ReZorce, a new range of recyclable beverage cartons, is set to debut on supermarket shelves at the end of this year. Developed by Zotefoams plc, the cartons aim to address the environmental challenges posed by traditional composite beverage cartons, which are not easily recyclable.
These composite cartons are made from a combination of liquid packaging board (LPB), polymers, and sometimes aluminium, making them difficult to process in recycling systems.
In contrast, ReZorce cartons are designed as a mono-material packaging solution, which simplifies the recycling process.
Approximately 250 billion beverage cartons are produced globally every year, and many of these end up incinerated or in landfill due to the multi-material composition.
ReZorce offers an alternative by using a patented technology to create a microcellular layered structure, which is designed to provide the necessary barrier properties for beverages, such as juices and dairy products, while remaining easier to recycle.
Design and testing for recycling compatibility
ReZorce cartons feature an innovative design that includes a foamed inner layer, which helps to prevent the transmission of water and oxygen, thus maintaining the quality of the beverage.
As a mono-material product, the carton is made from a single substance, including the tethered cap, which ensures compatibility with existing waste collection and sorting systems.
Testing conducted with waste management companies Biffa and Veolia has confirmed that the design meets the necessary recycling standards.
The use of a single material throughout the carton, including the cap, distinguishes ReZorce from traditional beverage cartons that often combine several layers of materials, complicating the recycling process.
Environmental impact compared to traditional cartons
An independent life cycle assessment (LCA) was commissioned by Zotefoams to evaluate the environmental impact of ReZorce compared to traditional LPB beverage cartons.
The LCA, conducted by Intertek, found that ReZorce cartons have a lower environmental footprint in several areas. Specifically, ReZorce cartons use 53% less energy, 51% less water, and have a 55% lower global warming potential compared to conventional LPB cartons.
These results suggest that ReZorce may offer a more sustainable alternative for beverage packaging.
The LCA compared ReZorce cartons containing 50% recycled high-density polyethylene (HDPE) with traditional LPB cartons, both used for packaging 1,000ml of apple juice.
While both products performed similarly in terms of functionality, the results highlighted significant reductions in resource use and emissions for ReZorce cartons.
As the demand for more sustainable packaging options grows, ReZorce represents one of the emerging solutions in the beverage packaging sector, offering a potential shift towards more recyclable and environmentally friendly alternatives.
