Nonwoven technologies play a crucial role in ensuring quality & performance in Food & Beverage. Photo: Collected
Avoiding a scalping when brewing up…
‘Flavour scalping’ is a term used in the packaging industry to describe when the flavour or aroma of a food or beverage is altered by its packaging. This can happen when the packaging either absorbs aroma compounds or transmits undesirable flavours to the product. Understandably, the avoidance of this is critical in the production of teabags and coffee pods, where nonwovens play a key role. These engineered fabrics are specially designed to enhance the infusion process, ensuring that flavour compounds and aromas are effectively released while keeping tea leaves or coffee grounds contained. They also provide a balance of permeability, strength and sustainability that other materials cannot achieve.
Storm in a teacup
A few years ago, however, there was a strong public reaction – notably in the tea-loving UK – to press revelations that the humble teabag contained plastic, with small amounts of oil-based polypropylene (PP) being incorporated with natural fibres to enhance the durability and heat-sealability of the materials and better equip them for automated production processes.
The story generated so much of a ‘stir’ in the UK that at the start of 2018, thousands of consumers signed petitions calling for an immediate change.
Four of the largest UK manufacturers of teabags – Twinings, PG Tips, Yorkshire and Typhoo – were quick to respond to the pressure and potential damage to their reputations, with the assistance of their nonwovens suppliers.
“The challenge of plastics in teabags relates primarily to the traditional tea bag that was first introduced in the 1940s,” explained a spokesperson for Twinings. “This type of tea bag uses a very small amount of plastic-based material to help seal it together, so it does not fall apart. However, we are pleased to say that at Twinings, we have found a way to do this without plastic while maintaining the quality and taste our customers expect – and we have now transitioned to plant-based materials across our range.”
Corn starch and abaca
PG Tips, meanwhile, a Unilever brand, announced it was moving to fully biodegradable teabags, having already manufactured over a billion of its unique ‘pyramid’ products from 100% plant materials by that time. Both Yorkshire and Typhoo also transitioned from the use of PP as a reinforcement to PLA (polylactic acid), as a polymer derived from corn starch.
PLA’s benefits include its suitability for running on multiple types of fibre processing and fabric forming lines and providing teabags with lower taste scalping, as well as offering improved end of life options. PLA nonwovens, however, cannot simply be home composted but require industrial composting conditions, which has prompted a further push towards plant-based alternatives.
Glatfelter, for example, which in 2024 merged with Berry to become Magnera, makes teabags and coffee pod materials on specialised inclined wire wetlaid technology based on specialised abaca pulp, which is produced at the company’s dedicated mill and plantations in the Philippines. Abaca is a species of banana plant known for its high tensile strength and superior filtering properties.
Processing
The production technologies employed in manufacturing nonwoven materials for teabags and coffee pods vary, with the choice of process largely dependent on the desired properties of the final product.
Wet-laid processing is common, since it closely resembles traditional papermaking, with the fibres suspended in water before being deposited onto a mesh conveyor, drained and dried to form a uniform sheet. This technique is particularly suitable for cellulose and other natural fibre materials which require high porosity and excellent infusion properties.
The spunbond process is also employed to extrude PLA or other polymers through fine nozzles to create continuous filaments which are then bonded together by heat and pressure. This results in highly uniform, strong and porous fabrics that are ideal as heat-sealable materials.
Structural integrity
In the coffee pod sector, the challenge lies in balancing material permeability with the need for structural integrity. Nonwoven materials must withstand high-pressure brewing conditions while allowing for efficient extraction. To address this, manufacturers have developed multi-layered composites that combine different fibre types to achieve the desired mechanical properties. Some solutions integrate a base layer of PLA for strength, a fine filtration layer and an outer layer designed for rapid infusion. Such innovations have enabled coffee brands to transition towards more sustainable packaging without compromising the consumer experience.
Regulatory and environmental considerations are also playing a significant role in shaping the future of nonwoven teabag and coffee pod materials. Certifications such as the OK Compost and FSC (Forest Stewardship Council) labels are becoming increasingly important for manufacturers, signalling compliance with compostability and sustainable sourcing standards. These certifications not only provide a competitive edge but also reassure environmentally conscious consumers that their purchasing choices support responsible production practices.
Looking ahead, the market for nonwoven teabags and coffee pod materials is expected to continue evolving, driven by sustainability trends and technological advancements. Innovations in fibre composition, processing techniques and material engineering will play a pivotal role in shaping the next generation of such filter media.
With consumers increasingly seeking both convenience and environmentally responsible choices, manufacturers are endeavouring to strike a delicate balance between performance, cost-effectiveness and ecological impact.
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Source: Online/NAN
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