Innovative packaging solutions: How a fiber-based lidding solution with hinge function sets new standards

Optimization potential in the packaging industry

Consumers are increasingly demanding packaging solutions that contain less plastic but remain functional. Many manufacturers are already using fiber-based materials to reduce the amount of plastic. Nevertheless, essential parts of the packaging, especially closures with complex mechanisms, are still usually made of plastic. Against this background, Optima has launched an innovation project. 
Reduce plastic, retain functionality – Optima has taken up this challenge and developed an innovative solution: a fiber-based lid with a hinge function that retains the advantages of existing plastic solutions. Our expert Sebastian Gruber, packaging engineer at Optima, accompanied this project and describes the development process.

The challenges: Hinge function and product protection

The development of a fiber-based lid with a hinge function poses two key challenges:

• Hinge function: The lid must be able to open and close reliably without the material losing stability. The challenge is to develop a flexible, yet robust, hinge made from fiber-based materials.
   
• Product protection: A high barrier effect against moisture and oxygen is essential, especially for sensitive products such as coffee or baby food. The lid must offer a protective function comparable to plastic to guarantee the shelf life of the products. 

The innovation process: from sketch to prototype

From initial sketches, CAD models, and simulations to real prototypes, each development phase was extensively tested. The biggest challenge was to develop a fiber-based hinge that functions reliably. At the same time, the proportion of aluminum in the barrier was reduced by testing alternative barrier materials and the necessary sealing processes.

In addition, the design and manufacturing processes were continuously optimized. The creation of high-quality prototypes proved to be particularly valuable, as physical samples are essential for making innovations tangible and further developing them.

The result: A flexible, sustainable, and patented solution

The result of the development is a fiber-based lid with a hinge function that can be seamlessly integrated into existing packaging solutions and flexibly adapted to different product requirements. Optima is setting a new standard for alternative packaging with high functionality.
This innovation shows that plastic and aluminum content can be significantly reduced without compromising on functionality and product protection. Companies that rely on fiber-based packaging solutions will find a strong partner in Optima – from the initial idea to successful implementation.