a new generation of coffee capsule San Diego, Septmber 2018

Transcription

1 a new generation of coffee capsule San Diego, Septmber 2018

2 PRESENTATION INDEX ü The Flo Group ü The European context ü Case history: GEA ü The results: ü Food Contact Compliance ü Shelf life ü Compostability ü Functionality ü Coffee Cupping ü Conclusions

3 THE GROUP EU Fr-Ruitz De-Munich IT- Verona IT-Catania Flo Vending, Sevran ES-Barcellona ArtPlast Polska-Jaroszowiec UK-Wrexham UK-London Pulp 5 Česká republika ES-Barcelona

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5 THE PRODUCT RANGE Moulded Pulp Tableware PP and PS tableware for home and away Coffee Pods Containers for food in plastic and vegetable fibres Plastic tableware in colors Branded cups in plastic and paper Vending Cups in PS and Hybrid Beer cup in traditional plasic mterials (PP,PS,PET) and bioplastic (PLA) To Go and Vending Cups in paper Water cartridge

6 EUROPEAN CONTEXT

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9 CASE HISTORY:GEA PRODUCTS DEVELOPMENT STRATEGY: LAVAZZA A MODO MIO and BLUE PP and PP/EVOH/PP NESPRESSO PP/EVOH/PP LAVAZZA A MODO MIO CPLA/PVOH/CPLA

10 MARKET REQUIREMENTS: Food Contact Compliance (focus on THF) Oxygen barrier Compostability Functionality (same as original PP capsules) and NO aging Coffee cupping (same as original PP capsules)

11 «We decided not to use compounded materials to avoid issues with THF migrations and aging. CAPSULE DESIGN We learned that all the elements of the system are related. When we switched from PP to PLA in our thermoforming process we had to reconsider all the elements to be able to provide a solution» LID SOLUTION MATERIALS PP PLA unit Specific Gravity 0,90 1,24 MFR 4 8 g/10 min HDT (0,45 Mpa) C Shrinkage 1,5 2,5 0,3 0,4 % BREWING MACHINE COFFEE

12 PROJECT TIMELINE: MATERIAL TESTS - DIFFERENT POLYMER S GRADES - ADDITIVES - CRISTALLIZATION PROCESS CAPSULES DESIGN - LAB MACHINE - DIFFERENT SAMPLES TO TEST CAPSULE BREWING TESTS - TESTING PROTOCOL THERMOFORMING PROCESS SCALE UP - MOULD MAKING - PARAMETHERS SETTING - IN CUSTOMERS S FACILITIES - DOUBLE INTERFACE - SEALING TESTING - UNDERSTANDING THE CUSTOMER S PROCESS - FOOD COMPLIANCE, THF - SHELF LIFE, OTR, WTR, PANEL TEST - COMPOSTABILITY - AGING INDUSTRIAL FILLING TESTS ANALYSIS 0 12 months 24 months

13 The result is a new generation of coffee capsule developed with NatureWorks made with Ingeo PLA

14 Food Contact Compliance Limit Units Conditions O.M. 2,1 ± 0,8 10 mg/dm 2 Acetic Acid 3% 2h 70 C O.M. LoQ 10 mg/dm 2 Ethanol 20% 2h 70 C O.M. LoQ 10 mg/dm 2 Acetic Acid 3% 5 min 100 C O.M. LoQ 10 mg/dm 2 Ethanol 20% 5 min reflux O.M. 5 ± 1,2 10 mg/dm 2 MPPO total immersion in solvents 10 days 60 C O.M.: Overall Migration; LoQ: Limit of Quantification No PVOH has been found in brewing simulation test. On liquid of extration On liquid of extration On MPPO migration Limit Units THF n.d. 0,6 mg/kg Heavy Metals n.d. - mg/kg Maleic Anhydride n.d. 12 mg/kg Vinyl Acetate n.d. 12 mg/kg Primary Aromatic Amines n.d. - mg/kg Phtalic Acids 2 7,5 mg/kg 1,4 butanediol n.d. 5 mg/kg Limit Units THF n.d. 0,6 mg/kg Maleic Anhydride n.d. 12 mg/kg Vinyl Acetate n.d. 12 mg/kg Phtalic Acids 2 7,5 mg/kg 1,4 butanediol n.d. 5 mg/kg Limit Units THF n.d. 0,6 mg/kg Maleic Anhydride n.d. 12 mg/kg Vinyl Acetate n.d. 12 mg/kg Phtalic Acids 2 7,5 mg/kg 1,4 butanediol n.d. 5 mg/kg n.d.: not detectable

15 Panel test Olfactory n of answers score Panel test Organoleptic n of answers score 0 = no differences 0 0 UNI 10192:2000 Head Space 500 cm 3 1 = very low difference difficult to detect 3 3 Conditions: 40 ±1 C, dark, 24 h 0 = no differences 1 = very low difference difficult to detect UNI 10192:2000 Conditions: 40 ±1 C, dark, 48 h Simulant: water 2 = weak difference but detectable = weak difference but detectable = clear difference = clear difference = very strong difference = very strong difference 0 0 Total score - 15 Total score - 17 Average score - 1,9 Average score - 2,1 Std deviation - 0,8 Std deviation - 0,6

16 Shelf life Unit Conditions OTR on GEA capsule 0,001 cc/(pack 24h air) 23 C 40% RH OTR on GEA capsule + lid 0,002 cc/(pack 24h air) 23 C 40% RH OTR on GEA capsule 0,001 cc/(pack 24h air) 23 C 90% RH OTR on GEA capsule + lid 0,005 cc/(pack 24h air) 23 C 90% RH OTR on GEA capsule 0,001 cc/(pack 24h air) 38 C 50% RH 30 days OTR on PP-EVOH-PP capsule 0,001 cc/(pack 24h air) 23 C 40% RH OTR on PP-EVOH-PP capsule 0,001 cc/(pack 24h air) 23 C 90% RH OTR on PP capsule 0,102 cc/(pack 24h air) 23 C 40% RH OTR on PP capsule 0,103 cc/(pack 24h air) 23 C 90% RH A Panel Test and a Head Space analysis are in progress every 30 days of storage in accelerated aging conditions to evaluate the chemical modifications and the tasting stability of coffee. No aging phenomena are occuring. WTR on GEA capsule 0,025 cc/(pack 24h air) 38 C 90% RH WTR on GEA capsule 0,037 cc/(pack 24h air) 38 C 50% RH 30 days OTR: Oxygen transmission rate WTR: Water transmission rate

17 Compostability All the raw materials used to produce GEA are certified for industrial composting system according to global standards such as EN (EU) and ASTM D (USA). The new capsule is now in final testing by TÜV Austria and the Italian Composting and Biogas Association (CIC) for the compostability certification. EN 13432:2000 Norm Requirements for packaging to be recovered by composting or bio degradation 3. No negative effects on composting process 2.Disintegration 90% disintegrated in fragments < 2mm in 3 months 4.Eco toxicity and compost quality Heavy metals, volatile solids, N, P, K, Mg, PH, salt composition can t be deviate from the reference compost 1.Biodegradability 90% into CO2 and H2O in 6 months COMPOSTABLE

18 Functionality Model Number of tests Coffee weight (g) Capsule deformation Average diameter of the holes (mm) Crackings Brewing failure Capsuleextraction difficulties Magia 50 7,7 Rounded edges 1,8 0% 0% 12% 50 7,2 Rounded edges 1,8 0% 0% 6% Fantasia 50 7,7 Rounded edges 1,8 0% 0% 0% 50 7,2 Rounded edges 1,8 0% 0% 0% Minù 50 7,7 Rounded edges 1,8 0% 0% 0% 50 7,2 Rounded edges 1,8 0% 0% 0% Jolie 50 7,7 Rounded edges 1,8 0% 0% 0% 50 7,2 Rounded edges 1,8 0% 0% 2%

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20 Coffee Cupping Model Coffee weight (g) Number of tests Volume brewed in 30 sec (ml) Coffe temperature in cup ( C) Residual powder (mg/g) Cream persistence (sec) Magia 7, ,3 79,4 0,37 6 Fantasia 7, ,8 78,7 0,31 8 Minù 7, ,1 81,9 0,34 7 Jolie 7, ,8 79,1 0,28 12 Very positive feed back by several coffe roasters who tested GEA

21 CONCLUSIONS ALL THE MARKET REQUIREMENTS HAVE BEEN ACHIEVED Total solution approach Complete set of analysis Very deep understanding of the crystallization process Team working

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23 THANKS FOR YOUR ATTENTION