Decoration of Compostable Coffee Capsules

The Challenge: Innovation and Sustainability in a New Format

In 2020, one of Switzerland's most prominent coffee companies launched a pioneering project: replacing traditional capsules with a new, compostable version, thereby eliminating the use of plastic and aluminum. The material, designed by them, is fully biodegradable—a revolution aligned with the market’s growing demand for sustainability. To complete the project, the client decided to personalize the top of the capsule directly in-line using digital printing. The goal was to eliminate the need for pre-printed reels, reducing stock and logistics costs.

The First Obstacle: Ink Compliance with Regulations

The first hurdle to overcome was not mechanical but chemical, as regulations did not allow the use of food additives in the intended application. Xlogic was already working on a new type of food-grade liquid, and this project became the decisive push to complete the work and release a compliant, safe, and certified edible color.

Engineering at the Limit: An Out-of-Scale System

The technical solution developed was one of the most complex ever created by Xlogic:

• The printer was installed 3 meters above the ground, suspended over the line

• It included 4 printheads, with the print unit weighing 25 kg, perfectly balanced

• The system was equipped with a dual electric lifting mechanism for maintenance and adjustments

• The management software was completely rewritten to eliminate misalignment errors between the printheads caused by friction and tension in the compostable film

Everything was custom-designed: from the mechanical structure to the software, all the way to the synchronized feeding system with the client’s production line.

An Outstanding Project Between Sustainability and Precision

This case demonstrates Xlogic’s ability not only to face scenarios of extreme technical complexity but also to respond to new regulations and environmental constraints with concrete solutions. The in-line decoration of compostable capsules allowed the Swiss client to:

• Reduce warehouse costs

• Increase production flexibility

• Offer a personalized, sustainable, and certified product

Once again, technology and ingenuity come together to make a difference in the world of food printing.