In recent research conducted by Innofibre, a Quebec-based applied research center, it was found that recycled food and beverage cartons have great potential for use in making moulded fiber packaging. This discovery is significant as currently, no manufacturer of such packaging in North America uses pulp made wholly or partly from fiber derived from recycled cartons.
For the research, Innofibre produced pulp from recycled food and beverage cartons, which was then transformed into moulded products using two commonly used techniques: transfer moulding and thermoforming. Principal researcher at Innofibre, Eric Desnoes, explains that the tests confirmed that recycled carton fiber pulp has similar mechanical and physical properties to virgin kraft pulp. This means that high-quality moulded products can be manufactured using recycled carton pulp.
Desnoes also notes that the strength of carton pulp is significantly higher than that of mechanical pulp, such as that obtained from old newspaper, which is currently the pulp most frequently used for moulded products made from recycled fibers. Additionally, the research concludes that carton pulp would be particularly suitable for industrial manufacturing, given the relatively short production time of items and a shrinkage rate that does not interfere with nesting.
Isabelle Faucher, managing director of Carton Council of Canada, which commissioned the research, highlights the potential applications of packaging made from recycled carton pulp. She mentions that it could be used to contain or protect a wide variety of products in both the food and non-food industries.
The partnership between the Carton Council of Canada and Innofibre aims to encourage the emergence of new local recyclers for cartons collected in Canada, with possibilities in the U.S. as well. The Carton Council hopes to collaborate with pulp and moulded packaging manufacturers in both countries who would be willing to further explore the possibilities offered by recycled carton pulp.
In conclusion, the research conducted by Innofibre has shed light on the untapped potential of recycled food and beverage cartons for use in moulded fiber packaging. The findings have opened up new possibilities for sustainable packaging solutions and have the potential to drive innovation in the recycling industry. The full research report by Innofibre can be downloaded for further exploration of this exciting development.