Until now, there has been no alternative to plastic, especially when it comes to packaging foodstuffs and other filling goods. However, the volume of plastic waste and the low recycling rate generate considerable problems. IQPAK® offers the food industry, gastronomy and the chemical and cosmetics industries a new solution for packaging: eco-friendly, material minimalistic, cradle to cradle, cost-conscious, digital.
Plays the main role: the system layer
Responsible for the external appearance: The handling layer
Holds the content: The content layer
The system layer is the reusable component of IQPAK®. It is injection-molded from polypropylene monomaterial. Foam injection molding is also possible, reduces weight and improves the thermal insulation properties.
The system layer ensures the stability of the packaging and can be reused immediately after the separation of the handling and content layers by machine. As it is protected by the handling and content layers at all times during use, it is not contaminated and does not require energy-intensive washing.
A near-field communication chip (NFC) is permanently installed in its base. The system layer has a material thickness of 1 to 2.5 mm. It accounts for over 90% of the total weight of IQPAK® packaging.
The handling layer protects the system layer as an outer film cover. It is the contact surface to the consumer and can be provided with product information and designed.
It is very thin (30-60 µm) and consists either of oriented polypropylene (OP), which is pulled over the system layer as a shrink film in a so-called “sleeve process”, or of polypropylene applied in the classic thermoforming process.
It is 100% recyclable: the recycled PP granulate obtained from handling layers is used to produce new system layers as well as new handling and content layers.
The content layer is a very thin film layer (30-60 µm) that is placed inside the system layer. It absorbs the respective filling product and encloses it hygienically. It is made of polypropylene monomaterial, which has suitable barrier or food-grade properties depending on the contents.
It is 100% recyclable. Today, recycled PP granulate obtained from used content layers is used to produce new system layers. IQPAK® is also aiming to reuse content layers for new handling and content layers, and even in the food sector in the future. The use of virgin material is still unavoidable for the production of new content layers – however, due to the low thickness of the film, the amount of material used is very low.
Material cycle almost completely closed: avoids waste, conserves resources, reduces CO2 footprint, reduces costs.
After use: super-simple automated separation of the three packaging components in our own machinery. Separate collection, easy recycling of the film components.
System layer does not get dirty. Therefore: no need of washing. No water and energy consumption, no material fatigue. Reusable components can basically be reused an infinite number of times.
Film components (content and handling layers) are almost 100% recyclable. New layers are made from recycled material. Which ones: depends on previous use. Sure: little use of new material necessary.
Suitable for products up to 1 liter. Can become a yogurt pot, bowl or milk carton - and much more.
Ready for the digital product passport: track material, manage pool, track usage cycles, assign deposit value variably, record returns, create life cycle assessment - all super simple.
A near-field communication chip (NFC chip) is permanently installed at the bottom of the IQPAK® system layer. Thanks to the integrated NFC chip, IQPAK® packaging is ready for the Digital Product Passport (DPP-ready). The DPP is required by the Ecodesign Regulation ESPR from 2027/28. We are anticipating the legal obligation and are already assuming product responsibility now.
Every IQPAK® packaging communicates with the IQPAK® database via the chip. This facilitates recycling, logistics, variable deposit and customer loyalty. DGSVO-compliant: data protection for users is guaranteed at all times.
IQPAK® makes a direct contribution to reduce CO2 emissions.
In comparison with a 500 ml reusable cup, as used in system catering or in the coffee-to-go sector, an IQPAK® cup of the same size saves almost 60 percent CO2.
Washing a standard reusable cup is therefore more than twice as emission-intensive as refurbishing an IQPAK® container (mechanical separation of the three packaging layers, recycling the films, covering the system layer with a new handling and content layer).
“By eliminating the energy-intensive rinsing process, IQPAK® performs better in terms of its carbon footprint than current reusable systems in the market.”
Benedikt Kauertz, Head of Industry and Products, Institute for Energy and Environmental Research Heidelberg
IQPAK® performs even better in terms of its carbon footprint compared to single-use solutions such as the common beverage composite carton:
With a circulation frequency of 50 cycles or more – i.e., if the system layer is reused 50 times and covered with new content and handling film – IQPAK® reduces emissions by up to 70 percent.
The clever combination of three different cycle components means that very little amount of material needs to be used and it functions in a closed loop cycle. This conserves resources.
All components of IQPAK® packaging are either immediately fed into the next usage cycle or recycled without any problems. This means there is virtually no plastic waste.
As a reusable component, the system layer does not require energy-intensive washing. Washing chemicals and mechanical loads therefore do not affect the material. The robust IQPAK® component therefore theoretically has an infinite number of cycles.
Thanks to the integrated NFC chip, each package can be identified. This simplifies labeling, reprocessing, transport and reverse logistics – and also makes material tracking and consumer interaction easy.
The film components made from pure polypropylene mono-material are recycled and the recyclate is then returned to the material cycle. Barrier and food-grade properties are possible.
The database-supported recycling system with its own IQPAK® refurbishment park and intelligent IQPAK® collection containers offer ecological and economic advantages over conventional packaging solutions. It is easy for consumers to return the packaging.
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