NatureWorks, a top manufacturer of polylactic acid (PLA) biopolymers derived from renewable sources, has developed a compostable coffee pod solution suitable for use with Keurig® brewers in the North American market. This achievement was made possible through a partnership with IMA Coffee, a global leader in coffee handling, processing, and packaging technologies. The solution offers excellent brewing performance, can be produced at commercial speeds comparable to existing options, and is made using eco-friendly, biodegradable materials.
Combining NatureWorks’ expertise in processing PLA biopolymer with IMA Coffee’s proficiency in processing and packaging technologies, the partnership developed a compostable coffee pod solution and supply chain. For the rigid capsule body, NatureWorks was able to combine non-compounded, highly crystalline, and heat resistant Ingeo PLA grades with a refined single-stage thermoforming process to achieve production rates comparable to incumbent polypropylene (PP) capsules. The rigid thermoformed capsule was then combined with a nonwoven filter and multi-layer top lidding solution also made with Ingeo.
“Over the past few years, IMA’s approach to sustainability has led to the design and adaptation of packaging technologies to effectively handle compostable materials. The collaboration between NatureWorks and IMA, bolstered by IMA OPENLab, the Group’s network of technological laboratories and testing facilities, laid the groundwork for a new market-ready coffee pod,” said Alessandro Nobili, Head of Product and Project Management at IMA Coffee, Packaging Division. “Multiple studies and tests on the new compostable material and its performance throughout the packaging process have led to the proper configuration of IMA’s coffee pod filling and sealing machines, enabling them to handle the rigid capsule, filter, and multi-layered top lid made of Ingeo PLA biopolymer with high precision. This will facilitate the easy setup of new production lines, thereby offering a turnkey compostable and sustainable solution at high production speeds, ensuring high-quality brewing.”
A recently published study by Wageningen University & Research concluded that compostable coffee pods made with Ingeo™ biopolymer are the most sustainable option when considering both greenhouse emissions and material circularity, which included considering the fate of used coffee grounds inside the pods.
By weight, 90% of a coffee pod consists of the valuable coffee grounds contained inside. Compostable packaging ensures it is simple for consumers to help divert those remaining organics away from landfills. Instead, diverting compostable pods to industrial composting ensures both the used coffee grounds and the packaging are composted, helping create a valuable soil amendment that improves soil quality and biodiversity.
