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Paper-based packaging: a sustainable solution for organic chocolate bars

CUSTOMER’S REQUEST
Adopt a compostable material and improve shelf life of chocolate without compromising its quality.

IMA-ILAPAK
Machine engineering to process the film at comparable speed with respect to standard materials with the possibility to use modified atmosphere packaging.

FILM MANUFACTURER- SACCHITAL- SAES GROUP
Design of a paper-based high gas/moisture barrier industrial compostable film

Problem 1: Paper-based materials have higher coefficient of friction and rigidity due to fibers packing -> Parts consumption and material breaks.
Solution: folding box re-thinking both in shape and surface treatment to reduce friction effects and smoothen the bending forces.

Problem 2: standard sealing jaws micro-punctured the material.

Micro-fractures could not be detected at first. Only monitoring the O2 content over time revealed that the gas was slowly entering.

Solution: re-thinking of jaws profile (smoother) avoided puncturing, while maintaining good sealing properties.

The O2 content over time remained low, showing the disappearance of micro-holes.

Problem 3: hot sealing bars could partially melt the product inside.
Solution: ultrasonic sealing to avoid the consequences of heat application on the product.

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