Fresh from a rebrand and off winning two Great Taste awards in 2023 (for Little’s Smooth Colombian instant coffee and Little’s Creamy Caramel coffee pods), Little’s is now a thirty-strong team and is creating new jobs in Devon.

MD, Will Little, saw the potential in manufacturing in house and made the decision to champion British manufacturing and create local jobs.

Will Little, commented, “We’re so excited to announce we’re commissioning our own Nespresso capsule production line. Not only does this represent the most significant investment in the company’s history, but it also makes us the only brand of capsules in the UK to actually make their own capsules in the UK. By bringing this manufacturing in-house we’re increasing our agility, quality, profitability, and helping create jobs here in the Southwest.

“We’ve been working closely with two outstanding machine manufacturers to bring this line to life. Both based in Spain, we’re utilising the most up-to-date production technology including a cartoning machine built by renowned robotics experts IMASD. This will be the first machine of its kind in the UK and utilises cutting edge Siemens automation. This is all housed in our new 3,000 sqft facility dedicated solely to capsule production.

“The new line is now fully operational and will allow us to also offer own label and contract packing solutions in early 2024.”

Little’s flavour-infused coffee is vegan friendly, 4kcals per cup and contains no added sugar. Little’s is the first instant coffee in UK supermarkets to go 100% plastic free, instead utilising UK-made glass jars with UK-made aluminium lids, for freshness.

The Little’s range is available via the Little’s web shop or from Sainsbury’s, Tesco, Waitrose, Amazon, Ocado, Selfridges & Co, Harvey Nichols Harrods, Booths, Whole Foods and Holland & Barrett. Its prices vary from RRP GBP £4.99 for its 50g jar of Premium Instant Coffee, £3.50 for its flavoured instant coffees, £4.00 for a pack of ten capsules, and £3.29 for a 100g pack of ground coffee.

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The Italian packaging machinery manufacturers’ sales are driven mainly by exports, which account for 81.3% of revenues and are expected to reach 7.36 billion euros by the end of the year, a 12% increase over 2022. This increase in exports concerns almost all geographical areas. Based on the latest available figures (from January to August), export sales have increased year on year by 25% in North America, 17% in the European Union, 22% in Asia and 31% in South America. In contrast, domestic sales fell by 14% compared to 2022 to 1.68 billion euros.

The industry is also looking ahead confidently to 2024, having already secured 8.2 months’ worth of orders (another record). Nonetheless, a degree of caution is required given the constantly changing geopolitical scenarios, and in addition European countries are awaiting the final EU directives on the use of packaging. The latest developments, however, appear to take account of the specific characteristics and technologies of the individual member states, in which case the Italian sector’s virtuous waste management model will not be impacted.

“In 2023, the issue of component delays has finally been resolved, allowing companies in our sector to focus exclusively on securing and fulfilling orders and in turn enabling them to achieve this new record,” stated Ucima Chairman Riccardo Cavanna. “However, especially in recent months, orders have been falling compared to 2022 and this trend is expected to continue in 2024. The 14% decline in domestic sales is also a cause for concern, demonstrating that the Italian market has been impacted by both the inflationary crisis and uncertainties surrounding Industry 4.0. Our industry and its client sectors require clarity, as well as a new plan that supports both supply and demand. In this regard, the RePowerEU initiative’s allocation of 6.3 billion euros for the Industry 5.0 plan is a positive development, although we would like to know more about how the funds will be distributed and under which criteria. To date, we have heard nothing about incentives for capital goods to facilitate the ecological transition, and we are awaiting a response from the government.”

According to the export figures, the Italian packaging industry has maintained its world leadership position. “Italian-made technologies and solutions continue to attract sustained demand from food, beverage, pharmaceutical, tissue and cosmetics companies all over the world, who appreciate the quality, reliability and innovation that we are able to deliver,” noted Cavanna. “As for innovation, some of our companies have already integrated artificial intelligence solutions into their machines. This is one of the biggest challenges we will face in the coming years, and Ucima is ready to support companies in identifying the best opportunities for their development and international expansion.”

The European Parliament’s latest vote on the packaging directive is a step in the right direction. “Common sense has prevailed,” commented Cavanna. “However, we are waiting to see what the next steps will be, as the process is not yet complete. Ucima has always been at the forefront in defending the Italian way, a model that has established us as a leader in terms of waste recycling. We will continue to work in collaboration with the other associations in the supply chain to defend a system that delivers both environmental and economic advantages.”

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We were given a tour of the facility, with its state-of-the-art materials and component testing laboratory, dedicated processing area and pilot manufacturing facility, which allows the company to simulate its customers’ factory conditions as well as test shelf life in temperature controlled stores. Eviosys was also proud to show off the manufacturing process for its Ecopeel innovation, which offers customers a lighter, easy-to-open packaging format. Eviosys also had on display its Orbit and Horizon technology, the former which allows for easier-to-open screw top jars, and the latter an impressively thin and unobtrusive resealable metal lid, allowing for a 100% metal packaging format and therefore improved recyclability.

The latter piqued my interest especially, in regards to tea and coffee applications. I have seen a fair amount of coffee, particularly instant coffee, sold in tins on the shelves, but with plastic lids. While this is better than a completely plastic tub, and certainly a step in the right direction, I can’t help but think they are so close to a truly sustainable option. The metal lid could be recycled alongside the tin, and made into something new again and again, with no degradation of quality. Meanwhile, plastic, while certain types are recyclable, the quality and application opportunities decrease the more it is done so. The visual appeal of an all metal can is also something that offers further benefit. Companies such as Eviosys can offer myriad ways to finish and decorate metal packaging, from contrasting gloss and matte areas, embossing, debossing, and holographic foils, as the company demonstrated yesterday. The image attached to this blog is one of the promotional examples Eviosys gave of its capabilities.

Specialty tea and coffee in particular, already utilises metal packaging to some extent, as it offers valuable resealable capabilities, as well as a quality feel. Tins have the fabulous quality of not just being infinitely recyclable, but infinitely reusable in their original format. I can’t be the only one who has an extensive collection of various tins alongside my hoard of jars, for storing biscuits, grains, nuts, lentils, anything from a packet that I have opened and want to keep stored fresh, tidy and stackable.

Chatting to Isabelle Le Graët, Eviosys marketing, communication and sustainability manager, yesterday, she touched on a report that Eviosys is due to publish soon about how consumers use their metal packaging and the role they play within the home. The report showed that 80% of consumers keep tins after purchase. This presents a phenomenal opportunity for brands to not only enter consumers’ homes, but to remain in them for potentially years to come, their packaging being got out of the cupboard and reused time and time again. Every time a consumer uses a brand’s tin, they are being reminded of the brand, the product, hopefully the enjoyment they got out of drinking the tea or coffee that the tin contained, and perhaps even the fond memory of the receipt of the tin if it was a gift. Highly decorative tins are much more likely to be kept and reused, and where the specialty tea and coffee industry is striving to offer quality and a memorable experience to consumers’ interaction with their products, a beautiful and repeatedly functional tin is an exciting as well as sustainable opportunity to expand this objective.

The concept has already been utilised in some categories for refillable solutions, where consumers buy a tin, and then going forward only need to buy bags or packets of their products to refill their tins, or some places even have opportunities for customers to bring their tin to be refilled. This is already beginning to have applications in the tea and coffee industry.

It will be interesting to see how metal packaging applications evolve within the tea and coffee segment, particularly for specialty, and how brands will utilise what is a great opportunity for memorable branding, consumer experiences, and unparalleled sustainability.

• Kathryn Brand, associate editor, Tea & Coffee Trade Journal.
  Keep in touch via email: kathryn@bellpublishing.com Twitter: @TCTradeJournal or LinkedIn: Tea & Coffee Trade Journal

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Ferrarelle Società Benefit, one of the largest mineral water producers in Italy well-known for its unique naturally sparkling water properties, bottles “Boario”, “Vitasnella” and “Fonte Essenziale” mineral waters at its Boario plant. Vitasnella ‘Le Linfe’ combines the lightness of Acqua Vitasnella with the benefits of the natural ingredients, sugar-free and calorie-free.

Sidel supported Ferrarelle Società Benefit in installing its aseptic technology for its functional teas to ensure a high-end taste experience, product integrity and a long shelf-life, utilising its Predis dry preform decontamination solution – a safe, hygienic, cost-effective way of packaging a variety of sensitive beverages.

By installing Sidel’s Aseptic Combi Predis to produce Vitasnella ‘Le Linfe’ product range, the line is capable of handling two different formats, 0.5 litres and 1.25 litres, and achieves 18,000 bottles per hour.

“‘Le Linfe’ functional waters and tea ranges are extremely important for us and we wanted to avoid any potential risks,” said Nicola Tignonsini, operations director at Ferrarelle.

“As our only line producing sensitive beverages, it was crucial that we had an aseptic system that could ensure the highest level of product safety and integrity,” said Marcelo Astrini, plant director at Boario.

Find out more about Sidel’s Aseptic Combi Predis and how you can access this kind of support for your business on the Sidel website.

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While innovation and new/upgraded technology are always key themes, similar to most exhibitions of late, the main theme was sustainable innovation, with exhibitors touting their sustainable/eco-friendly machinery and initiatives.

For example, Cimbria’s new SEA.IQ Optical Sorter is designed to recognise all defects and imperfections. It features cameras with integrated RGB, NIR and SWIR or UV working multifrequency to match multiple data collected during thousands of scans per second.

Goglio introduced a coffee capsule equipped with a degassing valve. This design makes it possible to immediately package fresh coffee without having to wait for the degassing process, which reduces storage times and preserves the aroma of the coffee. The capsule is also available in a 100% compostable version to meet the regulations being discussed in Italy and Europe, and is already certified as industrially compostable.

Mikafi, a Swiss startup, launched its electric tabletop roasting machine at Host Milan. The founders believe that in a world where sustainability, personalisation, and quality experiences are becoming more important, coffee roasting must be ‘rethought’. Designed for the HoReCa market, and in partnership with Thermoplan, the MikafiOne is a fully automated roasting system that uses AI and IoT that offers pre-programmed roast profiles – so non-baristas or inexperienced roasters can use it – as well as customisable roast profiles. “Anyone can roast the coffee, you do not need a roast master and it frees up the barista, said co-founder and CPO, Claudio Vögtli. He shared that the MikafiOne roasts 1 kilo of coffee, which enables businesses to offer a special roast daily in addition to their standard coffee assortment.

Caffe Vergnano was highlighting its ‘Women in Coffee’, which is the company’s women-focused sustainability initiative developed by CEO Carolina Vergnano. Launched in 2018 in collaboration with the International Women’s Coffee Alliance (IWCA), the initiative is aimed at supporting women working in small coffee plantations. The initial project in 2019 focused on the Dominican Republic, followed by Honduras beginning in 2020. This year’s project is a further evolution of the Honduras initiative, which will provide equipment for the library (that was built between 2021 and 2022) and a cafeteria. Proceeds from the Women in Coffee items – all pink – that are sold online and in WIC Cafés around the world, contribute to the project. For more information or to purchase items, visit caffevergnano.com.

After being decimated during the pandemic as stay-at-home orders were implemented globally, the office coffee service (OCS) industry is making a comeback this year. At Host Milan, OCS machine manufacturers exhibited a range of products that are stylish, fully automated, offer high quality beverages, and, most importantly, are durable, easy to use and easy to maintain. Bravilor Bonamat, Rancillo and Bunn were just a few of the companies that showcased the latest in OCS technology.

The 44th edition of Host Milan will be held at fieramilano from 17 to 21 October 2025.

• Vanessa L Facenda, editor, Tea & Coffee Trade Journal.
  Keep in touch via email: vanessa@bellpublishing.com Twitter: @TCTradeJournal or LinkedIn: Tea & Coffee Trade Journal

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Jim Pittas, president & CEO, PMMI (The Association for Packaging and Processing Technologies), said “Pack Expo Las Vegas (‘PELV’) was the largest since its inception” with more than 32,000 attendees and over 2,300 exhibitors spanning more than one million square feet of exhibit space. PMMI executives said the show had reached maximum capacity despite continued interest from companies wanting to exhibit as the new West Hall was occupied with a different exhibition.

Pack Expo – whether in Las Vegas or Chicago – is the premier trade show in the United States annually to observe the latest packaging and processing solutions in action, with suppliers showcasing diverse innovations for more than 40 vertical markets. According to PMMI, industry growth remains steady at 3.4 percent with the total size of the market in the U.S. reaching $10.2 billion.

Sustainability and automation were the major themes of PELV. A new Sustainability Central area served as an interactive resource to learn about design, materials, manufacturing, recovery, logistics, and data. At the accompanying Sustainability Stage, presenters spoke on a range of packaging sustainability topics, advising attendees how to make their brands more environmentally friendly. The Pack Expo Green Program – which identifies exhibiting companies that provide sustainable solutions via new materials, technology, or strategies such as sustainable processes and machines, renewable and biodegradable packaging, source reduction and lightweighting, recyclable and recycled-content materials, or innovations that reduce carbon footprint – returned to PELV.

At a media briefing on the opening day of Pack Expo Las Vegas, Pierre Pienaar, president of the World Packaging Organisation, which facilitates solutions to global challenges in all areas of packaging, said that the packaging industry is “at a crossroads where the future of packaging is in our hands. “Decisions need to be made that will alter the course and map the path for future generations.” He believes that the reduction of food waste can be achieved through the better use of packaging and awareness.

Pienaar noted that the material types that we use “have and will change the landscape, having a direct impact on sustainability.” He added that the technology that we design and implement, will “map the course of energy reduction that we will follow over the next 10-20 years.” Furthermore, the “innovation of new ideas in packaging will make the difference in creating a successful and sustainable circular economy. We need to empower consumers with the ability to lead their lives in a more environmentally positive way.”

In an exclusive conversation with T&CTJ, Jorge Izquierdo, vice president of market development, PMMI, said that labour and manufacturing challenges have fuelled innovation because many technologies – primarily in automation – have been adapting to close gaps in availability and skills. Additionally, the area of remote access continues to gain strength. “Remote access is not new,” he explained, “it’s been around but companies didn’t take advantage of it because of cyber security concerns. Covid forced them to look. Covid was a catalyser and once companies started using it, they realised they can utilise remote access technologies in multiple areas.”

Izquierdo noted that there are still supply chain challenges, but they are not as bad as in 2021 and 2022. “A lot of orders in 2023 are from 2022 but they were delayed because of supply chain issues that have finally been resolved (such as the delays with electronic components),” he explained, noting that wait times have improved significantly but they will not return to pre-pandemic levels until 2024.

“E-commerce exploded during Covid. We’re finding significant demand for packaging and fulfillment machinery at the warehouse level because of companies doing to direct to consumer,” said Izquierdo. “When sending direct to consumer, there is a mix of different products so the box will have different varieties in it and they will need to be packed into smaller boxes. This is happening at the warehouse, not the manufacturing plant so now warehouses need case sealing equipment, labelling equipment, etc. All this requires different types of equipment in warehouse.”

Pack Expo Las Vegas offered 100+ educational sessions organised into five different areas (Innovation Stage, Processing Innovation Stage, The Forum, etc). Topics ranged from robotics, automation, AI, and sustainability, to advances in food and beverage processing, digitalisation, cybersecurity, integration of cobots into manufacturing, to the benefits, ROI, and points of consideration for companies switching to reusables.

One sustainability session, ‘Sustainability — What Does it Mean in Packaging Materials?’, focused on the trends and developments specific to food packaging. The presenter, Gregg Poffenbarger, business unit director, materials at the Multivac Group, noted how methane gas is 80 times worse for the environment than CO2. He then listed several holistic approaches to mitigating waste that included reducing plastic content in favour of paperboard and formable papers as well as smaller packages. “With smaller packages, there is portion control so there is less food waste and less packaging water going into landfills.”

PELV also raised $30,000 for the Tunnel to Towers Foundation, an organisation dedicated to helping the nation’s first responders, military heroes, injured veterans, homeless veterans, and their families. For over 20 years, the Tunnel to Towers Foundation has honoured the late FDNY (Fire Department of New York) firefighter Stephen Siller’s legacy by supporting the heroes who continue to risk life and limb in the line of duty.

“With our show opening on 9/11, we could not think of a better way to honour the lives lost during that tragedy than to support an organization like Tunnel to Towers that keeps the legacy of those heroes alive by providing support to the first responders, military heroes, and veterans who are with us today,” said Pittas. “We’re grateful to all who donated and showed their support.”

Pack Expo International will take place 3-6 November 2024 in Chicago, Illinois. — Vanessa L Facenda

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Packaging has always been a balancing act. Consumer packaged goods (CPG) companies must weigh cost versus performance and market appeal versus machinability. As interest in sustainable packaging has grown, brand owners also must balance circularity with price, safety, distribution requirements, material availability, and overall environmental impact. This requires a dialogue among stakeholders about packaging design, material choices, and end-of-life disposal options.

To begin this conversation, PMMI, The Association for Packaging and Processing Technologies, and AMERIPEN (the American Institute for Packaging and the Environment) have published the 2023 PACKAGING COMPASS: Evaluating Trends in US Packaging Design Over the Next Decade and Implications for the Future of a Circular Packaging System. The study and accompanying infographic identify key trends in packaging design and materials and the implications of these trends on legislation and the recovery systems for consumer-packaged goods (CPG) companies.

By releasing this deep dive into the trends driving the circular packaging system, PMMI hopes to facilitate an industry dialogue that will help close the gap between design needs and recovery needs. Based on extensive research and analysis, the study’s goal is to spark a conversation on trends, present forecasts for the coming decade, and recognise the role of multiple stakeholders in advancing a circular packaging system.

The 10-year forecasts and materials sales projections indicate plastic packaging, particularly the flexible pouch format; recycled-content packaging, primarily paper and plastic; and compostable packaging will experience the highest demand, although the latter represents a small share of the market. Despite the disparity in usage, these three formats have the same hurdles to overcome, a lack of end-of-life recovery infrastructure as well as effective legislative and investment strategies.

A survey of 394 CPG brands and retailers shows:

• 75 percent use plastics in packaging
• 61 percent use paper
• 14 percent use glass
• 13 percent use metal

Projections show plastics will grow across every category, and the use of flexible film will expand at a 4-6 percent compound annual growth rate (CAGR), slightly above the 3-4 percent CAGR for plastics overall. Plastic films offer significant operational and sustainability benefits. Tensile strength delivers more protection with less material. Light weight and compact footprint reduce carbon emissions during distribution. Highly customisable materials run efficiently on filling lines and reduce overall cost and cycle time. Consumers appreciate the format’s light weight, reduced shelf space requirements, and potential for easy-opening and resealing features.

Although usage continues to grow, figures from the Recycling Partnership show only 1.9 percent of the US population has access to flexible film recycling. Most of this film is recovered from retail drop-off programs, but consumer participation in these programs is low. As a result, establishing a circular economy for flexible films will necessitate a substantial expansion in recycling infrastructure that involves better collection, sortation, and end-of-life reprocessing, potentially including widespread use of chemical recycling. The report explains chemical recycling is an emerging technology that reverts materials to their original monomers. Its adoption could enhance opportunities for the circular reuse of flexible films by increasing collection, lowering sortation requirements, and improving recycled resin quality by reducing contamination, colour, or scent concerns, thereby simplifying the regulatory acceptance of recycled resins for food-contact applications.

Compostable packaging has a projected CAGR of 15-16 percent during the next decade and is receiving a lot of attention because there is a perception that it offers a less-complicated end-of-life option. However, composting also suffers from a lack of infrastructure. According to statistics from the Sustainable Packaging Coalition, only 27 percent of the U.S. population has access to curbside composting programs, and only 11 percent of those composting programs accept packaging.

To realise the full circular potential of compostable packaging, the US needs to increase consumer access to composting by investing in the collection of compostable materials and in expanded access to composting facilities that accept food scraps along with packaging. As the US looks at investments into the necessary collection and processing infrastructure, the most immediate impact is likely to be attained if closed systems like stadiums, foodservice outlets, and cafeterias were implemented before household collection programs.

Recycled-content packaging is a popular path toward circularity. Design for recycling guidelines have been developed by several organizations and are helping the packaging industry choose combinations of polymers, labels, and additives that do not hinder a package’s recyclability. Many brand owners use these guidelines to help meet commitments to increase the use of recycled content. Unfortunately, a disconnect between strong demand and insufficient supply and processing capacity for recycled resin must be overcome. Like flexible packaging, potential solutions lie in simplified and improved collection, better sortation techniques, and greater capacity for end-of-life reprocessing. Chemical recycling could be a potential way to increase capacity as well as recycled resin quality.

Improving infrastructure

Achieving a circular economy depends on improving the infrastructure for collection, sortation, and end-of-life reprocessing. Policy changes will be needed to achieve these objectives. According to the report, establishing a circular economy will depend on the development of:

• Extended Producer Responsibility (EPR). EPR programmes shift financial and operational responsibility for end-of-life management of products to producers instead of taxpayers and the government. As of spring 2023, four states (California, Colorado, Maine, and Oregon) have enacted EPR requirements, and more states are considering EPR bills. However, a national law would overcome a patchwork of differing state requirements and simplify compliance.

The research within this study indicates EPR programmes should include a focus on ways to improve the quality and quantity of recycled materials. Key considerations should explore how best to invest in the composting infrastructure, including packaging, and address how to handle hard-to-recycle materials by investing in collection and sortation technology and supporting end-market development. The data also show package design needs to consider many factors beyond design for recycling. Leveraging EPR to help balance all the design variables should create benefits for each stakeholder.

• Universal Access. Providing all households with convenient and consistent access to recycling and composting services would increase collection.
• Standardised Definitions. Definitions for commonly used terms like recycling and composting would ensure stakeholders are communicating a consistent message and reduce consumer confusion.
• Alternatives to Material Bans. Material bans can prevent CPG companies from choosing the optimum packaging material and increase a product’s environmental impact. Shifting from material bans to dialogues about collection, sorting and reprocessing gives brand owners the freedom to pick the best option.
• Recovery Innovation. Federal investments into programs uncovering emerging science and data are needed to drive efficiencies across packaging design and waste management.
• Data Collection. Consistent data collection will help measure and benchmark the performance of a circular packaging economy.
• Reusables Infrastructure. Reusables are another promising option to achieve circularity. However, as with other options, infrastructure is lacking, and investment is needed. According to the report, successful reusable packaging programs depend on redesigning distribution systems for reverse logistics. This will involve establishing safe and hygienic drop-off or pick-up collection points, which are convenient to consumers, and equipping production lines for washing and refilling. Currently, the adoption of reusables poses a daunting challenge for many packaging companies due to the costs to develop and scale a system to achieve a significant impact. A collaborative strategy that incentivises innovation is needed. Understanding the challenges and opportunities of reusables will require participation from a wide range of stakeholders.

Conclusion

A circular economy can be achieved by focusing on how best to invest in recycling and composting infrastructure across the US and tying that dialogue to what is happening with packaging design and the multiple variables packaging designers must juggle. Success will depend on how well members of the packaging value chain understand each other’s challenges and opportunities.

• Jorge Izquierdo is vice president of market development for PMMI, The Association for Packaging and Processing Technologies. Based in Herndon, Virgina, PMMI organises the Pack Expo portfolio of trade shows. This year’s Pack Expo Las Vegas takes place 11-13 September. To register or for more information, visit packexpolasvegas.com.

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The two organisations have already been cooperating at various events, including ProPak and CPHi exhibitions in Asia, MENA and South Asia, and will endeavour to develop joint agendas wherever possible to further the creation of smart packaging solutions which meet the goals of the global industry and particular market needs.

According to WPO president, Pierre Pienaar, “Both organisations have been aware for some time that we share common goals and objectives and it is a logical next step to formalise these in a constructive and practical way. The two of us have a clear focus on our responsibility to the sector and the way packaging can be a solution, not a problem – as it is so often characterised today. Packaging for good is high on our agendas and we see this collaboration as a way to demonstrate these benefits in a very impactful way.”

Andrew Manly, communications director at AIPIA added, “WPO is the major global packaging organisation and has a strong profile in both the developed and developing world. It is a tremendous boost to the smart packaging sector to be able to join with WPO in promoting these technologies and helping to reinforce the organisation’s agenda on sustainability, innovation and supply chain efficiency. We are particularly delighted to be able to tap into so many talented people, in particular Pierre’s tremendous knowledge of materials science.”

“This agreement adds strength and knowledge to both organisations. We look forward to working with AIPIA and ‘spreading the good word’ about packaging and its benefits across the globe. We also intend to develop joint agendas at each other’s conference wherever possible”, concluded WPO senior vice president marketing and president-elect, Luciana Pellegrino. The MoU WPO AIPIA also aims to encourage the development of a Smart Packaging category in WorldStar Awards, the global packaging competition organized by WPO.

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Produced by PMMI, The Association for Packaging and Processing Technologies, Pack Expo  Las Vegas 2023 is a premier destination to witness cutting-edge packaging and processing solutions, with suppliers showcasing diverse innovations for more than 40 vertical markets, making it the most all-inclusive packaging and processing show in North America this year.

The theme of Pack Expo Las Vegas 2023 (PELV) is ‘Expect Innovation’ as PMMI notes that this show “will provide more solutions and innovations under one roof than available anywhere else in North America this year. Show attendees will see machinery in action, discover the latest materials, hear from experts, experience innovations firsthand, gain insights into critical industry trends, and discover solutions they didn’t know existed.”

Sustainability will be a major theme at PELV. A new Sustainability Central area will serve as an interactive resource to learn about design, materials, manufacturing, recovery, logistics, and data. At the accompanying Sustainability Stage, attendees will hear from experts on a range of packaging sustainability topics and learn how to make brands more sustainable. In addition, the Pack Expo Green Program returns to PELV and is the commitment of Pack Expo and its partners, vendors, and exhibitors to work together to create a more sustainable world. Pack Expo Green identifies exhibiting companies that provide sustainable solutions via new materials, technology, or strategies such as sustainable processes and machines, renewable and biodegradable packaging, source reduction and lightweighting, recyclable and recycled-content materials, or innovations that reduce carbon footprint.

Below is a sampling of some of T&CTJ’s advertisers that will be exhibiting at Pack Expo Las Vegas 2023.

Fres-co System USA

NexTrex® Certified Store Drop-Off Recyclable High-Barrier Coffee Packaging

With the NexTrex Certification and Fres-co’s extensive coffee packaging expertise, Nextpak is primed to help coffee brands, roasters, and manufacturers make an immediate positive impact on the environment and accelerate time to market.

Benefits of Nextpak:

• First NexTrex-Certified High-Barrier Coffee Package
• Recycle-Ready, All Polyethylene Material with Degassing Valve
• No Compromise on Shelf Life or Venting Performance
• Complete Packaging System Capability to Assist with Machine Integration
• Ability to Upcycle Single-Use Packaging into High Performance Durable Trex® Decking
• Available as Rollstock or Premade Bags

Nextpak, Fres-co’s recycle-ready, all polyethylene gusseted retail coffee package, is the first high-barrier coffee package with degassing valve to be certified by the NexTrex Recycling Program, a sustainability initiative focused on sourcing, collecting, and assessing polyethylene film materials for use in the making of Trex’s high-performance composite decking.

Fres-co System USA, Inc

Telford, Pennsylvania, USA

Web: fresco.com

Pack Expo Las Vegas: #SL-6113

Modern Process Equipment Corporation

Robotiq Palletizing Solutions

Robotiq offers turnkey palletizing solutions to streamline the implementation process and start working immediately, so you can quickly earn a return on your investment.

Engineered to meet the specific requirements of palletizing, Robotiq Palletizing Solutions address a wide range of business needs to eliminate the need for costly and time-consuming customizations. The solutions come with built-in adaptability, which allows businesses to easily scale future operations. They’re also built on proven methodologies and have undergone extensive testing to ensure reliability and efficiency. Talk about cost-effectiveness!

What also sets Robotiq apart from competitors is its unrivaled software ease of use. The palletizing solutions make automation accessible, regardless of your level of robotics expertise. You can rest easy knowing that installing and operating Robotiq Palletizing Solutions is risk-free.

If you’re looking for a way to resolve labour shortages, speed up your processes, and improve packaging flexibility, you might want to follow the many coffee and tea manufacturers that are turning to palletizing automation as a valuable tool.

See the Robotiq Palletizing Solutions in action at Pack Expo Las Vegas. Visit booth SL-6870 (lower south building). Or contact one of our palletizing experts and discover the many benefits these automated solutions can bring to your business and workforce.

Robotiq Palletizing Solutions

Levis, Quebec, Canada

Web: robotiq.com/solutions/palletizing

Email: contact@robotiq.com

Pack Expo Las Vegas: #SL-6870 (lower south building)

Syntegon

Processing and packaging for a better life – this is what 5,800 Syntegon employees work for every day. Be it with individual machines, systems, or services, Syntegon helps its customers in the global pharmaceutical and food industries to improve people’s lives. The company, which is headquartered in Waiblingen, Germany, looks back on more than 160 years of experience and achieved annual sales of 1.4 billion EUR in 2022.

In the food industry, Syntegon’s flexible and reliable technologies produce and pack confectionery, dry food, frozen food, and dairy products. In the pharma sector, the company’s intelligent solutions enable the safe and high-quality production, processing, filling, inspection, and packaging of liquid and solid pharmaceuticals.

With 1,100 service experts and a comprehensive service portfolio throughout the entire machine lifecycle from spare parts management to digital line optimisation, Syntegon lays the foundation for smooth production processes for all customers. More than 35 sites in almost 20 countries keep a firm eye on Syntegon’s impact on the environment and society. Syntegon is a leader in the development of sustainable packaging solutions, reduces the energy consumption of its machines and pursues ambitious goals to lower its emissions.

Syntegon

Waiblingen, Germany

Web: syntegon.com

Pack Expo Las Vegas: #C-2800

Tecpacking Group

Tecpacking is your partner in pyramid teabag Packaging. When it comes to tea packaging, precision, efficiency, and quality are of utmost importance. That’s where Tecpacking comes in. As a leading provider of innovative tea packaging solutions, we are dedicated to helping tea companies around the world elevate their packaging game.

With over a decade of experience in the industry, Tecpacking has established itself as a trusted name in tea packaging. Our focus on research and development has led to the revolutionise the way tea is packaged.

One of our standout innovations is the pyramid tea bag machine. Designed to produce visually appealing and flavour-packed pyramid tea bags. We have also developed envelop machines that securely seal the tea bags, preserving freshness and extending shelf life. The speed reach 80bags/min. But it doesn’t stop there. At Tecpacking, we understand the importance of sustainability. That’s why our machines are designed to handle paper and other compostable envelop materials. By choosing our solutions, you not only enhance your brand but also contribute to a greener future.

What sets Tecpacking apart is our commitment to customer satisfaction. We work closely with tea companies of all sizes, from small-scale boutique brands to large-scale producers, to understand their unique packaging needs. Our team of experts is always ready to provide personalised guidance and support, ensuring that our machines integrate seamlessly into your production line.

But our partnership doesn’t end with the purchase of our machines. Tecpacking offers comprehensive training and technical support to ensure that your team is well-equipped to operate and maintain the equipment. Recommend good tea supplier for customers. We believe in building long-term relationships with our customers, supporting them every step of the way.

Join the growing number of tea companies that have chosen Tecpacking as their packaging partner. Experience the difference that our innovative machines can make in enhancing the quality, efficiency, and sustainability of your tea packaging. Contact us to learn more about our solutions.

Tecpacking Group (Tianjin) Co, Ltd

Tianjin China

Web: tecpacking.com; teepacking.com; teapacker.org

Email: paul@tecpacking.com

T: +86-22-24304649

F:+86-22-59951519

M: +86-13920958606

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The ANSI/PMMI B155.1-2023 standard has undergone a meticulous revision, guided by a panel of industry experts convened by standard developer, PMMI, to address evolving safety concerns, technological advancements, and changing operational landscapes. The development committee includes new contributors providing deep insights from machine builders, consumer packaged goods companies, and technology suppliers.

“By introducing these comprehensive updates, the ANSI/PMMI B155.1-2023 standard sets a new benchmark for safety in the packaging and processing machinery industry,” said Tom Egan, vice president, industry services, PMMI. “This revised standard reaffirms the commitment of PMMI to the safety and well-being of industry professionals, ensuring that technological advancements go hand-in-hand with the highest levels of safety.”’

“Safety is critical to all operators. With an evolving work landscape, having industry standards that are rigorously evaluated on a consistent basis allows us to stay vigilant in mitigating risk,” commented John Uber, head of product compliance for PMMI member company, Mettler Toledo.

The standard guides packaging and processing machinery suppliers and users through a formal, documented risk assessment process designed to ensure that reasonably foreseeable hazards are identified, and corresponding risks are reduced to an acceptable level.

A few key highlights of the standard’s updates include:

• Refined Responsibilities: The revised text explicitly outlines the responsibilities of machinery suppliers, users, modifiers, purchasers of used machinery, and other stakeholders, fostering a safer working environment through increased accountability. The update addresses machinery-as-a-service, or MaaS, including equipment loaned or provided by a third party and located in a user facility, as well as mobile platforms, robots used for logistics, cleaning, and more.
• Introduction of Co-Packer / Co-Manufacturer Concepts: The new edition introduces the concept of co-packers and co-manufacturers, delineating their associated responsibilities within the framework of safety regulations.
• Updated Legacy Machinery Requirements: The responsibilities for existing (legacy) machinery have been updated and clarified to ensure that older equipment is brought in line with the latest safety standards in a practical, cost-effective, and appropriate way.
• Clarified Scope: The scope of the standard has been clarified to provide a more precise understanding of its applicability, reducing ambiguity, and allowing for improved implementation.
• Remote / Tele-Operation Enhancements: With the advancement of remote operations, the standard now offers improved information and guidelines for safely operating machinery through remote means.
• Reorganised Clauses 4 and 5: The standard now features a restructured layout for enhanced clarity and ease of reference, streamlining the reading experience for professionals in the field.
• Whole Body Access Requirements: The standard now includes comprehensive requirements for situations where whole body access is applicable, safeguarding operators from potential hazards.

The first version of this standard was approved by the PMMI membership on 27 September 1972. It was approved by ANSI on 6 August 1973. The standard has been reviewed and revised with subsequent approvals by the ANSI Board of Standards Review in 1979, 1986, 1994, 2000, 2006, 2011, and 2016.

The ANSI/PMMI B155.1-2023 standard will be available for purchase through the ANSI webstore.

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According to the organisers, “Packaging is no longer just a means of protecting products; it plays a pivotal role in sustainability, brand recognition, and consumer engagement. Recognising this, the Sri Lanka Institute of Packaging has designed a comprehensive and industry-relevant Diploma in Packaging Technology that equips students with expertise to address modern packaging challenges.”

Luciana Pellegrino added, “It is an honour to be part of such an important moment to the history of packaging industry in Sri Lanka and WPO is proud to support such holistic initiative. I was particularly proud of being invited for the inaugural class in a program that will be conducted by seasoned professionals and experts in the packaging field both locally and globally. Their industry experience and academic prowess will ensure that students receive top-notch education and guidance throughout their learning journey. The faculty members also foster a collaborative learning environment, encouraging students to think critically and creatively.”

The curriculum of the Diploma in Packaging Technology, which was developed by a resourceful team of experts, covers an array of subjects and topics, ranging from the packaging for global society and markets, packaging manufacturing and application process, principles of packaging design and materials science to logistics, marketing, and environmental impact assessments. Students gain a deep understanding of various packaging materials, their properties, and their suitability for different products. The programme emphasises the importance of sustainable packaging solutions, encouraging students to explore biodegradable, recyclable, and compostable alternatives.

“As the world embraces a more sustainable and technology-driven future, the role of packaging technology has become increasingly pivotal”, completes WPO president, Pierre Pienaar. “The Diploma in Packaging Technology equips participants with foresight and adaptability to stay at the forefront of industry trends and innovations, by fostering a deep appreciation for sustainable practices, the Sri Lanka Institute of Packaging with the support of the Ministry of Industries is moulding responsible packaging professionals who can shape a greener and more prosperous future.”  

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This important work is being made possible through cooperation from Continental Terminals, a third-generation, family-owned warehousing company that has been a partner in the coffee value chain for more than 50 years.

US-based roasters can now send their used liners to Continental Terminals locations in Keasbey, NJ, or Alameda, California, via their preferred service (USPS, FedEx, UPS or DHL) or by personal delivery. Once the bags reach a Continental Terminals warehouse, they’ll be prepared to continue their journey to a unique recycling facility.

How it works

Participation is simple:

• Begin by emailing sustainability@grainpro.com saying you’ll be sending bags; an automatic response will offer helpful details and answers to FAQs.
• Next, put clean, empty bags in a box or GrainPro bag; adhere a label addressed to a Continental Terminals location; and apply postage. OR: Bring the bags to one of the warehouse addresses during a coffee pickup.

The warehouse addresses are:

CTI Annex                                        CTI NJ
300 Mitchell Ave                            300 Mac Lane
Alameda, CA 94501                       Keasbey, NJ 08832

“It’s our goal to be a responsible partner and leader in the green coffee industry, which means guiding the way toward improved sustainability,” said Nicolas Rueda, CEO of Neumann Gruppe USA. “We’re delighted to encourage the success of this effort by communicating its availability to our clients and networks.”

Neumann Gruppe USA (NGUS) represents InterAmerican Coffee, Rothfos Corporation and Atlas Coffee Importers, the three US-based import companies of Neumann Kaffee Gruppe. The NGUS companies have long-established relationships with roasters of every size and need across North America, as well as decades-old relationships with coffee producers, cooperatives and associations. Prioritising the future of coffee — via the social, environmental and economic factors impacting it — works in service of NGUS clients on both ends of the supply chain, as well as the NGUS vision to lead with responsibility, respect and an unwavering dedication to the product and people elevated through its best work.

In the near future, GrainPro and Neumann Gruppe USA plan to expand their partnership to similar collection efforts across Europe.

Without question, improving sustainability will require industry-wide approaches and collaborations. GrainPro and Neumann Gruppe USA are hopeful that coffee roasters — true to their passion for coffee and commitment to the environment — will agree to be the essential additional collaborators in this effort and take this powerful step toward a more sustainable tomorrow.

The post NKG and GrainPro collaborate on coffee bean liner recycling scheme appeared first on Tea & Coffee Trade Journal.

With over a decade of experience in the industry, Tecpacking has established itself as a trusted name in tea packaging. Our focus on research and development has led to the revolutionize the way tea is packaged.

One of our standout innovations is the pyramid tea bag machine. Designed to produce visually appealing and flavor-packed pyramid tea bags, We have also developed envelop machines that securely seal the tea bags, preserving freshness and extending shelf life. The speed reach 80bags/min. But it doesn’t stop there. At Tecpacking, we understand the importance of sustainability. That’s why our machines are designed to handle paper and other compostable envelop materials. By choosing our solutions, you not only enhance your brand but also contribute to a greener future.

What sets Tecpacking apart is our commitment to customer satisfaction. We work closely with tea companies of all sizes, from small-scale boutique brands to large-scale producers, to understand their unique packaging needs. Our team of experts is always ready to provide personalized guidance and support, ensuring that our machines integrate seamlessly into your production line.

But our partnership doesn’t end with the purchase of our machines. Tecpacking offers comprehensive training and technical support to ensure that your team is well-equipped to operate and maintain the equipment. Recommend good tea supplier for customers, We believe in building long-term relationships with our customers, supporting them every step of the way.

Join the growing number of tea companies that have chosen Tecpacking as their packaging partner. Experience the difference that our innovative machines can make in enhancing the quality, efficiency, and sustainability of your tea packaging. Contact us today to learn more about our solutions and how we can help take your tea brand to new heights.

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The UK-based roaster’s new single-material bags are 100% recyclable and made from 70% recycled materials, which are plastics commonly disposed of in recycling bins.

For every 1,000,000 bags created, the equivalent of 53,000 600ml plastic bottles will be collected from rivers in the Philippines and Indonesia by the ethical recycling programme, Plastic Bank.

Paul Turton, Pact Coffee’s CEO, said: “If climate change continues at its current trajectory, it’s estimated that we’ll see a significant impact on 75% of Arabica supply, which has already fallen short of demand for the past two years”.

“Plastic pollution significantly reduces ecosystems’ ability to adapt to climate change, so reducing our usage, promoting a circular economy and funding schemes like this bag saves is exactly what we need to do to protect the future of coffee and the planet.

There was the option to instead choose ‘compostable’ packaging, and we understand that this is the preference for well-meaning customers.

However, around 90% of people don’t have the means to compost at home, and the growing data shows that lots of this packaging is ending up in landfill or blocking the food recycling process.

For this reason, we’re confident that we’ve chosen the most sustainable option while maintaining the trademark Pact Coffee freshness”.

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Commenting on the launch, Fabien Simon, JDE Peet’s CEO, said, “This is an important step in driving the sustainability agenda of our company and yet another sign of our leadership in innovation. We know that reducing packaging and promoting recyclability and reusability are increasing consumer needs. By providing more sustainable solutions within soluble coffee, one of the world’s most beloved and consumed beverages, we can maximise our positive contribution in decarbonising our own portfolios and the coffee market as a whole.” 

JDE Peet’s is working to reduce the amount of packaging material and associated carbon emissions, used in both manufacturing, transport, and end-of-life disposal. This new paper pack directly supports the company’s effort of minimising its carbon footprint across its entire value chain and its goal of moving towards 100% of packaging designed to be reusable, recyclable, or compostable by 2030. In line with this, in 2022, JDE Peet’s set targets validated by the Science Based Targets initiative (SBTi) to reduce emissions across scopes 1, 2 and 3. 

The new range will be available in selected markets across multiple brands of JDE Peet’s’ portfolio as of 2024. 

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Within the specialty tea segment, loose-leaf tea has its advocates, yet tea bags remain a popular and convenient way in which most tea consumers will brew the beverage. However, with 68 percent of consumers drinking tea every day in the UK alone, 21 percent of whom drink between four to five cups a day, according to Statista, this mass consumption of single-use tea bags produces significant amounts of waste, much of which ends up in landfills. As consumer awareness of this builds, the pressure on tea brands to ensure sustainability within their operations is paramount, hence manufacturers must continue to meet the rapidly growing demand for sustainably made tea bags.

Tea bags are commonly made of bleached paper, plastic or nylon, and sealed with glue, resulting in a product that will not fully biodegrade and can contribute to the contamination of soil and waterways with microplastics. Fortunately, there has been much innovation in recent years, with many manufacturers making the switch to compostable bio-plastic-based materials, known as PLA (polylactic acid), normally made from corn or sugarcane, rather than petroleum.

Clipper Tea was among the first to make the switch in 2018, bringing to market its “world first’ unbleached, plant-based, non-GM, and fully compostable tea bags,” said Adele Ward, marketing director, Ecotone UK, Clipper Tea’s parent company. Clipper was driven by the ethical and sustainable principles it was founded on to make the change with its tea bags, but customer demand has also incentivised others.

Taylor Clayton, sustainability impact manager at Traditional Medicinals, commented, “While the launch [of its BPI-certified compostable tea wrapper] was partially inspired by the company’s vision to be a leader in finding solutions to plastic waste, we did also [consider] the feedback of our customers who feel just as passionately as we do about protecting the environment.”

Image: Traditional Medicinals

Tecpacking, while manufacturing tea bag packing machines, also produces tea-bag packing material, most of which are PLA-based and compostable, and Paul Zhang, sales manager, Tecpacking, revealed that while there was certainly some demand from customers, the company felt that it was how different industries were moving forward. “Tecpacking is committed to driving sustainable solutions to ensure that the company is directly an enabler within sustainability, so we promote the compostable material to our customers,” said Zhang.

The costs of converting

Whether companies make the switch due to customer pressure or their own sustainability principles, the demand is undoubtedly there, especially among “boutique and eco-conscious tea drinkers and tea brands,” which is where One Earth’s managing director, Erin Heryford, has noted the increase. One Earth manufactures its tea bag material in the US from non-GMO sugar cane, using a dry process so there is no waste water or water contamination, further reducing the impact of its tea bags on the environment. The eco-conscious may be driving the change towards compostable tea bags across the industry but the demand is widespread and increasing in enthusiasm.

The PLA-based compostable tea bag material used, is undoubtedly strides ahead of the conventional wrappers containing petroleum-based plastic, in terms of sourcing, waste, and consumer health, but there is still progress needed. Tecpacking’s and One Earth’s tea bag wrappers, as well as the wrappers used by Traditional Medicinals and Clipper, are only fully compostable in a commercial or industrial facility, rather than at home in a garden compost bin. Unlike biodegradability, which is a natural process where microorganisms degrade materials into simple components like biomass, carbon dioxide and water, compostability requires human intervention to contribute water and oxygen for the materials to fully break down.

“BPI-certified packaging – or packaging that meets the most stringent standards for biodegradability and eco-friendliness – requires ‘industrial aerated composting’ to fully breakdown, and this composting process only happens in a commercial-scale composting facility. In the simplest terms, in order to ensure a product truly breaks down and returns to the earth, leaving no harmful residue behind, it must be industrially composted,” explained Clayton.

In landfill, the material will break down faster than wrappers containing plastic but will still produce harmful GHGs (greenhouse gases) as a byproduct it breaks down, whereas in an industrial composting facility, the conditions are optimised for the material to break down efficiently, minimising GHG production, as well as producing a saleable product as a result: compost, farm fertiliser, or biogas. Therefore, the sustainability of the PLA-based tea bag wrappers is unavoidably reliant on the manner of which its end consumer is willing or able to dispose of it. Most consumers do not have access to industrial composting facilities, or if they do, lack the willing or awareness to separate out the conforming items. In the US, only 15 percent of consumers currently have access to an industrial composting facility, according to Clayton, and in the UK, where the figures are better but still low, almost half – 160 councils, covering 11.7 million households – of local authorities do not provide any food waste collection for their residents.

“We acknowledge that, due to limited availability, industrial composting is somewhat of an imperfect solution, however, it is the only viable option for breaking down compostable packaging at scale. We strongly believe that this is a waste solution that we should support and advocate for, and we feel that we are leading by example with the launch of this BPI-certified tea wrapper,” said Clayton, adding, “it is our hope that as more and more companies take a stance like us on the importance of industrial composting, that more and more facilities will become available.”

Having the necessary infrastructure and end-consumer awareness are not the only challenges facing bio-based tea bag material producers and tea brands. Like with so many other food and drink packaging formats, “The main challenge with compostable wrappers is finding a packaging material that effectively protects the stability of the ingredients within while also meeting biodegradability standards,” commented Clayton.

There needs to be a balance between the material being food-safe and non-detrimental to the shelf life of the product, to minimise food waste, while simultaneously being sustainable and biodegradable, to which there is seemingly slim overlap. Ward added, “It’s not an easy (or a cheap) switch. The challenge is sourcing an effective sealant that will prevent the two sides of the paper from separating and releasing the tea leaves into the cup. Clipper’s compostable heat-seal tea bag was the result of an extensive period of detailed trials and material sourcing.”

Once the appropriate material is found, the challenges do not stop there; “the traditional plastic envelope material is soft and flexible, but compostable material is a bit harder and difficult to form,” explained Zhang, and therefore the packing machine used needs to be adapted accordingly, requiring a high capital expenditure, which is a hurdle for large companies, but possibly an insurmountable barrier for smaller companies.

Image: One Earth

This is something One Earth recognises; “We work with some co-packers so that the One Earth tea and coffee filter material can be accessible to smaller tea brands,” shared Heryford, a move which is necessary for the industry as a whole to progress sustainably.

The cost of the wrapper material itself is also higher, as Clayton revealed, “Increased costs are mostly due to the use of novel, bio-based materials, such as the PLA layer in the wrapper. The bio-based inputs include more processing steps from farm to manufacturing.” But the costs should come down as it is more widely produced and used.

“Compostable tea bag material has still not captured the mass share of the market,” said Zhang, likely due to the manufacturing, disposal and cost challenges given, and until it does, manufacturers and consumers are having to absorb the additional costs associated with making the sustainable choice.

Challenges remain

Tenacity is undoubtedly necessary on the journey towards sustainability, and while there may still be numerous challenges associated with biodegradable tea bags, they are being met with innovation and persistence. Zhang explained that Tecpacking has “three points to do in the future: first is to try our best to work with our raw material suppliers to make good compostable material, second is to improve our machine to make it suitable and easy to run the compostable material, and third is to recommend and promote the compostable material to all of our customers, to try to make 100 percent of [our] customers use compostable material.” He noted that Tecpacking is a global company operating in local markets like Sri Lanka, the Netherlands, and the US, with different partners. “Our sourcing is within the local communities, and we drive the empowerment of these local communities,” as sustainability is about people as much as it is about resources.

Meanwhile, One Earth has a research lab in Naples, Florida, where it continues to develop its compostable and biodegradable products. With Traditional Medicinals’ global advocation of sustainable materials to its customers, and Clipper’s holistic approach to reduce packaging weight and improve recyclability, strides are being taken to counter decades of willful indolence by manufacturers and consumers alike.

Matching the innovation with the infrastructure and awareness needed remains a challenge, as, even if PLA packaging becomes widespread, there need to be means by which consumers can dispose of it in a way that makes the sustainability efforts of the manufacturer worthwhile. Although, it could be argued, that placing almost the full responsibility of the sustainability of a product on the consumer, rather than on the manufacturer which produced the product in the first place, may be a misdirection of accountability, and unsustainable in the long term. However, most will agree action is needed along the entirety of the supply chain, all the way to the consumer, to drive lasting and necessary change.

• Kathryn Brand is an associate editor on T&CTJ, while still writing for several of Bell’s other magazines. She joined Bell Publishing as an editorial assistant at the beginning of 2022 after graduating from the University of East Anglia with a degree in English Literature and Creative Writing. She may be reached at: kathryn@bellpublishing.com.

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As the global tea market continually becomes more sophisticated, tea-packaging tech is following the same path. Helping tea manufacturers meet the demand for more sustainable, environmental-friendly packaging is one of the critical challenges in the present time, and yet there are several other vital goals that must be chased.

The global automatic tea bag packaging market is expected to see a 4.9 percent average growth through 2026, owing to surging tea production and consumption in the coming years, primarily in the emerging economies of India and China, forecasted Mordor Intelligence (MI), an Indian think tank.

Packaging has a significant role to play in the expanding tea market as it not only protects and preserves the product within but also enables brand communication. It is perceived to be almost as crucial as the selection of the tea product itself and is a driving factor for the increasing versatility of tea packaging, with luxury aesthetics and smart carton design at the forefront of consumer attraction, MI analysts stated.

“Consequently, the packaging equipment manufacturer must explore long-term investment opportunities in versatile and adaptable packaging equipment to increase output, reduce labour costs, and maintain a foothold in the market,” per MI.

Among the key vendors in the tea packaging market, the MI study lists Teepack Spezialmaschinen GmbH & Company KG, Selo Group, Xiamen Sengong Packing Equipment Co Ltd, Liaoyang Conoval Machinery Co Ltd, ACMA SpA, FUSO International, IMA Group and Sammi Packing Machine Co Ltd.

All tech suppliers tend to shape up their offer in their own way, but there are some common trends everyone in the industry clings to.

Individually tailored solutions

Teepack recently presented a new model of the Constanta machine family – a highly popular tea-bagging line. Mario Kuhn, Teepack’s sales and marketing manager, disclosed that the company kept the characteristics of the old Constanta by being a rugged, reliable machine that does what it is supposed to do: producing good tea bags around the clock.

In addition, Teepack added flexibility by implementing a platform approach using standardised modules and connecting points. “If the machine is delivered in a certain configuration, it is easily upgradable and amendable in the field. For example, the version with a speed of 180 bags per minute (BPM) can be rebuilt in the field into the 250 BPM version,” Kuhn said.

“The same goes for envelopes: if your machine is equipped to produce heat-sealed envelopes, the machine can be upgraded in the field to produce also crimped paper enveloped bags. This benefits a customer in that the machine can grow with their requirements and allows them to react flexibly to new market developments, without having to buy completely new machinery,” he explained.

This approach also allows Teepack customers to use a multitude of consumables. The customer can decide which modules fit into the slots for consumables, so that they can produce with their current supply. The customer can choose from a total of 1320 possible configurations: two bag sizes, two types of envelopes plus naked bags, two speed versions and three types of removal options are just a few of the options available.

“We are especially proud of our newly developed pre-grouping system for the Constanta. The ejection chute is formed in a way, that an empty box can be put in front of the opening and the pusher pushes the stack into the box. With that innovation, the speed of 250 bags per minute can be operationally used without having to acquire additional staff. For the mature markets, a box erector with filler and lid closer is available, further automating the process if so desired,” Kuhn said.

With Industry 4.0 pushing network-centric connectivity, Teepack is currently looking into how to best apply these new and exciting opportunities for the benefit of its customers. Integrating the machines into a network and presenting the machine’s data in an easy-to-understand way helps to further improve reliability and profitability. Virtual reality is also a field in which there is a lot of potential. This technology enables customers to train personnel while being able to continuously produce with their machines, Kuhn explained.

Sustainability seems paramount

The desire to be more sustainable has become a primary concern in the tea bag packaging industry, the MI study has shown. Packaging equipment manufacturers are increasingly adopting automation in their production lines and adhering to sustainable trade initiatives throughout the world.

Nandini Roy Choudhury, client partner of Future Market Insights (FMI), an Indian consulting agency that recently conducted a comprehensive study of the global pyramid tea-bagging market said that the switch towards pyramid-shaped tea bags itself is one of the key consumer trends tech vendors need to address. The growth in this segment in the coming years is expected to outpace the rise in demand in the global tea market.

“Pyramid tea bags have gained popularity as premium tea products for several reasons. First, pyramid tea bags offer a higher quality tea experience compared to traditional flat tea bags. The pyramid shape allows for more space for the tea leaves to expand and infuse, resulting in a better flavour and aroma,” Choudhury said, agreeing that sustainability plays a particularly important role in the tea bagging industry now.

“Consumers are becoming more environmentally conscious and are looking for products that are packaged in a way that minimises their impact on the environment,” Choudhury explained, adding that customers globally are becoming increasingly aware of the impact of packaging waste on the environment. A particularly important factor is that consumers are willing to pay more for products that are packaged sustainably. “Pyramid tea bags that are packaged using sustainable materials and practices are becoming more popular as consumers look for ways to reduce their environmental footprint.”

When it comes to the growing popularity of sustainable solutions, there are several factors in play. Many governments around the world are introducing regulations to reduce packaging waste and promote sustainable packaging practices. This means that tea bag brands that adopt sustainable packaging practices can avoid regulatory penalties and maintain their market share, Choudhury said.

“Sustainable packaging practices can also create opportunities for innovation and differentiation. Brands that use innovative sustainable materials and packaging designs can differentiate themselves in a crowded market and appeal to consumers looking for new and sustainable packaging solutions,” she added.

Different tastes

The MI study disclosed that when choosing tea-bagging equipment not all tea manufacturers seek the same features. For instance, larger manufacturers in developing nations are anticipated to increase their use of tea packaging materials and adopt new packaging technologies to address issues such as contamination, extend the shelf lives of their products, and make them more aesthetically appealing.

Smaller firms in these countries are expected to mechanise tea-packaging processes to expand output and increase efficiency, further boosting tea bag-packaging machinery demand.

Laura Maria, sales area manager with Italy-based IMA Maisa said that the company primarily focuses on providing customers with easy-to-use solutions. “Our machines are very simple to operate with high performance, extreme simplicity, and mechanical sturdiness which are the most outstanding advantages we offer,” she said, adding that customers are also looking for better automation of their packaging lines.

The FMI study further disclosed that sealing is an important field in which a growing number of companies see room for improvement. “Traditionally, heat-sealing has been the most common method for sealing tea bags, but there is growing interest in alternative methods such as ultrasonic sealing, which can offer faster production speeds and reduce the need for adhesives,” Choudhury shared.

MI also said that the demand not just for an individual tea bag but also overwrapping for a tea bag is gaining popularity to preserve freshness, and for those consumers wanting hygienic and premium design. “Thus, packaging manufacturers are [developing] machinery that not only forms the bag but will also wrap the product,” MI analysts disclosed.

Streamlining operations

Manufacturers are designing solutions to make tea-bagging lines more effective. New Jersey-based Munson Machinery does not manufacture tea-bagging equipment, but its mixers are typically positioned upstream of tea bagging and packaging lines, which as explained by Susan Schaaf, office manager of Munson, require totally uniform blends to maintain consistent flavour.

“Because Rotary Batch Mixers continue to rotate during discharge, they prevent stratification and segregation of the batch regardless of disparities in the size, shape or bulk density of ingredients. This is especially critical when filling individual tea bags, since variations in blend ratios are likely to increase as the size of a given sample decreases,” Schaaf said.

While Munson Machinery offers eight types of mixers and blenders, the company’s Rotary Batch mixer design remains the clear preference among tea processors worldwide remains due to its tea-specific performance advantages including: rapid, gentle blending, fast cleaning, and equal efficiency, Schaaf added.

New form, new meaning

Sustainability has truly taken center stage across all sectors, and tea bagging is not an exception, said Viju Vasishta, sustainable materials expert at PA Consulting, which has recently rolled out an innovative product — tea sheets, designed to be an alternative to conventional tea bags. Vasishta said that the product is currently in the prototyping phase, though the company has already demonstrated the proof of principle in terms of performance compared to standard tea bags.

Brand owners will have to make their packaging sustainable, especially for end-of-life purposes such as recyclable and plastic-free, due to both consumer and regulatory pressures, Vasishta claimed. “Currently, some branded tea bags are packaged in foil wrap and other flexible plastic packaging, and the sector needs to be innovative to either fully eliminate the wrap or use alternative sustainable materials which can be recycled,” he explained, adding that paper and pulp are emerging as key substrates across many food and FMCG packaging and a similar movement regarding these materials is seen for the tea sector.

Generally speaking, the tea-bagging sector lacked groundbreaking innovations in the past few decades, Vasishta shared. “Consuming tea should be a moment of joy for the consumer, and we haven’t seen much innovation in the tea-bag market over the last few decades. We see the same format of tea bags with slightly varying shapes, and the consumer experience feels pretty flat,” Vasishta admitted.

“The [coffee sector], for example, has made the concept of coffee into a premium product. The tea sector has not yet reached that level of innovation. There is an appetite for the tea sector to transform itself, but brand owners are risk averse, and therefore, we are seeing low levels of innovation,” he said.

Digitalisation on the horizon

Automation and robotics are already being used in tea-bagging production to some extent, but the industry may see further advancements in this area, particularly in terms of the use of artificial intelligence and machine learning to optimise production processes.

Choudhury assumes that integration with technologies is not limited to automation. “There is already some integration between tea bagging and technology, such as the use of smart labels or QR codes to provide consumers with more information about the tea they are consuming. We may see further integration in the future, such as the use of augmented reality or virtual reality to enhance the tea-drinking experience.”

“Overall, as consumer preferences and technological capabilities evolve, the tea-bagging industry will likely continue to see innovation and advancements in production processes,” Choudhury added.

• Vladislav Vorotnikov is a Batumi, Georgia-based multimedia B2B freelance journalist writing about the tea and coffee industry since 2012.

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After generating over a million unit orders and even more product demand from its debut in Germany, GaeaStar has raised USD $6.5M in seed funding from Morningside Technology Ventures, at.inc/, Dart Labs Ventures, Sand Hill Angels, VSC Ventures and Climate Capital Ventures to bring its products to the United States, starting in San Francisco.

The world is currently creating more plastic waste than ever before. In 2021 alone, we generated over 40 million metric tons of plastic, yet only nine percent of all plastic ever made has been recycled. With GaeaStar, recycling is rendered obsolete.

Inspired by 5,000-year-old clay cups known as “Kuhlars,” GaeaStar presents a modern-day twist on the ancient Indian tradition of drinking from disposable clay cups that can be tossed — or smashed — on the ground without environmental harm. By combining this cultural practice with 21st-century technology, the company has created a viable fix for our single-use waste problem.

“Although many sustainable food and beverage containers are in the market, finding ones that are also exceptional products overall is a challenge. Our technology finally offers a solution that meets the convenience of being disposable without causing harm to the Earth while giving users a high-end experience,” said Sanjeev Mankotia, founder and CEO of GaeaStar. “It’s all based on the premise that the answer to ditching plastic is to create something that comes from and returns to the Earth in essentially the same form. Ultimately, we have the potential to scale our technology for generations to come without adding more harmful waste to our landfills and waterways.”

How it works

Unlike soggy paper straws or chemical-ridden plastic packaging, GaeaStar’s clay containers are ultra-thin yet 10x stronger than paper cups. The sourcing of the raw materials and delivery of the product is all done locally via a micro-factory model to limit the environmental footprint from start to finish.

Landing somewhere between single-use and reusable containers, these vessels can be taken home and safely used dozens of times with proper care while still having impact and guilt-free disposability.

Each container can be printed in an average of 30 seconds and, at scale, is cost comparable to single-use incumbents so businesses can move towards their sustainability goals in a cost-effective way.

“With the amount of single-use plastic piling up in our environment increasing, it’s obvious that recycling is not a functioning solution to plastic. Sanjeev and his team at GaeaStar have finally presented a realistic way of doing so without the need to drastically change human behavior while making it easy for us all to do our part in creating a future with less waste. Our team is humbled to join this journey and witness GaeaStar transform the market for plastic alternatives,” explains Sophie Lamparter, managing partner of DART Labs Ventures.

GaeaStar will begin distributing its coffee cups in the US through a pilot with California-based Verve Coffee Roasters. The collaboration will give Verve customers at select cafes a more eco-friendly option when ordering particular food and beverages, and allow GaeaStar to fine tune its original container prototype to meet the needs of Verve and other US businesses.

“Our mission is to, not only craft the future of coffee but, to protect its future – and that means being more intentional and sustainable with everything we do. Our customers are mindful about how their choices impact the planet and we think they’ll be thrilled about this more eco-friendly swap to enjoy their daily cup,” said Colby Barr, co-founder of Verve Coffee Roasters. “We’re honored by the opportunity to work with GaeaStar to help pioneer a more sustainable solution while maintaining the high-quality experience we seek to deliver with every customer interaction.”

To learn more, visit gaeastar.com.

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All of Partners’ rotating roster of Single Origin coffees are now packaged in the new cream bags. Partners’ Single Origin programme highlights the brand’s farm relationships and sustainable sourcing efforts. Maintaining strong relationships at origin allows Partners to offer blends with a consistent flavour profile year over year, while celebrating the growing and processing efforts of the brand’s producing and importing partners. Rotating Single Origins – featuring farm relationships from Colombia, Burundi, Brazil and more – are some of the brand’s bestsellers, while El Ramo (Partners’ mainstay Single Origin from Colombia) is Partners’ fourth best selling product overall.

The new packaging was first debuted on the company’s seasonal Block Party blend, which includes notes of strawberry, blueberry, and watermelon and can be served hot or cold. To celebrate Pride, Partners is donating USD $1 for every Block Party bag sold during the month of June to The Center, a West Village-based organisation offering a spectrum of programmes for New York City’s LGBTQ+ community.

Block Party is now also available as an Instant Coffee. With notes of orange, cranberry and honey, the instant coffee sachets can be made hot or cold and are ideal on-the-go.

Partners ships nationwide, is available on Amazon, Skimlinks + ShareASale, and at one of the brand’s five NYC cafes.

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Bizzy Cold Brew’s elevated rebrand, which was designed by Los Angeles-based creative agency Day Job, now clearly communicates the quality of its product line, from its craft-brewed process, stronger taste, high caffeine content and zero sugar in all its brews. Unlike competitors who hide or omit caffeine content from bottles, Bizzy Cold Brew moved its caffeine content to the front of the bottle, directly on the pour spot, to be more transparent with consumers about caffeine per serving. The shape of the bottle has also been changed to improve pourability for its consumers.

“We wanted our new look to elevate our visual identity and clearly communicate our craft product. With nods to an era when quality was the rule and not the exception, Bizzy Cold Brew’s superior taste and higher caffeine content makes it the best value for coffee lovers,” said Alex French, CEO and co-founder of Bizzy Cold Brew. “Bizzy Cold Brew is an affordable luxury and we’re excited that the branding now embodies our values and will stand out on shelves.”

Bizzy Cold Brew’s product lineup includes a variety of craft-brewed products, from unsweetened ready-to-drink, multi-serve bottles of cold brew to coarse grounds that can be brewed at home and convenient, eco-friendly brew bags. Bizzy Cold Brew is crafted using a unique brew process to ensure the smoothest taste and highest caffeine, with USDA Certified Organic Arabica coffee beans from Central and South America.

The Minneapolis, Minnesota-based brand is also committed to sustainable practices in all areas of its operations. The brand’s cold brew bottles are made of 100% post-consumer recycled plastic (excluding the cap) and it composts spent coffee grounds (650,000 pounds last year alone). Bizzy Cold Brew recycles and repurposes 100% of its burlap coffee bean sacks and its roaster utilises after-burner technology to eliminate airborne emissions from roasting.

Bizzy Cold Brew’s RTD products are available in more than 5,000 grocery stores across the United States. Its cold brew bags and grounds are also available for purchase on the Bizzy Cold Brew website and Amazon.com.

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