Innovations

At ALPLA, we are convinced that competitive packaging solutions with relevant benefits are only possible if we understand the market and its constantly changing requirements. Intensive partnerships with our customers and proactive research enable us to stay relevant with our products.

ALPLA has set itself the goal of being the most sustainable packaging manufacturer and is very much committed to realising the four Rs: Reduce, Reuse, Recycling, Replace.

All our developments are fitting into the goals of the new plastics economy.

Ultralighweight milk bottle

The Eco-Bottle – Ultralighweight Milk Bottle

The Eco-Bottle – Ultralighweight Milk Bottle

ALPLAs purpose designed HDPE bottle with handle offers a cost-effective, extremely lightweight solution combined with a minimized carbon footprint. This packaging solution is suitable for food products, is fully recycllable and environmental friendly due to PCR inclusion.

Technology: Extrusion Blow Moulding (EBM)

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Paper bottle

The Paper Bottle

The Paper Bottle

ALPLA and BillerudKorsnäs share the ambition to drive packaging innovation in a sustainable direction. The two companies intend to leverage the development by combining their resources, competencies and strengths to support scaling ecoXpac in the commercialisation of a fully biobased and recyclable paper bottle.

Technology: Pulp Moulding (PM)

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The Clear One – Designed for Recycling

The Clear One – Designed for Recycling

Although the requirements are demanding, design for recycling does not have to be like fitting a round peg in a square hole – and ALPLA has shown this with its innovation, The Clear One. At the moment, refill containers frequently consist of multilayer films that are considered difficult to recycle. In comparison, PET is a material that is very easy to recycle, which is why The Clear One is made from it.’ The packaging body consists of one layer of PET and the cap of recyclable PP.

Technology: Injection Stretch Blow Moulding (ISBM), Injection Moulding (IM)

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Reusable PET Bottle Visoke

REUSABLE PET BOTTLES – DURABLE, YET LIGHTWEIGHT

REUSABLE PET BOTTLES – DURABLE, YET LIGHTWEIGHT

Especially in reusable packaging, every gram counts towards the CO2 impact; therefore our reusable PET solutions significantly outperform their counterparts made of glass thanks to an adapted material composition and their strong build.

Technology: Injection Stretch Blow Moulding (ISBM), Injection Moulding (IM)

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Simple One

The Simple One – an ultralightweight packaging

The Simple One – an ultralightweight packaging

One of the most beneficial characteristics of this innovation is its weight – or lack thereof. The idea behind The Simple One bag was to reduce the material as much as possible, while still having an attractive and functional packaging solution. Compared to a standard HDPE bottle, The Simple One can achieve a weight reduction of up to 60%, lessening CO2 emissions during production, transport and even after consumption during the recycling process.

The bag even does not need a cap.

Technology: Extrusion Blow Moulding (EBM)

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Mehrwegflasche

Reusable PET bottle for Vöslauer

Reusable PET bottle for Vöslauer

Resource-conserving, light, stable and visually appealing – ALPLA has realised the first modern returnable PET bottle for the Austrian market together with Vöslauer. Weighing just 55 grams, the bottle developed by ALPLA is around 90 per cent lighter than the returnable glass alternative, reducing the carbon footprint by approximately 30 per cent.

Technology: Injection Stretch Blow Moulding (ISBM), Injection Moulding (IM)

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100 per cent rPET waterbottle

A Mineralwater bottle closes the loop

A Mineralwater bottle closes the loop

Jana natural, still mineral water made by the Croatian producer Jamnica is now available in a 0.5-litre bottle made entirely of recycled PET (rPET). The plastic used comes from the post-consumer recycling cycle.

Technology: Injection Stretch Blow Moulding (ISBM), Injection Moulding (IM)

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homecompostable coffee capsule

Homecompostable Coffee Capsule

Homecompostable Coffee Capsule

Biodegradable packaging – this is what Blue Circle, the subbrand of ALPLA, stands for. Modern materials offer new opportunities aside from the familiar solutions made of aluminium and the challenges these entail. Blue Circle is therefore offering coffee capsules that decompose in compost and are turned into soil.

Technology: Injection Moulding (IM)

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Tether Tube – one step ahead

Tether Tube – one step ahead

Simple, practical and good for the environment. That describes ALPLA’s Tether Tube. The lightweight mono-material tube is completely recyclable, can be used as a refill enabler, amongst other things, and is easy for the consumer to use. The real highlight, however, is the closure. When the tube is opened, there are no loose individual parts such as sealing foils or closures.

Technology: Extrusion Blow Moulding (EBM)

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Refill System for Concentrates

Refill System for Concentrates

With NOW, ALPLA is presenting an ideal packaging solution for concentrated cleaning chemicals. Alongside the numerous environmental benefits, it also offers special added value: it is safe, easy and fun for consumers to use.

Technology: Extrusion Blow Moulding (EBM)

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closure_rendering

Blue Ocean Closures

Blue Ocean Closures

The trio of Blue Ocean Closures, packaging expert ALPLA and advanced fiber materials specialist Glatfelter combine their know-how and expertise to develop innovative and sustainable fibre-based caps and lids. The new closures are bio-based, recyclable as paper and are made from degradable fibers.

Technology: Vacuum press forming

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PUMPS – FEEL THE QUALITY IN EVERY STROKE

PUMPS – FEEL THE QUALITY IN EVERY STROKE

Pumps from ALPLA meet the industry standards for liquid soaps and sanitizers. They work with a variety of neck types and are highly customizable. This means increased productivity and reduced costs through simple manufacturing without compromising quality. Furthermore, the pumps are also perfect for viscous products thanks to their dynamic spring possibilities.

Technology: Injection Moulding (IM)

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COMPAINTION – THE PAINT BUCKET AND PAINT TRAY REINVENTED

COMPAINTION – THE PAINT BUCKET AND PAINT TRAY REINVENTED

This innovation combines the best of both worlds: paint bucket and paint tray. The Compaintion has several advantages compared to ordinary paint buckets. This makes it the perfect companion for smaller painting and repair jobs.

Technology: Extrusion Blow Moulding (EBM)

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CDC - Controlled Dosing Cap

CONTROLLED DOSING CAP – NO VALVE, NO PROBLEM

CONTROLLED DOSING CAP – NO VALVE, NO PROBLEM

ALPLA has developed a cap for viscous liquids such as ketchup and mayonnaise which is made entirely of polypropylene (PP), making it optimally recyclable. Its innovative mechanism allows for controlled dosing and prevents unwanted dripping.

Technology: Injection Moulding (IM)

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Reusable PET Bottle

Refillable Mineralwater Bottle

Refillable Mineralwater Bottle

ALPLA has developed a one-litre reusable PET bottle together with KHS, the specialist for bottling and packaging systems. The refillable bottle weighs up to ten grams less than the standard bottles that are currently available and can be made of recycled materials, too.

Technology: Injection Stretch Blow Moulding (ISBM)

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crc_justone

CRC JUSTONE – A NEW GENERATION OF CHILD-RESISTANT CLOSURES

CRC JUSTONE – A NEW GENERATION OF CHILD-RESISTANT CLOSURES

With CRC justONE ALPLApharma has reinvented the production process of child-resistant closures (CRCs): The novel closure is produced in only one piece – unlike traditional tamperevident CRCs, which are injection-moulded in several pieces and subsequently assembled.

Technology: Injection Moulding (IM)

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The 4 Rs in a nutshell

Reduced material usage means less CO2e consumption. Wherever possible, we therefore only ever use as much input material as is necessary to produce new packaging. We continue to optimise the development of ultralight packaging that requires less and less materials for its production, thereby significantly reducing the proportion of CO2e attributable to packaging.

Ultralight bottles have a very low tare weight and this conserves valuable resources, saves energy and costs related to logistics and transport, and cuts CO2e emissions.

Plastics are just as reusable as other packaging materials. The longer they can be kept in the loop in their original form, the better it is for the climate. We therefore continuously optimise aspects such as production of and the attributes of plastic bottles so that they can be incorporated into established reuse systems like the KHS system and the deposit cycle of Genossenschaft Deutscher Brunnen (GDB).

 

We engage in ongoing dialogue with partners in the beverage industry to develop containers that can withstand the challenges and strains of the reuse system. The results are striking – we can already have a bottle go through the deposit cycle up to 25 times, which equates to an increase of 2,400 per cent.

Plastic is a recyclable material. Plastic packaging is therefore anything but waste – it is a valuable resource. The production of virgin PET bottles accounts for the largest proportion of resource consumption and carbon emissions. And if these bottles are then incinerated after use, they cause a high carbon emission load once again. What’s more, the material has then been irrevocably disposed of. Our overarching objective is therefore to keep as much plastic as possible in the recycling loop, process it into what’s known as rPET and use this to produce new packaging. The same principle is also applied to HDPE.

 

Design for recycling

Recycling is not only a technical challenge – it is also a question of design. It takes foresight to be able to feed packaging back into the recycling loop in a targeted way. The colour, material mix and processing are important parameters that influence the recyclability of PET plastics. With these parameters, we can pave the way for a long life in the recycling loop before packaging is newly produced.

Not all plastics are alike. As a technology leader in the area of packaging materials, we are constantly developing new input materials that avoid CO2e emissions and conserve resources.

In collaboration with various partners, we are developing

alternative input materials to be used for the packaging of the future, for example on the basis of cellulose, sugar cane and sunflower seed hulls.

 

To foster this development in the long term, we are investing in research on and the development of packaging materials which are quite literally grown to rise to the challenges of our times. This is our innovation aspiration.