Full closure: Innovations in the caps and closures industry | FoodBev Media

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Siân Yates

13 September 2024

Full closure: Innovations in the caps and closures industry

The 3 July 2024 marked the official implementation of new EU legislation mandating tethered caps on single-use plastic beverage containers, a significant milestone in the fight against plastic pollution. Proposed in 2018 and adopted in 2019 as part of the EU’s Single-Use Plastics Directive, this law requires that plastic caps and lids on beverage containers of three litres or less remain attached during use

and storage.

Initially met with resistance from major companies like Coca-Cola, Danone, Nestlé and PepsiCo – who cited the substantial time, effort and investment needed for redesigning packaging and retooling production – the industry has since adapted. Coca-Cola, for example, rolled out tethered caps a year and a half ahead of the deadline. The primary aim of this legislation is to reduce plastic pollution, with tethered caps expected to eliminate 10% of plastic litter on European beaches.

To ensure compliance, the Commission tasked the European standardisation body CEN with developing robust standards for tethered cap design. These standards consider factors such as strength, reliability, safety and compatibility with existing production equipment, leading to diverse

solutions like hinged tops and lasso closures.

However, the transition has not been without its challenges. Some consumers have expressed frustration on social media, complaining about fiddly elements and caps hitting their faces while drinking. But not all tethered cap designs are alike. Below, we explore some of the latest innovations in the caps and closures market.

Blue Ocean Closures released a new fibre-based cap designed for aseptically packaged products like long-life dairy, juices, plant-based drinks and soups. This innovative cap is recyclable as paper, aligning with sustainability goals in packaging.

With an estimated 135 billion carton board packages using plastic caps globally each year, this cap offers a drop-in solution, making it easy for producers to integrate into existing systems. Arla Foods recently collaborated with Blue Ocean Closures to create fibre-based caps for its milk cartons, potentially reducing plastic use by over 500 tonnes annually.

Alpla launched a no-spill beverage closure, designed for practical and child-friendly use. This closure dispenses liquid only when suction or pressure is applied to the mouthpiece, effectively preventing leaks and splashes. Developed in partnership with Norwegian company SmartSeal, this closure maintains a secure seal even under high bottle pressures of up to 2.7 bar.

The closure will be available in nine colours and customisable options for larger orders. Additionally, a two-part sports version is in the works, designed for easy drinking during physical activities.

Origin Materials launched a new sustainable PET cap designed for carbonated soft drinks. This cap is lightweight and compatible with the widely used PCO 1881 neck finish, making it suitable for a range of beverages, including juices and sparkling water. Claimed to be the first commercially produced cap made entirely from PET, it uses either virgin or rPET. The design includes a user-friendly tamper-evident feature, enhancing product safety.

Origin plans to start commercial production of these caps in Q4 2024, using a high-throughput production system. This development aims to improve recycling circularity, reduce plastic usage and extend product shelf life, demonstrating significant potential for food and beverage manufacturers seeking sustainable packaging solutions.

Kraft Heinz introduced its first 100% recyclable cap for squeezy ketchup bottles, developed in collaboration with Berry Global. This cap, made from polypropylene, replaces the previously used silicone valve, improving recyclability while maintaining functionality. The cap design project, which spanned eight years and included 45 prototypes, focused on optimising both sustainability and user experience.

Extensive testing ensured the new cap dispenses the same portion of sauce without compromising squeezability. The redesign is expected to prevent around 300 million plastic lids from reaching landfills annually. The caps were rolled out across 400ml and larger bottles of Heinz Tomato Ketchup, with plans for further expansion into other sauces.

In 2023, United Caps, in collaboration with UK-based start-up Mimica, launched the Bump Cap, a recyclable plastic closure designed to combat food waste. Using innovative plant-based gel technology, this cap activates upon opening, measuring spoilage based on time and temperature without direct contact with the beverage.

As beverages degrade, tactile bumps appear on the cap, providing a clear freshness indicator. In consumer trials with orange juice, 97% of participants extended their use beyond traditional expiry dates, with some enjoying their juice five to six days longer.

PolyCycle Innovation, in partnership with Closure Systems International, introduced PolyCycle PCR closures made from 100% post-consumer recycled (PCR) resin. These closures aim to provide a sustainable solution for food and beverage packaging while supporting ESG goals. The resin’s proprietary process ensures high quality and performance, making it suitable for various applications, including carbonated soft drinks.

PolyCycle closures are fully recyclable and reduce energy consumption by 79% and greenhouse gas emissions by 67% compared to virgin resin. Recently certified by GreenCircle, the company confirms its commitment to sustainability and circular economy practices. Available in both polyethylene and polypropylene, these closures meet diverse customer needs while maintaining performance standards.

Amcor Capsules announced a sustainability advancement for its Stelvin aluminium screw caps, reducing carbon emissions by up to 35%. This achievement marks Stelvin as the first low-carbon aluminium screw cap on the market, leveraging up to 46% recycled aluminium and low-carbon primary aluminium. The improvements apply to all Stelvin and 30H60 screw caps produced in Europe, North America and South America.

Wine and spirit brands can adopt more sustainable capping solutions by choosing the updated Stelvin screw caps. Additionally, they can enhance their environmental efforts by selecting the PVDC-free liner, called Stelvin Inside.