Case Study

Elopak

Setting new industry standards for aseptic cartons

Liquid carton packs have traditionally suffered the reputation that they are difficult to open and are not resealable. Plastic closures designed in recent years to resolve this dilemma were not particularly effective and themselves introduced further problems of hygiene and leakage.

Elopak took on the challenge to develop the perfect design solution to this problem - an improved sealer mechanism - meeting consumer demands while building its business in a highly competitive market. They appointed PA Consulting Group to lead the design management process based on its track record in food technology, innovation and design.

PA, working with Elopak and its closure supplier, designed and developed a new type of sealer, the Pure-Cap U. The sophisticated Pure-Cap U has met all of Elopak’s requirements by providing a hygienic, single-action, resealable opening device on aseptic cartons. Since its launch it has outperformed its nearest competitors and has been nominated for several awards.

Critical factors in the assignment were to ensure that the new closure was suitable for low-cost high-volume manufacture; was compatible with the existing production facilities and technology; and could maintain the essential barrier properties from production to consumer.

Working closely with Elopak, the PA team structured trials to determine reliability and microbiological integrity, to verify production tolerances, and to confirm that the conversion lines could meet production requirements.