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Thin, thinner, EcoPeelCover An award-winning lidding solution for Privatmolkerei Bauer
How can sustainability and efficiency in dairy packaging be improved without compromising quality? In partnership with Privatmolkerei Bauer GmbH & Co KG, we tackled this challenge by developing a more eco-friendly lidding solution. Through close collaboration, we optimized our innovative EcoPeelCover to meet Bauer's specific needs, resulting in an award-winning product that sets new standards in food packaging. This success was recognized with the prestigious Deutscher Verpackungspreis (German Packaging Award) in 2024 in the category Sustainability (material reduction). |
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The need for efficiency and sustainability Privatmolkerei Bauer, a leading German dairy producer, wanted to enhance the sustainability of its packaging while maintaining quality. To support this, we developed a thinner, eco-friendly die-cut lid for their polypropylene (PP) cups.
The goal? Reduce material usage and improve efficiency by creating a lid with a 25µm aluminum layer and a 13 grams/m² extrusion coating—significantly thinner than the standard 38µm and 24 grams/m² coatings. |
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| The solution: EcoPeelCover – The thinnest die-cut lid on the market Our EcoPeelCover stands out as the thinnest die-cut lid available, featuring ultra-thin aluminum and coextruded PP layers. Despite its reduced thickness, it delivers exceptional performance in peelability, corrosion protection, and puncture resistance. Plus, it provides superior barrier protection, safeguarding dairy products from moisture and oxygen while maintaining freshness. |
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| "EcoPeelCover shows how innovation in downgauging can deliver exceptional material efficiency without sacrificing performance. Our collaboration with Privatmolkerei Bauer allowed us to push the limits of more sustainable packaging while ensuring product protection and reduced resource consumption," says Claus Dworschak, Strategic Product Manager Die Cut Lids at Constantia Flexibles.
By reducing the aluminum layer to 25µm and the extrusion coating, which provides the sealing function, to 13 grams/m², we achieved a 25% reduction in aluminum thickness and a 50% reduction in the coating material. This not only minimizes resource use but also improves transport and packaging efficiency. |
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| Key highlights of EcoPeelCover | • | Material and energy efficiency: The thinner lid cuts material usage, reducing both aluminum and energy consumption. | | • | Performance: Despite its thinner design, EcoPeelCover matches standard lids in essential qualities like peel strength, barrier effectiveness, and puncture resistance. | | • | Sustainability: Using fewer materials helps lower environmental impact without compromising product protection and functionality. | | • | Recognition and award: Winner of the Deutscher Verpackungspreis 2024, category Sustainability (material reduction). |
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The success of EcoPeelCover was highlighted when it won the Deutscher Verpackungspreis 2024. The jury praised the lid for achieving significant material savings while maintaining high safety and performance standards. EcoPeelCover perfectly balances sustainability and efficiency, representing a bright future for eco-conscious packaging innovations. |
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| Looking ahead: Nothing is impossible This project with Privatmolkerei Bauer proved that innovation is not just possible—it's essential for the future of more sustainable packaging. The collaboration between our teams led to a breakthrough that showcases how technological advancements can achieve both material efficiency and environmental responsibility. |
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