Macpac has expanded its thermoforming materials portfolio with the addition of Sulapac Flow 1.7, a wood-polymer composite developed for packaging applications requiring the functionality of conventional plastics with a more natural, fibre-like appearance.
The Stockport-based thermoformed packaging manufacturer said the material, developed by Helsinki-based Sulapac Ltd, is food-safe under EU and FDA US requirements and is produced from biodegradable biopolymers and wood dust. According to the company, the wood dust used in Sulapac Flow is sourced as a by-product from the North European sawmill industry.
The material is designed for thermoformed packaging inserts and can replace materials such as PS, PP or PET in selected applications. Macpac said Sulapac Flow can be shaped in a similar way to traditional plastics, while offering a high-end natural look and feel that can remove the need for post-processing.
The company said the material maintains its shape, can be clicked in and out repeatedly, does not collapse in water and can be thermoformed to meet individual product requirements. It also allows detailed surface structures to be produced with high precision and is available in custom colours.
Sulapac Flow is described as biobased, industrially compostable and recyclable by design. Macpac also said the material contains no permanent microplastics, PFAS or other toxic chemicals, based on testing cited by Sulapac.
The material is being positioned for packaging inserts, point-of-sale displays, logistics trays and single-use food packaging. Its natural insulating properties are said to provide broader workable temperature ranges during manufacturing compared with some other biobased materials.
Macpac said Sulapac Flow requires lower thermoforming temperatures than conventional plastic, leading to energy savings of up to 20% through shorter heating times. The company added that faster heating can also reduce production time and support process efficiency.
Graham Kershaw, Managing Director at Macpac, said: “Adding Sulapac Flow to our range of packaging materials reflects Macpac’s on-going commitment to helping clients meet their environmental targets and provide the required functionality and protection for their products.
“As a forward-thinking thermoformed packaging manufacturer, it is important that we review and expand our material offering in response to the changing needs of our global client base and to meet our own ambitious long-term growth strategy and sustainability goals.”
Macpac operates in-house design, tooling and production facilities and supplies thermoformed packaging products for sectors including food, drink, pharmaceutical, medical, horticultural, engineering, manufacturing and automotive. The company said it recycles approximately 680,000kg of rPET per year, which is reprocessed into extruded sheet for further thermoforming production.
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