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Country: Brazil
Category: Non-Alcoholic Beverages
From a TRI-laminated flexible packaging structure, composed originally of PET film, aluminum foil and PE film, a BI-laminated high barrier flexible packaging structure was developed using advanced technology in terms of multilayer high barrier films extrusion equipment and the latest generation of special resins, resulting in the first flexible packaging for whole milk powder in Brazil, with a more sustainable structure, without aluminum foil, considered ready for recycling and guaranteeing the same product protection and shelf-life, with reduced consumption of energy and GHG emission during the conversion This implemented solution contributes to the sustainability goals established by Nestlé to be achieved by 2025, in which packaging is 100% recyclable or reusable, with improved environmental performance in terms of material consumption, energy and GHG emissions.
Highlighting that all this development was carried out in compliance with Nestlé's very high levels of technical, quality and performance requirements.
Starting from an initial TRI-laminated structure with aluminum foil (non-recyclable), Zaraplast initially developed a trilaminated structure without aluminum (foilless), but still considered non-recyclable, as it mixed PET and PE films. In the 2nd. phase, a structure was developed with these same materials, but BI-laminated, reducing one layer and a lamination process, already presenting environmental gains such as reduced material consumption, greenhouse gas emissions and energy consumption. At each stage, the challenge became even greater, requiring the development of special high barrier films and the use of high-performance resin. In a 3rd. phase of the process, a BI-laminated structure was developed considering only polyolefin films, thus being considered READY FOR RECYCLING, guaranteeing the necessary barriers for the protection of the product (shelf-life), machinability and final appearance on the shelf, maintaining protection necessary for the product (shelf-life). To guarantee the necessary barrier, it was necessary to produce PE-CoEx film in a 9-layer extruder.