Innovative Full PE Solutions

Sustainable blown film packaging

Sustainability without loss of quality. Saving resources while improving products. Hosokawa Alpine works together with partners along the entire value chain to develop mono-material solutions that are both high-performance and recyclable.

Recycling of films made of one material class is considerably easier and more efficient than recycling of plastics packaging in which different materials are combined with each other, e.g. PE with PET, PP, PA or EVOH. Full PE packaging solutions, i.e. laminates purely made of polyethylene based film structures, can be recycled after their original use and be reused in the circular economy for new end products. This results in applications in which the recycled material can be used again for products similar to the original one.

More than 25 years’ experience

MDO (Machine Direction Orientation)

The proven MDO (Machine Direction Orientation) technology from Hosokawa Alpine is a key element in manufacturing high-performance single-material laminates based on polyethylene. It is only by monoaxial orientation that outstanding film characteristics can be achieved that allow PE film structures to substitute PET or BOPP films. These include:

High stiffness
Increased oxygen transmission rate
Excellent optical properties
Reduction of film thickness

These outstanding film properties are fundamental for the lamination and printing of Full PE packaging films. Economy of production is ensured by Hosokawa Alpine‘s unique TRIO technology "Trim Reduction for Inline Orientation" that significantly reduces the amount of edge trims.

Alpine's unique vacuum technology optimizes the flatness of the films. This achieves outstanding roll quality and enables easy further procesfilms.sing of MDO PE

To the film orientation lines

ExxonMobil

Enabling flexible film circularity: from a recyclable full PE barrier packaging solution to a high end heavy duty sack

ExxonMobil collaborated with Alpine to create a >95% high oxygen barrier pouch - as an alternative to more difficult to recycle multi-material high oxygen barrier laminates – which can be recycled back into a high-end film application. This enabled flexible film circularity.

Link to Exxon Flyer

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Full PE thermoformed packaging with improved recyclability and uncompromising package functionality

Creation of a 95% PE thermoformed package, consisting of a formed bottom web and MDO (machine direction oriented) PE //PE lid film - with high oxygen barrier & outstanding package integrity through optimized corner thickness & puncture.

Link to Exxon Flyer

Watch the video

INEOS Polyolefins

MDO film with up to 50 % PCR content from mechanical recycling

25 to 51 % content in post-consumer recyclate (mechanical recycling, not intended for food contact applications)
Easy extrusion and MDO processing
High stiffness
Superior optical properties

5-Layer MDO-film, Orientation ratio: 1:5 -1:6 | Film thickness: 22 μm laminated against 5-Layer sealant web with up to 50 % PCR content, Film Thickness: 70 μm

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Borealis

Full PE Laminate with 35% PCR

Developed in collaboration with Borealis, Hosakawa Alpine, Henkel, GEA, Metlux and Digimarc, these concepts address the needs of different product categories:
Gas barrier laminate for oxygen-sensitive products including modified atmosphere packaging, such as nuts or cheese.
Metallised laminate for moisture-sensitive food products, such as crisps, biscuits, and confectionery.
Laminate with 35% Ecoplast LDPE post-consumer recyclate for non-food applications, such as detergent powder. Ecoplast is a member of the Borealis Group

In all three PE mono material solutions, BorShape™ provides the required mechanical and thermal stability performance, while Anteo™ combined with Queo™ delivers outstanding sealing performance.

These concepts were thoroughly validated, and their sustainability was optimised in collaboration with leading industry partners. It uses the latest innovations that support circularity, including digital watermarking technology.

Customer Stories

Typical film applications

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