The Mondi Group has developed a fully recyclable polypropylene structure for thermoforming applications that achieves an improvement in the CO2 balance of 23 percent compared to existing packaging.
For flexible food packaging manufacturers have previously had the choice of either exploiting maximum material performance or designing the packaging to be fully recyclable. Mondi now has created a recyclable polypropylene film that is ideally suited for thermoforming flexible packaging to keep products fresh under modified atmosphere (MAP) and in vacuum. Both methods are known for extending the shelf life of foods.
The new co-extruded material comprises a top and bottom film as well as a barrier layer that lies in between the two films and that makes up less than five percent of the overall structure. This qualifies the structure as a mono-material that can be completely recycled in existing waste streams. In an independent study by cyclos-HTP Institut für Recyclingfähigkeit und Produktverantwortung, a company in Aachen specialising in assessing and certifying recyclability, certified top and bottom films with this structure with the highest recyclability class AAA.
The previous multi-material structure not only prevents the recycling of packaging but also had a far worse CO2 balance in life cycle analyses. “We are pleased that this innovative new film reduces the carbon footprint of the packaging by 23 percent compared to conventional structures,” said Günter Leitner, Managing Director of Mondi Styria, the plant in Austria that produces this film.
“This project faced the challenge of ensuring the basic functionality for such applications, including outstanding oxygen and moisture barriers as well as high puncture resistance, while at the same time optimising the recyclability of the packaging. The latter was critical for Mondi supporting a successful cyclical economy in principle,” explained Thomas Kahl, project leader for EcoSolutions at Mondi Consumer Packaging.
Customers who use this product can thermoform a fully recyclable PP film that has all the functionalities of previous multi-material structures. They can now also produce packaging products with outstanding sealing properties because the top and bottom film are made from the same material as well as benefit from the exceptional visual characteristics and excellent gas barrier that ensures the packed foods have a longer shelf life, according to Mondi.