The significantly growing market for both disposable and reusable cups in the field of hot-fill applications, such as coffee cups, is facing increasing demands that require innovative and economical solutions in order to be prepared for the future. In addition to good thermal properties and health safety, regulations such as the Packaging and Packaging Waste Regulation (PPWR) must be complied with. 

To meet these requirements and offer a cost-effective solution, SML has collaborated with its valued partner KGL S.A., a Polish specialist in the manufacturing and development of plastic packaging products. Together, we have developed an innovative coffee cup that meets all legal standards and delivers exceptional performance.  

The outcome in detail  
The newly developed coffee cup is thermoformed from a 3-layer PP film with a foamed core layer encapsulated by two rigid outer layers. The fine microcells of the foamed layer provide good insulation properties and give the cup a heat resistance of up to 100°C. Additionally, the foam cell structure decreases density, thus saving material during production. A simple preheating process of the film ensures excellent thermoformability. 

100 % recyclable solution 
Since the cup is made entirely from recyclable mono-material, it fully complies with the PPWR and can be sorted in regular waste sorting facilities, making it a sustainable alternative to PS or paper-coated cups. 

If you’re interested in learning more about the technology behind the foamed PP coffee cup, visit us at the K-Show 2025 at the SML booth – Stand No. 17C39 / 17C42.  

Enjoy an espresso from our foamed PP coffee cup while talking with our experts from the sheet extrusion department, who will gladly share insights into the extrusion technology behind this remarkable product. 

At the KGL / WM booth – Stand No. 3A16 – you can witness the live thermoforming process of the foamed PP film.  

Redlham, 08.09.2025