markets feature | Single-serve capsules Right: The
capsule is part of a complete branding package that also includes the brewing machine
created by the interlinked success of systems such as Keurig K-Cups in North America and Nescafé Dolce Gusto in Europe. Until recently, injection moulding technology was reserved for the Tassimo system and the conventional Italian espresso discs of the past.
However, it seems to be
Below: Some 48bn single- serve capsules will be produced globally this year but there is still room for growth in the market
becoming the technology of choice for newcomers to the market while for existing injection moulders of thin wall packaging such as as caps and closures a portfolio diversification into capsules is a logical strategic step given the high margin and high growth opportunity. Injection moulders such as Alpla, Global Closure Systems (now part of RPC Group), and Menshen have all followed this route. Injection moulded capsule share is growing versus
thermoforming, driven by demand for “value” low oxygen barrier capsules that are compatible with Nespresso machines. This type of capsule is relatively easy to produce and the investment in moulds can be amortised quickly. Consequently, the barrier to market entry is much lower than for high-barrier thermoformed capsules, especially for production with integrated extrusion. Nonetheless, medium and high-barrier options are also acces- sible for injection moulders and many are
taking steps in this direction. Continuous compression moulding is a newly adopted technology in the capsule segment. Sacmi, the leader in compression moulding technology for the caps and closures market, has recently implemented a number of its CCM systems for production of capsules with Italian partners.
Technical requirements Single-serve capsules should not be considered a “simple” package
– their design often includes complexities that are not immediately apparent. Plastic Technologies Inc (PTI) has carried out research into the major commercially available systems to baseline the materials being used, the structures they were assembled into, the resulting barrier (oxygen, water vapour transmission rates) attributes, and the impact on taste to produce a comprehensive analysis of package type. The data reviews all requirements, which may start
with an iconic design to build brand equity. This iconic shape will be directly interacting with the dispensing appliance, so it has to be intuitive enough to make the consumer experience as simple and pleasurable as possible. Once in the appliance this “package” becomes an
integral element of the beverage preparation system itself. Even in the less sophisticated systems, the capsule will have at least one or two functions such as
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