adapa & Cafés Méo: “Design for Recycling” packaging for coffee with an incomparable taste

This press release is also available in French.

How does the traditional French brand Cafés Méo position itself?

Alice Roussaud – Product Manager, Cafés Méo: Cafés Méo positions itself as a family brand built on three essential pillars. The first is the quality and enjoyment of coffee, which has always been at the heart of its identity. The second is accessibility, with a commitment to offering coffees to suit all budgets and households. Finally, the third pillar is commitment, in the broadest sense of the word.

This commitment is reflected in a rigorous selection of certified high-quality coffees, sourced through direct collaboration with producers, as well as through control of the supply chain. It also extends beyond the product itself, incorporating a global approach to packaging, which must combine high quality, taste and sustainability.

What does adapa represent?

Augustin Caresmel – Sales Manager France, adapa: We are one of Europe’s leading manufacturers of flexible packaging solutions, from food to healthcare products and consumer goods such as tea and coffee. Sustainability and customer focus are at the heart of what we do. This means that we adapt to the conditions prevailing at the customer’s site, which is particularly important at the moment, when design for recycling is a major issue. For example, we adapt our packaging flexibly to existing machines and support changes with our application engineers on site in order to proceed as economically as possible.

Why has Cafés Méo decided to switch to materials designed for recycling for the packaging of Senseo®* compatible pads? 

Pierre-François Henry – Technical Director at Cafés Méo: This decision is part of a thoughtful and responsible approach. Consumers are increasingly mindful of the environmental impact of their purchases, a concern we fully share. Traditional coffee pad packaging was a sticking point that we wanted to resolve. Finding a recyclable solution without compromising on quality was therefore an obvious choice. We have chosen to anticipate the requirements of the European PPWR regulation scheduled for 2030, in order to position ourselves as pioneers in this transition.

This new packaging marks a concrete step in our transformation. By rolling it out today, we are giving ourselves the opportunity to adjust and optimise our approach before large-scale changes become unavoidable.

The transition to recyclable packaging, as required by the EU by 2030, affects the entire packaging industry. What does this mean for adapa?

Augustin Caresmel: Yes, it’s true, the entire packaging sector is undergoing major changes and the overall structure is changing. It’s as if someone has pressed the reset button. The big challenge for our sector is to become recyclable as quickly as possible. For our customers, our ability to adapt quickly, our decades of experience and our broad portfolio are an undeniable advantage. In addition, we have an excellent network of machine manufacturers whom we actively involve in the development of new packaging. Our technicians also often perform feats on the packaging lines. They know the machines and films down to the smallest detail and thus manage every time to enable our customers to produce the new materials with their new requirement profiles without errors.

What motivates adapa, in collaboration with Cafés Méo, to switch to D4R packaging now, five years before the PPWR comes into force? 

Benjamin Leviez – Product Manager France, adapa: There are two main reasons for our intrinsic motivation. On the one hand, our customer focus: thanks to our long experience, we know that changing packaging takes time. We want to avoid rushed, short-term changes just before the strict implications of the PPWR come into force. We see ourselves as a partner that develops the right packaging solution for the long term. On the other hand, sustainability is firmly anchored in our values. We are committed to protecting goods as effectively as possible fostering the transition to a circular economy for flexible packaging.

Alice Roussaud: Social and environmental responsibility plays a central role in our company. At the same time, this step is an important part of our brand strategy. We are proud to be among the pioneers in the transition and introduction of new packaging – it’s in Méo’s DNA.

What requirements had to be taken into account to ensure both optimal protection for the coffee and recyclability? 

Pierre-Francois Henry: Good packaging must protect coffee from oxygen, moisture and light in order to best preserve its aroma. The switch to a recyclable material required a complete rethink of the film’s structure while ensuring an effective barrier. This took several years of research and testing in partnership with adapa. The result is a mono-PE film specially designed for recycling while preserving the freshness and aromas of our coffee.

What was the biggest challenge in this joint development?

Benjamin Leviez: The biggest challenge was to develop packaging that meets recyclability requirements while retaining the functionality of traditional non-recyclable packaging. This meant foregoing certain materials, particularly aluminium foil and polyester. These two materials are currently the main components of coffee packaging. Our R&D department is firmly focused on our customers’ needs in order to find the best possible individual solution for them. This also involves intensive dialogue within the adapa Group at European level, as well as directly with our customers. This was also the case with Méo: working closely together, numerous variants were tested to determine the optimal composition of the films.

Augustin Caresmel: Coffee production generates volatile residues, which place special demands on the sealing layer to ensure the integrity of the packaging for 18 months or more. With over 200 years of combined experience in coffee packaging at our sites, we have developed the expertise needed to meet all these challenges. This is particularly valuable at the present time, as we transition from multi-material structures to mono-material structures.

How did you manage to meet Méo’s requirements?

Augustin Caresmel: We have a vertically integrated value chain, from PE extrusion to the forming of stand-up pouches. This allows us to influence all components and respond to each of our customers’ unique situations, from the product to the machine configuration. Our long-term relationships with our raw material suppliers help us find the perfect material, and thanks to our sites’ extensive expertise in extrusion, lamination and printing, we create the optimal packaging.

In addition, we systematically follow the approach of developing and validating several variants of solutions so that we always have a reliable backup option. At a time when the European market is affected by various crises and shortages, it is essential to be able to respond flexibly.

What are the challenges associated with the transition to mono-material packaging?

Benjamin Leviez: The ecosystem we have been accustomed to until now, namely machines and films that work perfectly together to produce high-performance packaging, is disappearing. Until now, multi-material composites were used to achieve the desired properties. Now we need to find new solutions. In short, we need to successfully transfer the functional properties that polyester and aluminium have offered in packaging to date to films made entirely from polyethylene, so that they can be used without any problems on customers’ machines.

At adapa, we have developed a comprehensive range of PP, PE and paper solutions that can replace traditional multi-material structures, such as those based on PET or PA, while offering high performance.

What impact has this transition had on Méo’s industrial and logistical processes? Can we talk about a radical change?

Pierre-François Henry: I wouldn’t call it a radical change. It was more a case of adapting to the different behaviour of mono-materials. Our packaging lines have been gradually optimised to handle the new material – a necessary development, in line with our strategic direction and sustainability goals. However, it is important to emphasise that although adjustments were necessary, they did not result in any fundamental changes to the way we work. Neither the expiry dates nor the machines had to be completely modified, and the logistics process also remained unchanged.

What makes the partnership between Méo and adapa so successful?

Pierre-François Henry: We have been working with adapa for years. The company offers several advantages: on the one hand, its long-standing expertise in the field of flexible packaging, and on the other hand, its ability to adapt to our requirements. These two factors were decisive for the success of this project. As a European supplier located only 50 kilometres away as the crow flies, adapa also gives us access to a wide range of packaging solutions, services and technologies, such as pre-press support and digital printing. Even when we encounter difficulties, we manage to find a solution that satisfies everyone.

Benjamin Leviez: We can now look back on more than 30 years of partnership-based collaboration. Back then, we were still a single family business, but today we are the adapa Group. It’s a period that leaves plenty of room for trust and exchange on an equal footing.

What are the next steps for packaging at Méo?

Alice Roussaud: This transition marks the first step in a global change, in response to our consumers’ expectations and in line with our CSR approach. Our goal is clear: by 2027, our entire range of coffees — around 50 products — will be packaged in recyclable packaging. Our aim is to eliminate all non-recyclable packaging and to be fully prepared for the entry into force of the new laws.