Alpla targets circular economy with metal-free PurePath pump

Alpla has successfully executed a complex integrated manufacturing operation for Hindustan Unilever (HUL) at its Silvassa facility, marking a significant step toward streamlined supply chains and reduced carbon footprints. The packaging solutions provider also demonstrated its agility by delivering a rapid turnaround for Godrej and introduced a fully recyclable pump that eliminates metal components from the waste stream.

Vaibhav Dixit, director at Alpla, speaking to WhatPackaging? magazine at Cosmoprof, explained that the initiative with HUL involves a wall-to-wall manufacturing concept in which bottle production and product filling occur in a continuous flow. The Silvassa plant, which began operations in 2021, saw full integration in 2023. The facility features a unique setup where the bottle-making machine is directly attached to the filling line. The product is manufactured on an upper level and fed directly into the packaging line below, where it is filled, labelled, and sealed.

Dixit noted that the primary motivation behind this integrated approach was to remain relevant in the workspace and innovate for clients while adhering to global carbon emission commitments under the Ellen MacArthur Foundation. Consolidating operations in a single location reduces logistics-related emissions and complexity.

However, the road to integration was not without hurdles. Dixit admitted there were initial challenges, including issues with bubbles in bottles, frequent design changes, and uncertainty regarding demand forecasts and SKU performance. Despite these obstacles, HUL remained a supportive partner throughout the process. Alpla collaborated with Unilever’s R&D team on the operational side and partnered with Avery Dennison to develop labels that could be applied at higher speeds to match the new line's efficiency.

Beyond the HUL project, Alpla demonstrated its operational flexibility with Godrej. Dixit highlighted a case where Godrej faced supply chain disruptions with another partner during the critical winter season. Leveraging a pre-approved site in North India, Alpla was able to step in and commence supplies within just two weeks, resolving stock-out issues for the client during their peak demand period. This move underscored Alpla’s dual capability in both packaging and contract manufacturing, where they follow client protocols to manufacture and fill formulations in-house.

Ritwick Mohapatra, senior executive for sales at Alpla, described the innovation as a monoplastic pump made entirely of polypropylene (PP). He explained that, unlike traditional pumps, which contain metal springs and glass balls that complicate the recycling process, the PurePath pump contains no metal parts. The elimination of non-plastic components ensures that the entire unit is fully recyclable and does not contaminate recycling streams.

The manufacturing process for the PurePath pump is completely in-house, utilising specialised moulds without reliance on outsourced components. Mohapatra confirmed that the product has already been launched in the USA with a pilot customer and is currently being exported. Alpla plans to introduce the pump to the Indian market in the coming months, having already shared samples with major domestic clients.