The chemistry has to be right

Translation of an article featuring an interview with Lorenzo Sacchi, published in the German magazine K-profi.
How certifications and formulation developments for recyclates drive sustainable projects forward.

For the dedicated chemist and recycling expert Dr. Manica Ulcnik-Krump, it's all about chemistry. Especially in plastic recycling, chemistry is the key to success, she is certain, and she is proud to lead the first and so far only EU-accredited research institution specializing in the analysis and development of recyclates. The competence center Interzero Plastics Innovations, accredited according to ISO/IEC 17025:2017, has just moved to its new location in Lenart, Slovenia. Nine employees, equipped with state-of-the-art equipment in the chemical-thermal and physical-mechanical laboratory as well as pilot plants, are advancing plastic packaging such as squeeze pouches from Gualapack, shipping boxes from Memo, and bottles from Rupar Plastika towards a circular economy.

"For us, Interzero's expertise in verifying the recyclability of our Pouch 5 has been and continues to be very important.", says Lorenzo Sacchi,
Sustainability Manager at Gualapack.

“Compromises on printability, feel, or functionality were not an option for us and our customers,” describes Lorenzo Sacchi, Sustainability Manager at Gualapack from Alessandria, Italy, the premise behind the development of “Pouch 5.” This is the first stand-up pouch with a spout (spouted pouch) made of PP monomaterial, which is 100% recyclable.

Every year, around 250 packaging solutions from manufacturers across Europe are tested and evaluated in Slovenia according to international standards. Pouch 5 was included in 2020 and 2022 and received 20 out of 20 possible points each time – fully recyclable. “For us, Interzero’s expertise in verifying the recyclability of Pouch 5 has been and continues to be essential. We are proud to have developed an optimal product,” says Lorenzo Sacchi.

The innovative packaging of the leading supplier of squeezable pouches was developed in 2020 in compliance with CEFLEX guidelines, tested by Tomra for sortability, and chemically and mechanically certified by Interzero. “The verification of recyclability and possible optimization for circular economy integration is one of our three key pillars,” explains Dr. Manica Ulcnik-Krump about the collaboration with Gualapack.

How useful the product is can be seen in its success. In 2021, the PP monomaterial pouch won the "Best Packaging Award" in Italy. More and more customers, including major brand owners such as Nestlé and Kraft Heinz, are adopting it. “Pouch 5 is now our flagship product. It already accounts for around one-third of our revenue from flexible packaging,” reports Lorenzo Sacchi.

This stand-up pouch with a spout from Gualapack was the first to be made entirely of PP, making it recyclable, and is suitable for both cold and hot filling.

The pouch is available in sizes ranging from 70 to 200 ml, suitable for both cold filling and sterilization and pasteurization, making it applicable for yogurt and baby food as well. Naturally, packaging for food filling requires good barrier properties, which in this case are achieved through a three-layer solution with a biaxially stretched middle film.

The monomaterial PP pouches have good printability on the outer layer and even allow for a matte varnish effect. The monovariant offers an additional advantage over the standard version: it generates around 40% less CO₂ during production, lifecycle, and recycling, making it particularly interesting for companies looking to reduce their carbon footprint.

However, Gualapack does not only offer the flexible packaging itself; upon request, a complete package including pouch, filling line, and closure is available.

Article originally published in German in the K-profi magazine, February 2025