Reusable packaging reinvented: How IQ*Pak makes the cycle more efficient

Put simply, the packaging consists of several layers:

The key point: the reusable component remains protected from the inside and outside by the hygiene layers. Contamination, product adhesion or visual wear mainly affect the replaceable layers – not the durable system layer.

Separating the system and function layers allows the reusable pool to be kept small, standardised and efficient – while at the same time allowing the brand, decor or product-specific properties to be reconfigured in each processing cycle.

IQPak attempts to resolve precisely this tension:

• The system layer remains largely standardised in terms of shape and basic geometry.
• The handling layer and the outer functional layers offer a wide range of design options: colours, printed images, haptics, brand claims.
• These outer layers can be re-selected for each preparation – without enlarging the pool itself.

This combines standardised reusable carriers with individual branding.

Conclusion. Reusable packaging taken to the next level – technically and digitally

For companies that want to make reusable strategies sustainable in line with economic and regulatory requirements, it is worth taking a look at such modular, data-based systems. In our formats at Innoform Coaching, we accompany these developments and discuss them with experts.

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Transkript

Then we always have a cycle that is represented accordingly. We have, um, um, the filling of a reusable packaging, the use of a reusable packaging. Then, so to speak, the reusable packaging is returned. It is inspected, either sorted out, goes into recycling or is typically cleaned through washing processes and, um, returns to this cycle.

The key to achieving cost effectiveness, meaning economic efficiency on one hand, and high ecological efficiency on the other, is that the packaging must be kept in the cycle as often as possible. And ideally, only a very small pool is needed for this. That means a small pool, high circulation cycles, high economic and ecological, um, efficiency here, so to speak, the classic approach is shown. And at which point might the approach, um, with regard to IQ*Pak deviate?

Somewhat, um, at this point, and you can see this affects many points, although the top point can be removed. Um, the current reusable packaging is of course flexible for different contents. The difference here is if we previously looked at the usage phase, there is naturally some form of mechanical impact on the reusable packaging. There’s an impact from the filling material on the reusable packaging.

In the case of IQ*Pak, the reusable component is protected, so to speak, by thin plastic films so that this reusable component is accordingly protected by the hygiene layer. Another point is that, um, now I’m jumping to the left side here. A traditional washing process can be omitted with IQ*Pak because these hygiene layers, which enclose this system layer, can be automatically removed and reapplied.

And a third point that I would like to highlight here is that, um, each individual package is stored in a database. Um, it can be read via an NFC chip, so to speak. Uh, the status can, um, be read, which brings various advantages, uh, both in terms of, uh, return logistics, but also in terms of the logistics of, uh, the pool system and also in terms of recycling. Um, which I will then go into a bit more detail on, uh, in the following slides.

Let’s take a look at the structure of the IQ*Pak packaging system, even though it is shown here in the form of a cup. The next slide will present examples of other geometries. This structural illustration is meant to help better understand the basic idea of IQ*Pak. Looking here, uh, on the left side of the presentation slide, you can see, uh, this green core. That means this is the so-called system layer, which naturally brings a certain robustness. This is the part that is also kept in circulation.

It amounts to approximately 90 to 95%. In this system layer, an NFC chip is integrated and through this NFC chip, each individual package is registered in the database and stored with additional information for each package. And then you can see, so to speak, on the left and right, the hygiene layers. The inner hygiene layer is referred to as the content layer in IQ*Pak.

That means it is a very thin, um, plastic film that can be mechanically, uh, recycled, um, which can naturally also be adjusted in terms of thickness and composition to the respective filling material, and can be integrated into the system layer in a scalable, classic plastic processing process. In this case, a thermoforming process. But this is just shown here as an example on the right side for, um, better visibility here, a white system layer and a dark colored film as the content layer.

Inhaltsschicht durch Thermoformen einsetzen

The special feature here is that the assembly, um, in quotes, meaning the insertion of the content layer takes place directly in the system layer during the thermoforming process. In order to be able to dispense with washing processes, the system layer must be protected accordingly on all surfaces. This means on the outer side of the IQ*Pak packaging, we have the so-called handling layer. This is the layer that comes into contact with the consumer.

This, um, handling layer can be applied either through a thermoforming process or through the traditionally known sleeve processes. Um, the advantage is if you imagine the packaging is in circulation, returns and is reprocessed, that means the hygiene layers are removed accordingly, through the information about the layers available in the database, they can be sorted by type. The packaging can be prepared, so to speak, in accordance with the new regulations.

And new regulations also mean, uh, that the packaging, uh, at least in the outer design, uh, can be individualized, so to speak, tailored to the customer. This means that here too, the topic of standardization in the packaging form plays a crucial role. One can then, so to speak, keep the pool small and standardized, but still design the packaging individually at each processing step here, for example, with a cup.

But IQ*Pak not only focuses on, uh, so to speak, food packaging or beverage packaging, but also has a focus on sealed level packaging in cup form. Because the content layer is integrated into the system layer, it is possible to seal without destroying the system layer. Here we again have a, a, a, a benefit, so to speak, sealable packet packaging that can be kept in a reusable system. And on the other hand, um, one can also consider whether existing, um, traces can be replaced accordingly.