Amcor develops recycle-ready film in major sustainability boost

26 Sep 2018 --- The creation of a unique polyolefin-based film that can be used for ambient and retort high-barrier applications has seen Amcor take a big step in its ambition to develop all packaging to be recyclable or reusable by 2025. Amcor claims the film will be an important building block in the development of flexible packaging which is recycling-ready across a huge range of products, from ready-meals to wet pet-food, coffee to nuts and snacks.

PackagingInsights speaks to Melinda de Boer, External Relations Director, about the development and sustainability credentials of the new film.

“The challenge for Amcor, and for our customers, was to find a replacement for PET and aluminum in flexible packaging that will deliver the same high-barrier performance while meeting the criteria for being recyclable,” she says.

“So far, there has been nothing on the market. The new film replaces aluminum and high-barrier PET films and is suitable for existing polyolefin recycling streams. It delivers excellent performance for barrier and heat processing without compromising packaging function and product shelf-life.”

While much of Amcor’s packaging is already recyclable or reusable today, the film is a significant step toward closing the remaining gap. The innovation will help the global companies Amcor serves to achieve their own ambitious sustainability pledges and, in markets where consumer goods companies pay Extended Producer Responsibility (EPR) fees, reduce costs.

R&D challenges
Recycling of flexible packaging is more complex than many other types of packaging, explains de Boer. “One key reason is the variety of materials and various plastics used, which can make it difficult to sort, separate and recycle flexible packaging.”

“Therefore, many recycling systems do not accept flexible packaging today. The predominant materials used in flexible packaging are polyolefins. Due to different melting points, polyolefins and PET generally cannot be recycled together.”

“A set of guidelines for recycling flexible packaging is being finalized by global and regional organizations such as the Ellen McArthur Foundation and CEFLEX. The aim is to align raw material suppliers, packaging producers, brand owners, retailers, sorting and recycling facilities and regulators on how to create flexible packaging that can be recycled.”

“The guidelines define the types of plastics that can be used in recyclable flexible barrier packaging. In simplified terms, one can say that Polyolefins are allowed (PP and PE) and should be maximized.”

“PET and aluminum have been commonly used in flexible packaging for products that require a high barrier (i.e. oily or high-fat foods, pharmaceuticals). PET is a very high performing base web for barrier layers, and known for enabling excellent sealing properties when combined with polyolefins, which maintains the pack’s integrity and offers a longer product shelf-life.”

“PET and aluminum are also very heat-resistant, unlike Polyolefins which distort under heat, so it is the material of choice for products that require high heat processing, such as retort or heat sterilization.”

Testing
Amcor is developing three grades of the new film, and each has been barrier tested.

• Ambient medium barrier – highly suitable for snacks, with good sealing properties, and for products that require a high water-vapor barrier.
• Ambient high barrier – achieves a barrier of 0.1 cc oxygen and 0.1g moisture.
• Retort high barrier – achieves <1cc Oxygen and <1g moisture after converting and retort processing. There are currently no other recycling-ready films available in the market that can offer this performance.

The film has been extensively tested by Amcor and performed very well in production processes, says the supplier. Live trials of the converted film are underway with several customers at their facilities.

Initial results are very promising and customers’ feedback is extremely positive, the company reports. In addition, recyclability tests with external recycling labs have proven suitability for recycling in the polyolefin stream.

“We are running trials with selected customers; once these are complete we will move to commercialization. The launch of the three grades of barrier film will be phased, starting with Ambient Medium Barrier. We estimate 18-24 months until full commercialization,” concludes de Boer.

By Joshua Poole