From bioplastics to coffee capsule: How Bio-Caps combines sustainable production with high performance

Demand for environmentally friendly packaging solutions is growing, while manufacturers must continue to produce efficiently and economically. Bio-Caps GmbH shows how sustainable production and high industrial performance can go hand in hand. With biodegradable coffee capsules made from innovative bioplastics and fully electric ENGEL e-motion injection molding machines, the company demonstrates that both goals are achievable.

 The company produces biodegradable coffee capsules from a patented, innovative biopolymer that is not only compostable but also provides an excellent oxygen barrier, preserving the aroma of the coffee for months.

Products made from bioplastics such as Terrablend® place high demands on processing, particularly when it comes to home-compostable materials. The capsules must be produced with a high degree of precision to ensure they function flawlessly in standard coffee machines. Even the smallest dimensional deviations can cause capsules to deform or leak.

In addition, high crystallization rates make bioplastics difficult to process. To ensure sustainable production, extremely fast injection times and maximum precision are required – the only way to maintain consistent quality and ensure reliable functionality.

To produce bioplastic products reliable processes, maximum performance is required:

• Injection times of 90 to 100 milliseconds to achieve complete mold filling

• Cooling water temperatures of approximately 15 °C (59 °F)

• A rapid cooling time of just 0.9 seconds, so the products exit the machine lukewarm and can be processed more efficiently

• High-performance machines to ensure process reliability in production

Bio-Caps relies on fully electric ENGEL e-motion injection molding machines, which were specifically developed for high-performance applications.

Advantages of the e-motion injection molding machine for high-performance applications include:

• Short cycle times enabled by highly dynamic electric drives

• Maximum precision for dimensional accuracy without warpage

• Clean production through fully electric technology without hydraulic oil

• High energy efficiency through optimized movement sequences

This combination enables stable, fast, hygienic, and sustainable production - ideal for bioplastic products such as coffee capsules, packaging, and other sustainable solutions.

The Bio-Caps example shows how close cooperation with ENGEL enables reliable processing of new and demanding bioplastics.

Additional examples of bioplastics in use include 100% biodegradable and bio-based materials in powder form. Intensive research and development is also currently underway in collaboration with SKZ, focusing on paper injection molding.

As the market continues to evolve, products made from newly developed bioplastics are regularly tested at ENGEL's customer technical center. This allows us to continuously expand our expertise and lay the foundation for future-ready solutions.