Huhtamaki, a leading global provider of sustainable packaging solutions for consumers around the world, set out to address this challenge by developing a recyclable paper cup solution for yogurt and dairy products, helping customers move closer to their circularity ambitions without compromising food safety, product quality and manufacturing efficiency.
The goal was ambitious: enable dairy brands to advance their circularity ambitions with a recyclable cup solution that performs in demanding applications—without compromising food safety, product quality or operational efficiency—and is compatible with existing paper recycling streams.
“Dairy packaging places very high demands on material performance, sealing and production reliability. Our task was not simply to reduce the plastic content, but to develop a cup that protects the product, runs reliably in production and can be validated with customers at commercial scale,” says Daniel Frey, Head of Innovation and Technology, Foodservice Packaging in Huhtamaki.
Solving a complex packaging challenge
For dairy brands, any new packaging solution must fit seamlessly into existing production processes while continuing to protect product quality. The cup needed to provide strong barrier performance for dairy products, run reliably through cup-forming and converting processes, and deliver effective sealing. At the same time, the solution had to be compatible with recycling processes and scalable for commercial production.
Huhtamaki developed the packaging solution, drawing on its expertise inbarrier technology, packaging design, cup-forming and customer requirements. Stora Enso supplied the paperboard and contributed to its material expertise.
“Stora Enso’s board provided the material foundation we needed. Building on this, Huhtamaki developed the packaging solution to meet the demanding performance requirements of chilled dairy products while keeping the plastic content below 10%,” says Daniel Frey.
Value-chain collaboration behind the solution
Huhtamaki tested and refined the packaging concept to meet the demanding requirements of dairy applications, with Stora Enso providing the solid paperboard material foundation.The final solution reduces the use of polyethylene from two PE layers to a single polymer coating while retaining an effective moisture barrier for chilled products.
The result is ProDairy, a recyclable paper-based cup solution that gives dairy brands a practical way to reduce material use and advance their circularity ambitions while maintaining the performance required for chilled dairy products. For dairy brands, this means packaging that supports circularity and regulatory goals without compromising product protection, shelf life, or the efficiency of existing filling and production processes.
ProDairy demonstrates how the right materials, combined with packaging design expertise and focused product development, can increase circularity and recyclability without compromising performance.
