An innovative Latvian start-up has addressed the challenge of sustainable beverage packaging by developing 100% recyclable to-go cups made from recycled PET (rPET). Utilising a unique ultrasonic welding process from Weber Ultrasonics, the cup bases are seamlessly attached without adhesives, enhancing their recyclability. This mono-material approach means that the foamed rPET can be recycled endlessly.
The project was initiated by Sergey Nikitenko, one of the managing directors of FORPET Baltic SIA, who sought to utilise rPET in a food-safe, high-quality form. Partnering with technology providers like NGR and Leistritz, the initiative processes recycled PET into versatile packaging materials.
"The whole thing started with the idea of producing packaging for the food industry from recycled polyethylene terephthalate (PET), known as rPET," he explained.
Their first product, to-go beverage cups, is produced on a sophisticated production line in Latvia that currently yields over 1.5 million units monthly.
Ultrasonic welding plays a pivotal role in ensuring the cups remain within a circular economy, with the entire process benefiting from precise welding technology equipped with integrated quality control features. This method not only ensures leak-proof cups but also aligns with Industry 4.0 standards. Plans are underway to expand production, potentially including a new facility.