Borealis/Bockatech use foaming technology for thinwall PP cups

Also at K2022, Austrian chemicals firm Borealis and Bockatech, inventor and licensor of the EcoCore manufacturing technology, showcased lightweight and ultra-lightweight reusable cups made of Borealis PP using the patented EcoCore plastic foaming technology.

These robust and fully recyclable cups represent the many thin wall and reusable packaging applications that can be developed using Borealis PP resins and the next- generation EcoCore foaming technology.

The cups are said to be even lighter than many conventional single-use paper cups. Yet they boast good insulation properties, with twice the thermal barrier of PP cups with solid walls of the same weight. Durable EcoCore mouldings can be microwave and dishwasher-safe. Because they are made solely of PP, they are easy to recycle once they have reached end of life after hundreds of use cycles.

EcoCore produces durable, monomaterial moulding walls with a composite skin-foam-skin structure in only seconds, and at low cost.

The companies say converters and brand owners benefit from:

Up to 50% less plastic used in production when compared to solid wall mouldings;
- Improved recyclability of moulding and injection moulded labels (IML) thanks to monomaterial PP;
- Suitability for existing injection moulding machines, ancillary equipment, and processes;
- Shorter cycle times of 5 to 7 seconds;
- Design freedom for shapes, colours, transparency, high-precision details as well as for decorative elements such as in-mould labelling.

Borealis/Bockatech use foaming technology for thinwall PP cups

“With our partner Bockatech we’ve made unique progress in making thin wall and reusable packaging even more sustainable. The compatibility of the EcoCore platform with a variety of PP resins enhances its appeal to our customers,” says Peter Voortmans, Borealis Global Commercial Director Consumer Products.

He adds, “Our Bornewables portfolio of circular polyolefins, and our transformational Borcycle C family of chemically-recycled grades can be used as drop-in solutions for food and non-food. In addition to that, Borcycle M our portfolio of mechanically recycled grades enables production of non-food applications. All three solutions can further lower the carbon footprint of thin wall packaging whilst maintaining high performance.”

Chris Bocking, Bockatech Founder/Chief Strategy Officer also stated that EcoCore can be used for a broad range of more sustainable reusable and thin wall applications, including bowls for to-go food service, pots for foods such as noodles as well as soups, pails and even aerosol caps.


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