Flexible Packaging
Material science evolution: How mono-material flexible packaging is achieving multi-material performance
Simon Buswell, sales & marketing director at Eco Flexibles, says the flexible packaging sector is at a fascinating inflection point
A
fter decades of development focused almost exclusively on barrier performance, shelf-life extension and product protection, the industry is now seeing a major shift toward mono-material structures, particularly monopolymer plastics and paper-based. This evolution is being driven by multiple factors, with both commercial and legislative pressures pushing packaging innovation in exciting new directions.
Demand for monopolymer packaging is surging largely due to its compatibility with existing recycling streams. While not all monopolymer packaging is inherently recyclable, properly designed single-material structures dramatically improve separation and recovery prospects compared to multi- material alternatives. This recyclability potential represents a fundamental shift in how the industry approaches packaging development. Another signifi cant driver is the advantage mono-materials off er for light-weighting. Traditional multi-material laminates typically require multiple adhesive tie layers to bond materials together, adding weight without contributing functional properties. Monopolymer structures eliminate the need for these tie layers, as compatible grades of the same polymer family can be directly coextruded. This streamlined construction reduces both raw material usage and associated transport emissions. However, the greatest technical challenge has been ensuring monopolymer packaging
32 May 2025
delivers equivalent or superior performance to incumbent mixed-material packaging designs. Historically, manufacturers combined diff erent materials precisely because each component contributed specifi c functional properties that no single material could provide alone. Replicating this performance using a single polymer family or paper-based substrate requires signifi cant material science innovation.
To address these challenges, developments have focused on several key areas of design. Material scientists have advanced polymer chemistry to create varied grades of the same base polymer with diff erent densities and characteristics. This innovation allows for the combination of these various grades in multi-layer structures while maintaining recyclability due to the use of a single polymer family. Simultaneously, coating technologies have evolved to provide enhanced barrier properties without compromising the recyclability of the base material. At Eco Flexibles, we’re fi nding success by approaching these challenges from a unique market perspective. As a team comprising experienced individuals from all corners of the packaging value chain, we’ve experienced fi rsthand the typical headaches that brand owners face when transitioning to more sustainable packaging formats.
This insight proves invaluable when developing solutions that work not just in theory, but throughout the entire packaging lifecycle – from fi lling lines, to distribution networks, to consumer usage.
Our technical approach involves developing bespoke mono-material structures tailored to specifi c product requirements, whether that’s high-barrier applications for sensitive foods or puncture-resistant designs. By combining material expertise with comprehensive knowledge of the packaging ecosystem, we’re helping brands make the transition without compromising performance.
The wider packaging industry now faces a critical responsibility as regulatory frameworks also intensify. Extended Producer Responsibility (EPR) schemes around the globe, as well as more regional initiatives such as the UK Plastic Packaging Tax and expanding carbon reporting obligations, are transforming sustainability into a commercial imperative. These pressures, combined with heightened consumer expectations, make mono-material packaging innovation more relevant than ever. Perhaps most importantly, we need to collectively move beyond the outdated notion that sustainability necessitates compromise. This binary thinking has held the industry back, creating unnecessary barriers to adoption. Today’s material science advancements mean that with the right expertise guiding the development process from concept to completion, brands can achieve their sustainability objectives while enhancing performance, not diminishing it. As monopolymer packaging technology continues to evolve, we’re not just making packaging more sustainable – we’re making it better, too. That represents true innovation, and a seismic shift in how the industry approaches sustainable packaging development.
www.convertermag.com
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50
