Flexible packaging is easy to use, but difficult to recycle. For example, UK's the recycling rate of plastic packaging has reached 46.5%, but the recycling rate of flexible packaging is only 4%. Flexible packaging is usually multi-layered, which increases the difficulty of recycling and separating packaging waste; but this can improve packaging performance and meet the packaging needs.

In recent years, many brands and packaging solution providers have worked hard on packaging design by increasing the proportion of mono-material, optimizing the structure of packaging materials, and increasing the PCR in packaging to make flexible packaging more convenient for recycling. Mono-layered packaging usually contains 90% of PP or PE in the packaging which is convenient for recycling.

Gerber announced a first-of-its-kind, single-material baby food pouch designed for the future of recycling. The single-material baby food pouch is designed to increase recycling value and promote the circular economy. This food packaging bag is designed with premade spouted pouches. The body and sealing lid are made of polypropylene, which can be filled either hot or cold.

HILL launched a fully PE "recyclable" pet treats pouch. This breaks restrictions of using only PE film for packaging, and adopts a completely "renewable" flexible packaging form without any compromise on appearance or performance. With the combination of new materials, innovative equipment and new processing methods, this packaging has a beautiful appearance, puncture resistance and grease resistance, high barrier properties, and easy opening and closing.

Hoffmann Neopac announced its latest sustainability initiative: Developing mono-material barrier tubes that provide exemplary protection for cosmetics, food, and pharma products, while being compatible with existing recycling processes. This material is mainly PE, and the content of other materials such as inks and adhesives is less than 5%. The tube is available in transparent and white colours, and compare with the Polyfoil, it can also achieve a weight reduction of 40%.

Huhtamaki launched a recyclable barrier packaging based on polyolefin (PO) materials to meet the packaging needs of shampoo and shower gel.This is one of the products of the recyclable flexible packaging from the company, made of a single-material PP/PE and paper. Huhtamaki has also developed similar solutions for coffee, detergent, ketchup, etc.

Not all flexible packaging can be used by mono-material. Multi materials include EVOH, PVOH, SiOX, and acrylic coatings could also be used under some situation. These materials should not account for more than 5% of the entire package, or they can be replaced by coatings or other degradable materials.

AmLite Ultra Recyclable packaging is made of high-barrier polyolefin film. This new type of high-barrier composite film can be used to package food, household and personal care and pharmaceutical products, and can be used in existing polyolefin recycling systems.

AmLite uses ultra-thin, transparent barrier coatings to replace aluminum and metallized barrier layers to reduce carbon footprint. This material combined with the material's recyclability, can reduce the carbon footprint of packaging by up to 64%.

EMSUR releases compostable two or three-layer barrier bag. The packaging bag can be composted. EMSUR said that the packaging materials used to produce this barrier bag have passed the compostability certification and the adhesives and special printing inks used can also be composted.

The barrier bag is suitable for rotogravure printing and flexographic printing. The laminar structure can reportedly be applied to different high added value categories such as dry food, snacks & confectionery or pet food.

In addition to optimizing the structure of packaging materials, increasing the content of post-consumer recycled materials (PCR) in packaging can also reduce carbon dioxide emissions and energy consumption, allowing processors, brands and retailers to achieve their sustainable development goals. With the improvement of material science and technology, the application of PCR in packaging has gradually expanded from the field of daily chemicals to food.

Source: Flexible packaging association

Source: C-P Flexible Packaging

Source: Flexible packaging association

ProAmpac produced a high-barrier pouch made with 25%PCR for JUSTIN’S Nuts. Utilizing a food-contact FDA-compliant structure, this snack pouch reduces its reliance on virgin resin by using 40 percent recycled plastic content in the sealant film that equates to 25 percent of the total structure.

C-P Flexible Packaging launced a line of flexible packaging options designed for sustainability utilizing post-consumer recycled content, recyclable materials, compostable materials, down gauged materials, and materials derived from renewable resources.This includes flexible packaging materials with over 40% post-consumer recycled (PCR) resin.

FlexFilms’s Asclepius™ PCR based BOPET films are a complete family of low carbon footprint BOPET film. It is available in 90–100% PCR content for printing and laminating, barrier, label and liner, and virtually all other flexible packaging needs.

There are countless design options for flexible packaging similar to these recyclables. However, there is a long way to go to realize the plastics circular economy. It is not enough to rely on packaging design innovation alone. It requires the cooperation of the upstream and downstream of the plastic value chain. It is necessary to promote the Life Cycle Thinking to evaluate the overall resource efficiency and environmental impact of products and packaging solutions. From production, consumption, waste management to packaging innovation and design, each link takes a small step forward.

Flexible Packaging becomes one of the trends of packaging. Sino-Pack/PACKINNO2021 will gather experts and suppliers of innovative and eco-friendly packaging products and technology, we will showcase how packaging could be functional and green. As a leading and professional packaging trade platform, Sino-Pack/PACKINNO2021, will be held again from 4-6 March 2021 at Area A, China Import and Export Fair Complex, Guangzhou, PR China.

Six theme zones are featured this year, they are “Smart Packaging + Smart Logistics”, “Food Packaging”, “Liquid Packaging”, “General Packaging”, “Coding & Marking” and “Packaging Products & Materials”, covering multiple end-use spectrum like food, food processing, catering, beverage/dairy products/alcohols, etc. Definitely a choice for you!

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