Looks of metal with the benefits of plastic

At Kornelis Caps & Closures in Steenwijk, innovation and sustainability are at the core of everything they do. The family business, which has been focused on manufacturing plastic closures for various industries for decades, is introducing an exciting new development: the metal look cap. In an interview, Dave Busstra, Sales and Marketing Director, and Karen Huisman, Sales Support, discuss this and other new products, as well as the company’s sustainability strategy.

The metal look was developed as an alternative to metal screw caps traditionally used in the food industry, especially for glass jars. 'We noticed that some of our customers choose metal caps for technical reasons, for example because they work with pasteurized or sterilized products,' says Dave Busstra. 'However, there is also a growing number of customers for whom there is no technical need but who still want to maintain the luxurious appearance of a metal cap.'

Sometimes takes some getting used to

That’s why Kornelis developed the metal look cap, a plastic cap with the appearance of a metal version. 'We offer these caps in various diameters, from 63 mm to 82 mm, in both low and high rim designs,' adds Karen Huisman. The cap has a raised rim on top and a smooth finish on the side, giving it a stylish and refined appearance. 'It looks like a metal cap, but the properties are different, and we can also offer tamper-evident closures, which is an added benefit.'

The first commercial application of the new metal look cap is found on the jars of truffle mayo from Van Wijngaarden at Albert Heijn. Nutural World in the UK also uses this cap on their peanut butter. 'The response has been positive, although we do notice that customers sometimes need to get used to the idea. It requires adjustments in their machines and market persuasion, but the benefits speak for themselves,' says Huisman.

Sustainability as the key word

Sustainability plays an increasingly important role at Kornelis. 'Our caps are lightweight, and the material used is easy to separate,' explains Busstra. 'In many cases, they are more sustainable than metal caps, especially when you factor in the plastic compound often used on metal caps in the life cycle analysis (LCA).'

The metal look cap contributes to a lower environmental impact because it is made from a monomaterial. 'For example, we use a seal with monoseal, which can be easily disposed of separately, making it more sustainable than the combination of metal and plastic compounds often applied to metal caps,' adds Huisman. The company also offers the option to use biobased materials, such as sugarcane or wood pulp. 'These materials have the same properties as virgin plastic, but with a significantly lower footprint.'

Inmould Label

In addition to the metal look cap, Kornelis has other innovations in store, such as caps with Inmould Labels (IML). 'An IML label is applied directly into the mold during the production process, making it part of the cap itself,' explains Busstra. 'This provides a luxurious appearance, saves on the use of a separate label, and is fully recyclable since both the cap and label are made from the same material.'

Huisman highlights the practical advantages for the customer: 'Customers no longer have to apply stickers, which saves extra handling and costs. Additionally, it provides an extra communication tool, as the entire surface of the cap can be used for branding.'

New product lines

Huisman presents a range of different closures, showing that Kornelis is constantly expanding its product offering, with recent additions such as a standard flip-top cap for sauces. 'Until now, we mainly made these caps custom-made, but due to high demand at trade shows, we decided to develop a standard version,' says Huisman. 'This cap is suitable for ketchup and mayonnaise and has a ribbed design for better grip.'

Additionally, Kornelis is also active in the sprinkle cap segment, with a range of sizes from 38 mm to 85 mm. 'For sprinkle caps, only a monoseal is needed, making them even easier to recycle.'

Sustainable production

Kornelis strives not only for sustainable products but also for an environmentally friendly production process. 'We have invested in an efficient water system and energy-saving machines,' says Busstra. 'We have also achieved various sustainability certifications, such as the ISCC PLUS certification for recycled material via the mass balance system.'

A new development in this area is the introduction of EcoVadis, a certification for sustainable business practices that is increasingly required by customers. Kornelis is also FSCC 22000 certified, meaning the company is allowed to produce packaging for the food industry. 'We are continuously working on making our production process more sustainable to meet the strict requirements of these certifications.'

Another sustainability advantage is the purchase of a new stacking machine, which ensures that the wide-mouthed caps are less prone to deformation. 'As a result, we can make the caps lighter, which contributes to a lower environmental impact,' says Busstra. 'In short, with a wide range of new products and a constant drive for innovation, we are a leading player in the closures industry.'

Would you like more information about our caps and closures?

Contact us at 0521 51 27 41 or [email protected]. Our professionals will be happy to tell you about the possibilities.