Dualit | Aluminum coffee capsules embracing the circular economy

The popularity of coffee capsules has risen dramatically in recent years. Popular systems use capsules or pods made from plastic, paper or aluminum. Aluminum is considered a premium option as it provides a high barrier for fresher coffee and is recyclable. In fact, recycling aluminum saves up to 95% of the energy needed to produce virgin aluminum from raw bauxite, and avoids the emissions associated with mining, refining and melting.

Spotlight on sustainability: Amcor’s partnership with Dualit

Answering the demand for more sustainable options, coffee brands are now innovating with aluminum. When it is melted, its properties remain intact, allowing it to be reused to make new aluminum products again and again – therefore widening its appeal to conscious consumers and improve companies’ sustainability efforts. One such company is Dualit.

Founded in 1945 by a German inventor who settled in the UK after World War Two, the family owned and run company developed a range of kitchen equipment. Most recently, its focus has been on its award-winning coffee machines and aluminum coffee capsules.

In this article, Giorgio Dini, Amcor’s coffee marketing manager, chats with Dualit directors Leslie and Alex Gort-Barten. They discuss their partnership with Amcor, which led to the development of their recyclable aluminum capsules.

See how Dualit’s Aluminum Capsules are made

Giorgio Dini: Developing an aluminum capsule is challenging, both in terms of IP protection and in getting it produced. How did you overcome the problems that inevitably occurred in every phase of development?

Leslie and Alex Gort-Barten: The process of developing aluminum coffee capsules took over 18 months of engineering development. One of our big innovations for the Dualit aluminum capsule was the unique gasket seal. This has a wide range of benefits such as compatibility for all types of coffee machines, color matching to the capsule and removability for recycling.

The challenge was finding a material for the gasket seal that could withstand the extraction pressures of the coffee brewing process, as well as being cost effective, easy to manufacture and most importantly one that did not infringe any existing IP protection.

To achieve this, we developed an entirely new material as there was nothing suitable on the market. With the support of Amcor’s expertise in aluminum (selection, lacquering and coloring) and ability to supply the material we were able to develop a high-quality capsule that met all our requirements.

GD: How is the market reacting to the new capsule – did you get a pull from the retailers knowing there is a clear trend to shift to aluminum capsules?

L&AG-B: We launched with a major grocer and moved another existing customer from plastic capsules to aluminum capsules. The level of returns and complaints are at an all-time low, which highlights the outstanding quality of our aluminum capsule. And, Dualit’s sales of coffee capsules are up, indicating clear market demand.

GD: Did you face any challenges running the aluminum capsules efficiently on regular filling lines? If so, how did you solve them?

L&AG-B: We developed the capsule with patented re-enforcing ribs on the side and this has produced a capsule 33-100% stronger than other aluminum coffee capsules. Having a stronger capsule means it can be used on a wider range of filling lines and reduces damage in transportation.

Related read: Enhanced differentiation and safety with new coffee capsule lidding

GD: The new aluminum capsule is for sale online under the Dualit brand and in supermarkets under private labels in UK. What is your strategy in terms of co-packing – can you receive roasted coffee from customers or is it roasted at Dualit? And are you able to follow customers’ bespoke blend requirements?

L&AG-B: We have a unique patented capsule design that works in all Nespresso® coffee machines. This is important for private label (co-packed) capsules.

Dualit can offer a co-packing service, either receiving green beans from the customer and handling the roasting, grinding, filling and packaging, or receiving directly roasted coffee beans from the customer. Yes, we can make the blend with coffee beans following the customer’s recipe.

GD: The capsule is receiving praise for its appearance and performance, but your range of activity is within the United Kingdom. Have you considered licensing the capsule to other brands to source and fill themselves?

L&AG-B: We recognize the demand for empty aluminum coffee capsules (to fill) worldwide. As such, we’re currently in discussions to start licensing the capsule technology and processes to brands and co-packers outside of the UK.

We understand that a licensing agreement could be the best way to utilize existing co-packing capacity – i.e. converting plastic filling capacity into aluminum capacity. Draft licensing agreements are ready if anyone is interested in licensing our capsules.

GD: Which standard capsule colors are currently available?

L&AG-B: We offer a wide variety of capsule colors for own-brand capsules as well as private label production. The colors currently available are black, purple, turquoise, blue, brown, orange, gold and silver.

Amcor can support the development of multiple new color ways in full compliance with food safety regulations. This is ideal for private label customers of Dualit who want specific colored aluminum capsules.

Related read: Sustainability challenges for today’s coffee market

GD: Since brand differentiation is so important, how else can it be achieved?

L&AG-B: There are many ways that we can achieve differentiation within the coffee capsule market.

For example, we’re helping customers to recycle their used capsules more easily. Our Ecopress device separates the coffee grounds from the capsule, removing the risk that the capsule will be rejected for recycling due to contamination from the coffee grounds.

Another effective way to stand out is through the personalization of the capsule packaging. We can print bespoke boxes for every private label customer, whether this be a full color box or printed label. There is also the potential for customers to have their own bespoke shape.

Amcor recently launched CapsLid Color, a lidding with Direct Food Contact inks available in a range of colors and print designs, which complies with all regulations. This is helping coffee brands differentiate their products in a mature but constantly evolving landscape.

If you want to find out more about Amcor’s recyclable aluminum capsules, contact us and a member of our team will be in touch to discuss the best options to suit your needs.

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