Bockatech is the creator of EcoCore®, a patented foam injection molding technology that offers a unique combination of benefits for converters, brand owners, consumers, and the environment.
Borealis have worked with Bockatech since 2016, supporting the development of EcoCore and creating joint solutions that combine the benefits of this innovative technology with the advantages of Borealis’ advanced and circular polypropylene (PP) materials.
Chris Bocking, the founder and chief strategy officer at Bockatech | © Bockatech
We spoke with Chris Bocking, the founder and chief strategy officer at Bockatech, to learn more about how EcoCore is transforming the packaging industry and driving progress in sustainability.
Bockatech is the creator of EcoCore, a patented foam plastic injection molding technology that creates lightweight, high-performance, recyclable and reusable PP packaging and products.
EcoCore is available to converters and brand owners under license. Right now, its main applications are in cups and other food packaging, but we’re also exploring new areas like industrial packaging and healthcare.
EcoCore stands out by delivering more with less. Cups made with EcoCore use up to 70% less material than solid moldings while maintaining good strength and stiffness. They also provide twice the thermal insulation of thin-wall plastic alternatives, and are reusable, microwavable, and dishwashable.
The technology also enables faster production, with cups made in just 5 to 7 seconds, driving both cost savings and increased efficiency. In addition, EcoCore cups are made entirely from PP, ensuring they are fully recyclable at the end of a long life.
It’s a powerful combination of sustainability, efficiency, and performance that delivers clear benefits for converters, brand owners, consumers, and the environment.
We’ve been working with Borealis since 2016, when we were still a relatively early-stage company, and the partnership has opened up a lot of opportunities for us. Their deep expertise in polyolefins has helped to accelerate the development of EcoCore technology, making it faster and adaptable for a wider range of applications. On the business side, Borealis has also supported us in scaling up and reaching new markets and customers globally. EcoCore uses optimized polyolefin resins supplied by Borealis to create moldings that have skin-foam-skin walls with high strength-to-weight ratios and excellent thermal insulation for hot and cold drinks.
Borealis shares our commitment to sustainability and the circular economy, so we’re aligned in our goals. EcoCore supports several key elements of Borealis’s circular cascade, including Design for Eco-Efficiency, Reuse, and Design for Recycling. We’ve also collaborated to produce cups made from Borealis’ Bornewables™, ISCC PLUS-certified polyolefins produced from renewable feedstocks, and from Borcycle™ C materials, chemically recycled feedstocks. EcoCore is fully compatible with the PP grades in these portfolios, allowing converters and brand owners to further enhance the sustainability of their products.
Bockatech EcoCore technology and Borealis polyolefin foam solutions facilitate the transition towards a circular economy.
© Bockatech
EcoCore technology is already being used in hot and cold cups for numerous reuse schemes around the world—most notably in Peteluma, California, for a city-wide re-use scheme. Some of the world’s largest FMCG companies have also developed thin-wall products, including porridge pots and aerosol caps, using our technology. These examples highlight the versatility of EcoCore and how it is helping accelerate the transition to sustainable plastic packaging across different market sectors.
Bockatech EcoCore® technology together with Borealis PP material enable a versatile portfolio of reusable rigid packaging solutions.
© Bockatech
One of the highlights of the last few years was when reusable cups made with EcoCore were chosen for the COP26 United Nations climate change conference. Since then, EcoCore has been selected by one of the world’s best-known coffee chains for their reusable cups. We’ve also been recognized by leading sustainability organizations like the Solar Impulse and Ellen MacArthur Foundation. These achievements confirm that that we’re moving in the right direction—contributing to circularity and reducing environmental impact.
We’re continually exploring new applications for the technology. Right now, our focus is on delivering high-volume moulds for food service and FMCG packaging to fulfil customer orders. EcoCore also has strong potential in sectors like industrial pails and healthcare.
We also see a lot of room for expansion in our existing product areas. As reuse and deposit return systems gain momentum across different countries and regions, products based on EcoCore have a lot to offer. And, through our ongoing collaboration with Borealis, we’re working to deliver an ever-wider range of solutions based on circular materials, which will help brand owners adapt to new regulations like the Packaging and Packaging Waste Regulation (PPWR) in Europe.