Samenvatting

Currently, a large share of the product portfolio, especially instant drinks and powder-based products is packed in multilayer laminates containing EVOH. These materials provide a strong oxygen barrier and have already been validated for long shelf life (up to 18 months). However, these structures are not fully recyclable and may not comply with future PPWR requirements. This creates pressure to transition towards mono-PE packaging solutions. The challenge is that mono-PE provides lower oxygen barrier performance compared to PE/EVOH. At the same time, many products are sensitive not only to oxygen but also to moisture, which increases the complexity of the transition. If not properly validated, this transition may lead to product quality issues such as caking, oxidation, and reduced shelf-life. Therefore, this project is highly relevant from both a sustainability and product performance perspective. This creates a clear gap between current packaging practices and future regulatory requirements. While existing multilayer laminates are technically validated, their long-term compliance under PPWR remains uncertain, particularly due to limited recyclability at scale (European Parliament & Council of the European Union, 2025). As a result, the company must evaluate alternative packaging solutions that balance material performance with regulatory compliance.

To provide context for the packaging system and its interaction with product characteristics, a simplified coffee production process flow is presented. The diagram includes the main processing steps such as raw material reception, cleaning, roasting, cooling, degassing, grinding (if applicable), and final packaging. These processing stages directly influence key product properties relevant for packaging performance. In particular, roasting and cooling determine moisture content and aroma stability, while the degassing stage leads to the release of CO₂, which plays a critical role in defining internal package atmosphere and the need for degassing valves. Grinding further affects particle size distribution, which influences oxidation rate and surface exposure.

To support the evaluation of packaging performance for powder-based products, a simplified process flow diagram is presented. The diagram includes key steps such as raw material reception, storage, mixing, transport, filling, and final packaging. Unlike coffee products, powder-based formulations are not influenced by degassing behaviour but are highly sensitive to moisture uptake and environmental conditions. Processing steps such as mixing and transport influence particle size distribution, bulk density, and powder homogeneity, which are critical for flowability and filling performance. These product properties have a direct impact on packaging requirements. In particular, high hygroscopicity makes powder products sensitive to water vapour transmission, leading to caking, agglomeration, and loss of functionality. In addition, fine particles can contribute to electrostatic charging and contamination of the sealing area, affecting sealing quality and package integrity.