A unique new technology to form bottle caps using natural fibers is coming to fruition through a partnership with nonwovens producer Glatfelter, its joint venture (JV) partner ALPLA Group, a global packaging solutions and recycling specialist, and Blue Ocean Closures (BOC), a startup based in the region of Värmland in Sweden, to develop innovative natural fiber-based closures and other molded packaging products using dryforming technology.

As part of this sustainability partnership, Glatfelter and ALPLA joined together to initially develop high-quality cellulose-based products, like screw caps, that are fully biobased and potentially ocean biodegradable. This unique collaboration will support BOC in its product development and shorten time to market even further.

Thus far, the partnership’s screw-cap technology has been recognized by the nonwovens industry when it was honored with the first IDEA Sustainability Advancement Award, presented at INDA’s IDEA22 exhibition and conference earlier this year in Miami Beach.

More recently, Glatfelter, BOC and ALPLA announced they are working with The Absolut Company to develop an innovative natural fiber-based screw cap for Absolut Vodka’s iconic bottle.

Glatfelter and ALPLA will support BOC and their partnership with The Absolut Company by developing a cellulose-based cap that will be used on Absolut Vodka’s existing glass bottles. These uniquely designed caps will be made from airlaid material, resulting in a product that is recyclable and ocean biodegradable. Prototyping and final design of the caps will be completed this year, with plans to launch commercially in 2023.

“This partnership brings together like-minded companies that share similar sustainability goals focused on protecting our environment through the use of natural fiber-based materials,” says Chris Astley, senior vice president and CCO of Glatfelter. “We are excited to expand our partnership with ALPLA and BOC, now working with Absolut Vodka, to make more innovative and eco-friendly packaging solutions that will benefit generations to come.”

Nonwovens Industry recently spoke with Vishal Bansal, vice president of Innovation, Glatfelter, about this exciting new technology and what’s next for this collaboration.

Nonwovens Industry (NWI): How did the partnership between Glatfelter, Blue Ocean Closures and ALPLA Group come about?
Vishal Bansal (VB): Glatfelter partnered with Blue Ocean Closures, a startup based in Sweden, and ALPLA Group, the global packaging solutions and recycling specialist, to accelerate and produce sustainable and environmentally friendly packaging solutions using novel press-forming technology. In combination with our expertise in nonwovens and ALPLA’s knowledge in packaging and molding, this partnership has been able to successfully create closure and lidding products like fiber-based screw caps, that are reliable and ocean biodegradable.

NWI: What was the inspiration behind the development of plant-based bottle caps?
VB: Sustainability and uniqueness were large drivers behind the development of our plant-based caps. Our closures are the first and only high-definition paper screw caps. We optimized our use of renewable and recyclable wood fibers and airlaid materials by creating cellulose pulp-based screw caps that are durable, strong and water-resistant. These biobased screw caps can be recycled as paper and are completely biodegradable in soil and in the ocean.

NWI: What type of airlaid technology is used for this application, and what are the raw materials?
VB: Combining the knowledge of fiber physics and airlaid technology with packaging and tool building has provided a means to manufacture cellulose-based screw caps with high form stability, excellent technical functionality, and a torque capability that the material could handle. We have achieved desired sustainability by creating a thin layer inside the top-seal screw caps where the barrier function stays in contact with the packed product. This airlaid starting material has been formed, reeled, transported and pressed, resulting in a fully functional product.

NWI: Why is airlaid a good fit for this application versus other nonwoven technologies or materials?
VB: Unlike other nonwoven technologies, the airlaying process can lay down cellulose pulp fibers with very low density, offering great versatility in terms of different fibers and fiber blends used in production & tooling configurations for forming. Compared to carded webs, airlaid webs have a lower density and are very bulky. Our unique bonding process increases the material’s strength and integrity.

NWI: Can the bottle caps be used on bottles filled with any types of liquids? 
VB: Our screw caps repel water and have barrier functionality, allowing them to be used for most applications, such as soft drinks, water, alcohol, and beauty/cosmetic products. Not only can they be used for liquids, but they can also be used to preserve food and other applications.

NWI: What’s next for this collaboration?
VB: Our partnership is currently working with The Absolut Company (Pernod Ricard) to develop a natural fiber-based screw cap for Absolut Vodka’s iconic bottle. Prototyping and final design of the caps will be completed soon, with plans to launch commercially within the next year.

We are excited to see what new and innovative opportunities this partnership brings to the packaging and nonwoven industries, as we continue manufacturing sustainable closures for companies that share similar sustainability objectives and goals.