Recyclable Paper Cup for Dairy Packaging

Huhtamaki and Stora Enso developed a single-coated paper cup to improve recyclability for chilled dairy products.

  www.storaenso.com

The dairy packaging industry faces strict technical demands for material performance, sealing reliability, and barrier protection in chilled environments. Conventional yogurt cups often rely on multiple polymer layers, complicating recycling streams and increasing environmental impact. To address these operational and sustainability hurdles, packaging developers have focused on reducing plastic content while maintaining food safety and manufacturing efficiency.

Technical Challenges in Dairy Packaging
Chilled dairy products require packaging that prevents moisture migration and maintains structural integrity during high-speed cup-forming, converting, and filling processes. Traditional multi-layer materials often hinder recyclability, conflicting with corporate circularity targets and environmental regulations. The primary objective was to engineer a paper-based cup that delivers robust barrier performance without compromising production reliability or shelf life.

Single-Coated Paperboard Solution
The collaborative development between Huhtamaki and Stora Enso resulted in ProDairy, a recyclable paper-based cup designed specifically for yogurt and dairy goods. Stora Enso provided the solid paperboard material foundation, while Huhtamaki applied its expertise in barrier technology, packaging design, and cup-forming requirements.

The technical advancement involves replacing traditional dual polyethylene layers with a single polymer coating. This modification successfully reduces total plastic content to below 10 percent while retaining an effective moisture barrier for chilled applications. The material maintains strong sealing capabilities and runs reliably on standard commercial filling lines without requiring equipment retooling.

By adopting this paperboard structure, dairy brands can advance their circularity initiatives and comply with packaging regulations while preserving operational efficiency and product quality.

Edited by Sucithra Mani, Induportals editor – adapted by AI.

www.storaenso.com