Reusable beverage packaging polymer development

Overview

This research initiative addresses the need for sustainable beverage packaging by identifying polymers suitable for reusable bottle applications. Current packaging materials present significant limitations: PET cannot withstand hot-water cleaning required for reuse protocols, while PP absorbs colors and odors from contents, compromising product quality. The project aims to overcome these challenges by screening and validating alternative polymers that meet the demanding requirements of reusable beverage packaging, including mechanical durability, hot-wash compatibility, and sensory neutrality.

The research responds to anticipated EU reuse targets, which will likely be established as reuse is ranked above recycling in the waste hierarchy pyramid. By developing polymer solutions that enable true packaging reuse rather than single-use or recycling-only approaches, this work supports substantial reductions in greenhouse gas emissions associated with beverage packaging production.

Technical specifications

Research approach:

• Screening of polymers suitable for injection blow moulding processes used in beverage bottle manufacturing
• Assessment of mechanical properties required for reusable packaging applications
• Evaluation of decontamination routes compatible with identified polymers
• Testing for organoleptic and sensory impact on beverage contents
• Determination of reuse cycles before bottles fall outside specification

Key polymer requirements being evaluated:

• Hot-water wash compatibility for decontamination
• Resistance to color and odor absorption
• Mechanical durability across multiple use cycles
• Processability via injection blow moulding

Validation phases:

• Feasibility study to identify critical properties and gather candidate polymers
• Moulding and mechanical assessment of promising materials
• Decontamination route verification
• Full study including production of injection moulds for preforms, with bottle production and reuse-cycle testing in collaboration with industry partners

Technology readiness level

The project is currently at the feasibility stage, focused on identifying critical properties of reusable packaging and screening candidate polymers. Initial work involves gathering suitable polymers, moulding test parts, and assessing mechanical properties against industry requirements. Future validation includes producing injection moulds for preforms at TUS, enabling injection blow moulding of bottles by industry partners, and determining the number of reuse cycles achievable before performance degradation occurs.