SÜDPACK’s PP spouted pouch film cuts carbon 40% with 95% recyclability rate

GERMANY – SÜDPACK has introduced a polypropylene-based film structure for spouted pouches, extending mono-PP laminates into cold-filled drinkable yoghurt packaging, achieving a 40 percent lower carbon footprint and more than 95 percent recyclability compared to conventional PET/aluminium/PE laminates.

The pouch, developed using CarbonLite PurePP, was designed for cold filling of drinkable yoghurt and other dairy products, with films that undergo UVC or hydrogen peroxide treatment to decrease microbial load. 

The barrier properties can be adjusted for oxygen and water vapour requirements, providing the same shelf life as PET, aluminium or PE laminates currently in use. 

CarbonLite PurePP and Mono-Material Design Enable 95% Recycling

When paired with a PP spout, the full package can be processed in the PP recycling stream, achieving a recyclability rate of more than 95 percent. 

The structure is based on a recycling-oriented design, with the packaging concept developed for cold-filled drinkable yoghurt. 

Internal calculations indicate that the CO₂e footprint per square metre of a PP-based spouted pouch with a film thickness of 111μm is more than 40 percent lower than that of a 103μm PET/aluminium/PE laminate. 

Conventional laminate structures are typically directed to energy recovery at end of life, while the PP-based format can be mechanically recycled. 

The films were developed for cold filling of drinkable yoghurt and other dairy products using packaging materials that undergo UVC or hydrogen peroxide treatment to decrease microbial load.

Adjustable Barrier Performance and Sealing Integrity

The barrier properties can be adjusted for oxygen and water vapour requirements, providing the same shelf life as PET, aluminium or PE laminates currently in use. 

The sealing performance and integration of the spout are designed to maintain seal strength and prevent leakage during handling and distribution. 

SÜDPACK drew on its extrusion capabilities and previous collaboration with machine and spout manufacturers in fruit purée filling applications to develop the packaging concept. 

The mono-material PP structure extends the use of recyclable laminates into the spouted pouch format, addressing a packaging segment where multi-material structures have historically been the standard. 

The solution was developed in line with PPWR design principles, responding to regulatory requirements for packaging recyclability in the European market. 

Spouted pouches are increasingly used for on-the-go dairy and beverage products, and the introduction of a recyclable mono-material option addresses a significant sustainability gap in this packaging format, where conventional structures have been difficult to recycle.

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