Packaging made from alginate

The ConProSachet system is a new process for packaging liquid or pasty products in sachets. These can be gels, beverages or even sauces. The casing is made of alginate and is produced in a coextrusion process during filling. Then the product ends are moulded and sealed during the gelling process.

Alginate is obtained from seaweed and is an ecological and sustainable alternative to existing plastic packaging. It offers the industry completely new possibilities for replacing existing materials. The most significant advantage is that alginate bio-degrades within a few weeks. If you like, you can even eat it without hesitation.

We're pursuing a new approach with the ConProSachet technology. We don't use prefabricated film. Instead, the casing is produced during the filling process. This is made possible by a specially moulded coextrusion head. First, a tube is formed from alginate. Following this, the tube is filled with the content product. Then circumferential dividing elements constrict the filled endless tube and divide it into a continuous chain of filled individual portions, the so-called sachets. In the process, the alginate gels out completely and seals the sachets, which are subsequently separated into individual portions. The resulting individual sachets are surrounded by an elastic alginate shell which can be further treated and packaged.

Both sachet manufacturers and consumers must be prepared to accept alginate as packaging. The first steps are already being taken. This is because alginate is already used in a wide range of industries as a food additive, in medicines or in agricultural applications. Transferability to other areas depends on research, development and adaptation efforts. Because you have to fulfil the specific requirements of different industries and their applications. When developing the system, we made sure that a wide variety of products can be manufactured with little conversion effort. For example, the coextrusion head is easy to replace and the conveyor belts with the dividing elements are designed as format parts.

We must succeed in convincing consumers of the need for sustainable forms of packaging. To do this, they have to change their own behaviour to some extent. If this succeeds, not only is the market potential huge, but also the benefit for the environment. In order to achieve this, the level of awareness of this alternative packaging must first be increased. In our opinion, this is best achieved by communicating the benefits, such as sustainability and the reduction of plastic waste, thereby raising consumer awareness.

Handtmann launched alginate casings for sausage-shaped products back in 2003. That was an absolute revolution at the time. It represented a completely new alternative to the conventional plastic or natural casings used up to that point. This attracted the attention of the London-based company Notpla. The two founders Pierre Paslier and Rodrigo Garcia Gonzalez have dedicated themselves to developing completely natural packaging solutions. And one of these is alginate pouches with a wide variety of fillings, such as dressings, gels or seasoning sauces. In coordination with Notpla, we then developed the ConProSachet system for the industrial production of these alginate sachets.

Exactly. We built our functional model of the ConProSachet system as simply and quickly as possible from aluminium profiles. We screwed belts onto it and off we went with the first attempts. We were absolutely delighted with the results. That was a great incentive for all colleagues to quickly develop the machine further.

Yes, of course. There are always hurdles to overcome with truly new technologies. One was to ensure that the sachets were sealed reliably. This is because the closure is only a few tenths of a millimetre thick and must be both uniform and precise. To achieve this, we had to precisely coordinate the individual process steps from the production of the casing to the sealing of the products, not only in terms of time but also in terms of space. This is because the ends can only be formed and the products securely sealed for as long as the gelling process of the alginate is not yet complete. That's because the top and bottom of the shell bond by cross-linking the alginate. To achieve this, calcium chloride is added. And then the individual elements must also be separated from the endless chain into finished sachets. As you can see, this is an extremely complex process involving machine technology with controlled actuation of the individual process steps, sequences and the gelling process. But we've overcome these difficulties.

Taking part in an award is always very emotional for us. After all, a new development always involves a lot of passion on the part of everyone involved. And then there's also the question of the right time to apply for an award. You don't want to go public too soon. But not too late either. In any case, it's always a thrill. But with the ConProSachet system, it was clear to us: Anuga FoodTec 2024 is the right time. We'll present our system there.

Of course, you always hope to win. But this time it really was different. We thought we had a good chance. Because we're certain that the ConProSachet has incredible potential to contribute to solving the plastic waste problem. Of course, we're at the beginning and there's still a way to go. But that's exactly what characterises absolute novelties.

The first thing we did, of course, was to protect our ideas, processes and technologies with property rights. We've chosen Anuga FoodTec 2024 as the kick-off for the market launch. We'll be presenting the ConProSachet system to an international audience for the first time there. But of course the system has potential for further development. For example, the basic concept already includes the idea of even higher production outputs. In addition, our likewise patented filling flow section technology provides the basis for offering a multi-lane solution if required. As a result, we can flexibly adapt the current entry-level system to future market developments and market requirements. When we realised the incredible potential of the ConProSachet technology and its positive effects, it was an absolute eye-opener for us. After all, alginate can be moulded in various sizes. That enables customised bag designs. And tailoring to specific products or brand requirements. Sachets for small packs or even in bite-sized form are currently all the rage. So there are no limits to the imagination for further applications.

For more information, go to: www.handtmann.de