properties of paper. And also change some layer to be mono-Plastic which still have barrier properties.
1. Planning before create prototype
After conducting a market study, the next crucial step is to perform customer interviews before starting the project. In the development of new products for flexible packaging, the process can be time-consuming and costly. Therefore, it is essential to reconfirm the project’s opportunities, assess the feasibility of meeting customer expectations, and ensure customer acceptance before proceeding. Gather key project details such as the budget, timeline, and target specifications to align efforts effectively.
2. Matching specification
Matching specification
- Customer existing specification(Type of plastic layers) : OPP20//MCPP25
- Proposing Eco-Specifications(Type of plastic layers) : MG50//MCPP20 + High barrier coat
3. Price calculation
To study feasibility for using eco-specification
Overall, after comparing the price of the existing customer specification with the new eco-specification, the eco-specification is approximately three times more expensive. After discussing this information with the customer, they still accepted the price and expressed interest in proceeding to the next steps, which include creating a prototype and conducting shelf-life testing. And The customer selected the exported SKU (exported to the EU) to be the pilot model.
4. Create first prototype
for testing shelf life compare between existing specification and Eco-specification
5.Testing shelf life (Period 4 months in control condition) :
in this process will simulate for shelf life in 12 months (align with customer specification)
6.Summary for shelf life result
After 4 months in control condition , shelf life result is Pass >> Customer accept this specification.
All factors were tested and compared with the customer’s specifications.
My team visited the customer, conducted a noodle tasting together, and summarized the results.
The test results were PASS:
- The noodles remain crispy.
- The rancid smell is lower than that of the existing customer specification.
- The color and taste are similar to the existing customer specification.
In summary, the customer has concerns about three key issues:
- Some of the packaging exhibits delamination, where the paper and plastic layers peel apart.
- Some noodles have punctured the packaging, creating tiny holes that could impact the shelf life.
- The maximum thickness that the customer's existing machine can handle is around 65–70 microns. However, the proposed specification is 95 microns, which exceeds the machine's capability. As a result, the customer will need to consider purchasing a new machine to accommodate this specification.
Solving problem
My team developed new solutions to address the customer’s concerns:
1.Delamination Issue:
- Solution: Tested switching the side of MG paper to laminate with MCPP (plastic).
- Action: Created samples and conducted testing with the customer.
- Outcome: The customer accepted the solution.
2.Noodles Puncturing the Packaging:
- Solution: Identified a new paper to replace MG paper, focusing on a paper with high burst strength ("MGI 35").
- Action: Proposed the idea to the customer.
- Outcome: The customer accepted the proposal and requested transportation testing.
3.Thickness Issue: The MGI35 paper has a lower thickness compared to the MG50 paper. Therefore, the specifications of the MGI35 paper are compatible with the customer's existing machine.
Price calculation
To study feasibility for changing from MG50 to MGI35
We have already discussed the proposal with the customer, and they have accepted the idea and pricing for the MGI35 paper. Therefore, our team will proceed with creating new prototypes using two specifications: MG50 and MGI35. These prototypes will be used for transportation testing in Q1 2025, with a trial shipment planned from Bangkok to Khon kaen.
This project is not yet complete. Our team has already discussed the project timeline with the customer, as outlined in the table below. I hope you are excited about this project! Personally, I find it very interesting because, if successful, it will be the first instant noodle brand to switch to paper packaging, which is also recyclable!
