Coveris targets medical packaging with recyclable mono-PE film launches

18 Nov 2021 --- Coveris is presenting two recyclable polyethylene (PE)-based monofilms branded Flexopeel T and Formpeel T for medical packaging. 

“We combined an uncoated Tyvek 1073B from DuPont and a mono-structure film from Coveris, based on PE resins. As Tyvek is also a HDPE material, we had to search within the PE family for a suitable monomaterial for the film to simplify recyclability,” Jan-Willem Bruijsten, segment lead medical at Coveris, tells PackagingInsights.

“Our main challenge was maintaining the required barrier performance and product protection properties, using a more easily recycled, monomaterial film with different characteristics.”

While Coveris typically focuses on the European market, its latest products can be used within the medical device industry worldwide and secondary packaging for pharmaceutical products.

Tyvek applicability
Flexopeel T is a triple-sealed pouch made from uncoated Tyvek 1073B from DuPont, sealed to Coveris’ new pouch film.

The solution stands out with good puncture resistance and can offer up to 10 years of product shelf life, depending on individual product features. 

Flexopeel fits with ethylene oxide sterilization and plasma and gamma irradiation.The films can be produced from 100 µm up to 350 µm. The broad variation of thicknesses makes it suitable for very flexible to semi-rigid packaging, replacing standard A-PET or even PET-G films. 

Coveris highlights the combination of Formpeel T and Tyvek achieves high recyclability (>90%), while the Flexopeel and Tyvek combination reaches “excellent recyclability” (>95%) levels. 

“This makes both material combinations easy to recycle and a very [environmentally] sustainable solution compared to standard packaging available on the market,” adds Bruijsten.

Medical packaging’s legibility
Correct identification is a “growing problem” in the medical packaging sector, according to Coveris, especially when it comes to recyclable packaging. 

Coveris is part of the Sterile Barrier Association working group creating new icons on packaging. The new identification system aims to simplify recyclability and material origin in one overview, eliminating product waste.

“We hear from end-users, such as nurses in hospitals, that they seek more guidance in identifying whether packaging is recyclable. By using simple symbols on the packaging, we should indicate if the pack can be recycled or if components should be separated to maximize recycling opportunities,” says Bruijsten. 

Solutions in this sector are varied. For example, PackagingInsights recently spoke with Dr. Laura Bix from Michigan State University about her artificial intelligence research to improve medical packaging design and legibility.

“With the different plastic taxes in European countries, we believe medical device manufacturers will be forced to review the current packaging guidelines and smart alternatives will be required to fulfil market demands,” Bruijsten adds. 

For example, the UK Plastic Packaging Tax imposes a £200 (US$270) per ton tax rate for plastic packaging with less than 30% recycled plastic produced or imported into the UK from April 2022.“We strive to design packaging solutions that offer better recyclability: our Flexopeel T film achieves this,” says Bruijsten.

Covering Coveris
Meanwhile, Coveris’ recyclability initiatives have gained a stronghold in the ready-to-eat sector. This year, the company developed two separate sandwich skillets to meet the different shelf life requirements of mainland Europe and the UK. 

The modified atmosphere RecyclaPEel sandwich skillet – launched at FachPack 2021 – is designed to provide extended shelf life for the European food-on-the-move and convenience sectors. 

Also, the RecyclaPaper monomaterial skillet – launched at Lunch! 2021 – is an entirely paper-based, recyclable solution featuring a translucent window for product visibility, intended for UK markets. 

In previous interviews with PackagingInsights, Philipp Pap, director of sustainability and corporate development at Coveris, argued the plastic packaging industry is “part of the solution” to environmental challenges like climate change rather than the cause.

Will Mercer, business unit R&D director at Coveris, highlighted the company’s latest circular economy solutions at FachPack 2021.

By Anni Schleicher