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Interesting facts about the production of disposable cups

The production of paper cups is a precise process designed to deliver high quality while being as sustainable as possible.

The manufacturing process of paper cups is extensive and includes several carefully coordinated steps:
  1. The trees are carefully selected.
  2. The bark is removed from the trees.
  3. Next, the trees are chopped into small wood chips.
  4. These wood chips are processed into pulp
  5. The pulp is ultimately used to make the paper cups that we use every day. 

 

This process is often certified by eco-labels such as FSC and PEFC to ensure that the paper cups are the result of responsible forestry and sustainable sourcing.

  1. Material procurement
  2. Printing process
  3. Preparation process
  4. Shaping
  5. Quality control
 

Differences between PE and PLA coatings

  1. Material properties

    • PE: Petroleum-based, water-resistant, temperature-resistant, durable, non-biodegradable.
    • PLA: Made from renewable resources such as corn starch or sugarcane, water-resistant, heat-sensitive (from 60–70°C), and biodegradable under industrial composting conditions.

  2. Sustainability

    • PE: Non-biodegradable, causing long-term environmental impact through microplastics. Recycling is difficult due to the separation of paper and plastic components. Often ends up in landfills or incineration.
    • PLA: Industrially compostable, but only under specific conditions (temperature and humidity). Reduces CO₂ footprint through renewable raw materials. If improperly disposed of, PLA is treated like conventional plastic.

  3. Recycling & Disposal

    • PE: Complicates the recycling of paper cups as the plastic layer is difficult to separate. Cups mostly end up in general waste or incineration. Sustainability is heavily dependent on local waste management systems.
    • PLA: Can theoretically be composted, but many countries lack the necessary industrial composting facilities. Improper disposal means PLA is not used sustainably.

  4. Economic aspects

    • PE: Cost-effective to produce, with an established infrastructure.
    • PLA: More expensive, but increasing demand for sustainable alternatives could lower production costs in the long term.

  5. Applications

    • PE: Durable, suitable for hot beverages, widely used in the hospitality industry.
    • PLA: More environmentally friendly, ideal for applications with a focus on sustainability, suitable for cold or medium-hot drinks, and less heat-resistant.

Conclusion
PE is more durable and cost-effective, while PLA is more sustainable and environmentally friendly. Promoting industrial composting facilities would be crucial to making PLA coatings more attractive and effective for the environment.

 

Comparison: PE coating vs. water dispersion

  1. Environmental compatibility

    • PE coating:
      • Petroleum-based, not biodegradable.
      • Recycling is difficult due to the strong connection with paper.
      • May produce microplastics if disposed of improperly
    • Water dispersion:
      • Biodegradable or easily recyclable
      • Supports easier separation of paper fibers in recycling.
      • More sustainable through renewable or less harmful chemicals.

  2. Processing

    • PE coating:
      • Energy-intensive, burdens the CO₂ balance.
      • Established for decades with optimized processes
    • Water dispersion:
      • Precise drying required, sensitive to environmental conditions.
      • Not yet widespread, adaptation of production facilities is necessary.

  3. Functionality

    • PE coating:
      • Very good barrier against liquids and grease, heat resistant.
    • Water dispersion:
      • Comparable barrier properties, better compostability.
      • Possibly more sensitive to moisture and heat.

  4. Cost

    • PE coating:
      • Favorable due to established production and economies of scale.
    • Water dispersion:
      • Currently more expensive, costs may fall as demand increases.

Conclusion
Water dispersion is more environmentally friendly and facilitates recycling and composting. PE coatings are cheaper and more reliable. The choice depends on the prioritization of sustainability or production costs.

 
 

 

  1. Recyclability
    Water dispersion-coated paper is more recyclable and is certified by Home Composting as well as DIN CERTCO and Keimling for industrial composting.

  2. Sustainability
    The technology requires fewer environmentally harmful chemicals, reduces pollutants, and reduces dependence on fossil fuels.

  3. Biodegradable
    Some water dispersions are completely biodegradable and minimize environmental impacts in case of improper disposal.

  4. No microplastics
    No microplastics are produced that could pollute the environment.

  5. food safety
    Safer for direct food contact as fewer harmful residues remain.

  6. Reduction of fossil materials
    Verringerter Einsatz fossiler Rohstoffe senkt CO₂-Emissionen und macht Einwegprodukte nachhaltiger.

Conclusion
Water dispersions enable more sustainable disposable products such as coffee cups without compromising functionality or food safety.

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