Types of Recyclable Food Packaging Materials Explained

It requires more than the mere removal of one film package for food brand switching to recyclable packaging.

The new packaging needs to provide the same protection as the previous packaging, have the appropriate shelf life, be compatible with the existing machinery used to fill the containers, and have the look the customers would expect. The cost and minimum order quantity, the recycling claims, and the compatibility of all functional elements like zippers, valves and spouts are also important considerations for brands.

These concerns can create more challenges in packaging conversion than may be anticipated.

Many flexible packaging applications can take a direction towards mono-PE recyclable food packaging. The structure, however, should be chosen depending on the product to be filled, filling process, storage conditions and the target market.

In this guide, we outline the key considerations for food brands should take into account when switching from a multi-layer laminate structure to mono-PE packaging structure.

What Is Mono-PE Recyclable Packaging?

Traditional flexible packaging is more commonly than not a combination of various materials.

The following is a typical structure for a common:

· Materials used for strength: PET

· Barrier protection such as aluminum foil/metalized film

· PE used for heat sealing.PE used in heat sealing.

· Layer 1 – Adhesives between the layers.

They can offer outstanding protection for the product, but are not easily separated for recycling purposes because of their different materials.

The packaging system called mono-PE is primarily made from polyethylene based resources. Its job is to make it simpler and more easily compatible with the right flexible packaging recycling stream.

Mono-PE can be employed for packaging formats like:

· Stand-up pouches

· Flat-bottom pouches

· Three-side seal bags

· Sachets

· Spout Pouches

· Rollstock film

But mono-material cannot be interpreted to mean that a package can be recycled throughout all locations.

The whole package needs to be taken into consideration, such as:

• Zippers

• Degassing valves

• Spouts and caps

• Labels

• Adhesives

• Barrier layers

• Printing inks

However, depending on the target market, the presence of appropriate collection, sorting and processing systems is also key to actual recycling.

Brands should avoid misleading claims. Instead, they should state that the packaging is designed to be compatible with PE recycling streams where collection and processing systems exist.

Can Mono-PE Packaging Maintain Food Shelf Life?

When making packaging changes shelf life is typically the greatest concern.

The level of protection needed is dependent upon the product contained within the package.

Product	Main Packaging Concern
Coffee	Oxygen, moisture, aroma loss and light
Snacks and Nuts	Oxidation and moisture absorption
Powders and Supplements	Moisture, caking and contamination
Pet Food and Treats	Oxygen, grease, puncture and seal strength

There are a number of factors to consider when choosing a suitable mono-PE structure:

· The sensitivity of the products towards oxygen.

· Moisture resistance of the product.

· Target shelf life

· Storage temperature

· Transportation conditions

· Filling method

· Ability to use a zipper, valve or spout.

The mono-PE structures with high barrier can be combined with other barrier technologies which are compatible.

The packaging supplier should make a comparison between the recommended material and its real needs for the product. Oxygen and water vapour transmission data can be used in conjunction to assess the barrier performance of products, though product testing should also be completed for final approval.

The look of the recyclable pouch is not one of the most important considerations when choosing a pouch. Prior to commercial production, it is still important to perform seal testing and product compatibility testing and shelf-life validation.

Will Mono-PE Film Run on Existing Packaging Machines?

The characteristics of a conventional PET based laminate may be different than the Mono-PE film.

The performance of the packaging lines can be influenced by the differences in flexibility, stiffness, friction and sealing temperature.

Possible issues include:

• Film stretching

• Rollstock tracking problems

• Wrinkling

• Registration movement

• Incomplete seals

• Reduced filling speed

• Increased production waste

Prior to suggesting a rollstock configuration, the manufacturer should take the time to look at the following:

• Packaging machine model

• Filling speed

• Sealing temperature

• Film width

• Roll diameter

• Core size

• Unwind direction

• Registration mark requirements

• Current film structure

• Current film thickness

Obviously it is strongly recommended that a trial roll be made prior to mass production.

This test is done on the customer's actual packaging equipment to check the feeding performance of the film, sealing performance, registration performance, appearance of the finished product and production speed before ordering in larger quantities.

Can Mono-PE Pouches Include Zippers, Valves and Spouts?

Yes. Functional components are an acceptable option in mono-PE packaging, although a benefit assessment needs to be carried out for the entire packaging system.

Zippers

A zipper that can be resealed is more convenient and will prolong the freshness of food after it's opened.

When the zipper is used, a material that can be compatible with PE packaging structure is used as much as possible. Repeat opening should be tested as should also be seal strength.

Coffee Degassing Valves

When fresh, a roasted coffee gives off carbon dioxide, and may need a one-way degassing valve.

It is possible to have a valve in a mono-PE coffee pouch but the material of the valve and the overall packaging weight should be taken into account prior to making a recyclability claim.

Spouts and Caps

For some liquid products, such as sauces, purees and certain liquids, mono-PE spouted pouches can be considered.

The pouch, spout and cap is considered a complete packaging system. The filling temperature is also an element that should be tested, in addition to the characteristics of product viscosity, drop resistance and leakage performance.

How Cailyn Supports Mono-PE Packaging Projects

Switching to new packaging materials without assessing the protection of the product and machine performance can create a potential risk.

Cailyn assists food brands with the packaging review process and pilot production and commercialization.

We can support you by helping you to:

The key first step for brands is to take a look at the existing packaging structure.

Gather data from reviews of the products and shelf life demands for the evaluation process.

– Making recommendations for an appropriate mono-PE structure

• Corresponds to requirements for oxygen and moisture barrier properties

Choosing zippers, valves or spouts that will work together.

• Making prototype pouches

• Manufacturing trial rolls to test for machines

Sponsoring pilot digital printing to market

• Developing new printing techniques and materials to meet the market demand

• Providing material specifications

• Making available available food contact documentation

• Development of the tooling for pilot production to mass production

Before a structure is recommended, a reliable supplier should have a knowledge of the product, application and packaging process.

Brands don't need to change a product line all in one go, they can start with a single important SKU.

A pilot project is a small-scale, limited production run of a material produced by the customer to verify that the material meets the requirements and that the package(s) can be sealed properly during the filling operation prior to placing a larger commercial order.

Does Mono-PE Packaging Cost More?

The price for mono-PE packaging varies according to project.

The primary costs are:

• Required barrier level

• Film thickness

• Pouch format

• Printing method

• Order quantity

• Number of designs

The need to have a zipper, valve or spout.

The cost of a basic mono-PE structure for a dry product can be different to a high-barrier structure for a coffee, a nut or a pet food.

Brands need to consider more than just the cost of the pouch.

The total project should also take into account:

• Trial material

• Packaging-line efficiency

• Product shelf life

• Production waste

• Retailer requirements

• Future packaging changes

A small pilot will limit the financial risk for a new project in switching materials.

Frequently Asked Questions

Can mono-PE packaging be recycled?

PE mono-fraction can be a step to enhanced compatibility with a PE recycling stream, but it is the complete package and local recycling infrastructure that will ultimately decide whether a PE stream is recyclable.

Is it possible to get a good barrier with mono-PE packaging?

There are high barrier mono-PE structures for select products. The barrier level necessary for the product and shelf life should be determined.

Will existing equipment be able to process mono-PE film?

In most instances, it can, but there is a need to adjust the settings of the machine. It is suggested to do a trial roll before mass production.

Is there a small beginning order?

Yes. Depending on the project, customer can start from samples as well as prototype pouches, digitally printed pilot quantities or trial roll.

Start with a Mono-PE Packaging Assessment

It's not necessary to make an all-or-nothing switch.

Please pass on all of the following to Cailyn:

• Product type

• Current packaging structure

The size of pouches or rolls.The size of pouches or rolls.

• Target shelf life

• Filling process

The zippers, valves or spouts that are required.

• Target market

• Estimated order quantity

It is our team who can review the application and recommend the appropriate mono-PE packaging direction and suggest the next testing direction.

Primary CTA:

Request a Mono-PE Packaging Assessment

Secondary CTA:

Get a Custom Packaging Quote