17 December 2020

PopPack is harnessing a recently signed cooperation agreement with PPi Technologies to develop its  air-powered flexible packaging. The “Air-Powered
Package^®” uses the “EasyPop” air bubble function as  a lever to open packages easily when the bubble is  popped.

Flexible packaging specialist PPi Technologies is customizing PopPack’s EasyPop feature to make commercial prototypes at its US packaging incubator facilities. Multinational brand owners have reportedly expressed interest in applying the PopPack technology to their packaging.

PackagingInsights takes a closer look at the Air-Powered Package^® with PopPack’s William S. Perell, president & co-founder and Cheryl E. Harrison, director & co-founder.

Popping proves popular

The Air-Powered Package^® and EasyPop inventions are designed to overcome commonplace difficulties opening conventional flexible packs. Consumers often resort to tearing at pouches with their teeth, Perell points out, while children and seniors can especially struggle.

“In some cases, flexible packages are sealed too well. In other cases, people do not have the dexterity or hand strength to open commonly used packages.”

“However, these same individuals could pop bubble wrap and clearly enjoyed popping the air bubbles. So, I thought: ‘Why not merge bubbles into the seals of flexible packages?’”

EasyPop can become a “universal design feature” for a wide array of flexible packaging, says PopPack’s William S. Perell, president & co-founder. “Early on, we were encouraged as we witnessed the positive emotions of anyone who opened our early packaging prototypes by popping an air bubble,” Harrison supports.

“EasyPop is a simple concept and yet fully gratifying on many levels. No caps, no fitments, no frustration opening, no tear strips, no applied labels, no need for knives, scissors or teeth.”

PopPack realized there could be thousands of iterations on this simple packaging concept, including various shapes, sizes, types and forms of packages, containing both liquid and solid products. EasyPop can become a “universal design feature” for a wide array of flexible packaging, the inventors say.

A pack for all occasions

The Air-Powered Package^® is designed for home and on-the-go use. Among the innovation’s numerous benefits, it can be opened with one hand and in the dark, avoid tearing and small pieces of litter, and take up less space through a compact and lightweight design.

“Consumers have busy lifestyles, and convenience and quality are key,” Harrison recognizes. “Since the air bubble is an integral part of the package, it can define an entire brand product line to be both convenient and sustainable, and signal a positive experience wherever it is used.”

“PopPack packages are fun to open. They provide instant, multi-sensory enjoyment,” adds Perell. “The popping sound of the bubble conveys a message there has been no prior tampering of the package or its contents. The product is safe to consume, fresh and ready to use.”

EasyPop also opens easily in wet, slippery conditions, ideal for products used in the kitchen, bathroom or shower.Moreover, EasyPop helps children open their own food snacks, squeeze a toothpaste tube, or drink a bottle of juice without spillage.

EasyPop helps children open their own food snacks at home or on-the-go.

“We have designed packages specifically for household goods, which provide portioning, no-spill, controlled
dispensing, spraying and self-closing and product safety features,” explains Harrison. “We have also created refill stand-up pouches to minimize packaging waste altogether. For people on-the-go, including outdoor enthusiasts, EasyPop allows for consuming food, snacks, beverages, durable goods, and other convenience items with very compact packaging.”

The package remains intact in all climates and conditions, from hot and humid to freezing, and is 100 percent recyclable.

Overcoming industry doubts

Perell recalls how senior packaging engineers couldn’t initially envisage how the design concept behind PopPack could materialize.

“There was no set of readily obtainable instructions or guidelines in the packaging industry explaining how to make a ‘poppable’ air bubble in films,” Perell says. “Experimenting with different methodologies to produce the air bubble led us to focus first on making EasyPop on a horizontal platform.” “Initially, all of our packaging prototypes were made by hand. We used trial and error as our formula and conducted many trials, most of them unsuccessful.”

PopPack spent more than a year developing the proof of concept technique to reliably make its first air bubble in a sealed flexible package.

Integrating with packaging machinery

The next goal was to ensure the Air-Powered Package^® could be made with existing commercial packaging machinery without compromising production line speeds.

“We had to devise a means of making bubbles using only ambient air, without injecting air,” Perell explains. “We did this by developing a unique vacuum and sealing design.”

PopPack designed the air bubble to be created for VFFS so it would always pop reliably with easy-open peel tabs. The team achieved this by experimenting with unequal seal strengths for the bubbles’ periphery and varying the margins around the bubbles.

“We devised a means of controlling and fine-tuning film temperatures to make it easier to create the air bubble for fast production line speeds. This was done by working with a team of Japanese professionals in Tokyo,” Perell says.

The Air-Powered Package^® is compatible with thermoformers, VFFS and HFFS packaging machinery.

PopPack eventually devised a means of making the Air-Powered Package^® on thermoformers and VFFS and HFFS packaging machinery, working with senior packaging engineers in the US, Europe, Japan and India.

“We worked with a hand surgeon at the University of California, US to test the ergonomics of the package and ensure its ease of opening for consumers with very weak hand strength or arthritis,” Perell continues.

“We tested various packages with children and seniors to observe if the bubble served as an intuitive means for package opening. We analyzed the package opening process and abilities of children, the arthritic, handicapped and sight-impaired in informal environments and focus groups.”

Next stop liquids and flowables

PopPack is working with brand owners, film suppliers, and packaging machinery makers worldwide, including the cooperation agreement with PPi Technologies. The design-tech company holds over 150 patents worldwide, both issued and pending.

“The Air-Powered Package^® has received continued interest in recent months as a premium, sustainable, cost-effective solution for flexible packaging,” Perell says.

“Additionally, we recently received a grant from the Netherlands government to accelerate our further development and production of sustainable packaging for beverages and liquid products,” Harrison adds.

The team’s primary short-term focus is improving the packaging machinery for flowables, solids, powders, medical devices and durable goods. PopPack’s next set of innovations focuses on introducing new packaging designs for a wide array of liquids and flowables.

“Expect to see multi-use sachets and other packages soon replace single-serve sachets. Also, expect to see capless, self-closing bottles that open by popping the EasyPop bubble,” Perell shares.

“Concurrently, we are working with industry partners on creating the sustainability metrics for the Air-Powered Package^®, from the beginning of life to end of life, so our brand owner customers can more accurately report on achievements toward ESG goals, including circularity and progress toward the Sustainable Development Goals,” Harrison concludes.

PopPack is an “Activator Member” of the US Plastics Pact and Plastics Pact Netherlands, working in collaboration with the World Wildlife Fund and guided by the work of the Ellen MacArthur Foundation, to help accelerate industry-wide efforts to reduce plastic waste.

Article by Joshua Poole, Packaging Insights