High-barrier Single Sachet Solution for Coffee Pods

The global coffee market continues to experience sustained growth, with Europe alone representing nearly 30% of total worldwide consumption. This increasing demand has intensified the need to rethink packaging solutions capable of meeting the sector’s evolving requirements.​

As packaging plays an increasingly strategic role, not only in product performance but also in supporting consumer awareness around circularity, the development of alternative solutions has become essential to effectively respond to these market expectations.​

​Challenge​

Coffee is an inherently complex product, with highly demanding requirements from a packaging standpoint. Ensuring superior protection results to be critical, not only to preserve its organoleptic qualities against exposure to moisture, oxygen, mineral oils, and light, but above all to maintain the rich and distinctive aroma that defines coffee itself.​

In parallel, the increasing diversification of coffee-based products has generated demand for packaging systems that combine efficiency, versatility, and sustainability. Within this framework, the challenge was to develop a single-sachet solution for coffee pods capable of integrating all these requirements in the most effective and advantageous way.​

Solution​

In collaboration with GIMOKA and Gerosa, Taghleef successfully designed and developed a PP material sachet based on the EXTENDO® XZRL structure.​

This advanced packaging solution delivers exceptional product protection and ultra-low sealability performance, while the BoPP white solid layer enhances the final aesthetic with a sophisticated pearlescent finish, elevating both functionality and visual appeal.​

​Benefits​

• ​Superior protection: ​

EXTENDO® XZRL technology provides outstanding barrier performance against moisture, oxygen, mineral oils,and light, effectively preserving the coffee’s characteristic properties and shelf life.​

The film’s advanced structure, built around an internal barrier layer, ensures consistent and reliable product protection throughout the lifecycle of the sachet.​

• ​Improved yield​

The reduced density of the EXTENDO® XZRL white voided film contributes to an increase in final yield, translating into greater production efficiency for the customer.​

• ​High machinability​

Thanks to its ultra-low sealing temperature, the material ensures excellent machinability making it particularly suited for high-speed packaging systems, supporting optimal production performance.​

• ​Higher sustainability​

This innovative structure, based exclusively on PP layers, makes the packaging significantly easier to recycle compared to conventional multi-material alternatives, strengthening its sustainability profile.​