Flexible plastics: Emerging tech developments and innovation offer circular solutions

Packagers are advancing the use of digital tools to make their flexible plastic packaging solutions more sustainable. At the same time, software providers can enable packaging companies to adapt to ongoing developments through AI-supported systems. 

Traceability, efficiency, and sustainability tracking are key to improving the material circularity of flexible plastics, according to experts at Aicomp, Berlin Packaging, Constantia Flexibles, Coveris, and Henkel.

“In recent years, we’ve seen increased demand for recyclable and compostable flexible plastics, driven by consumer awareness and regulatory pressure. There’s also a growing interest in monomaterial solutions that simplify recycling,” Matthias Waltz, co-head of software solutions at Aicomp, tells Packaging Insights.

“Aicomp brings over 25 years of experience in the packaging industry and delivers industry-specific solutions across various packaging segments, including flexible packaging.”

He adds that the software solution company VCPowerPack offers an intuitive product configuration tool that is easily integrated with the enterprise resource planning software S/4HANA by SAP. “This enables customers to fully leverage SAP’s capabilities, enriched with industry knowledge.”

Achim Grefenstein, head of group R&D at Constantia Flexibles, says: “Flexible packaging is evolving rapidly with innovations like monomaterial solutions using Machine Direction Oriented PE and Bi-axially Oriented PE, which replace complex multi-layer laminates without compromising performance, where our EcoLam range is a prime example.”

“Another major step forward is our HolyGrail 2.0 project, using digital watermarks and near-infrared spectroscopy sorting to improve identification and separation of packaging, resulting in cleaner recycling streams and higher quality recyclates.” 

Constantia Flexibles invests in systems like Regenerative Thermal Oxidizers to cut emissions from printing and coating. The company says that beyond recyclability, smart features such as RFID, QR codes, and digital printing enable traceability, personalization, and waste reduction.

Software solutions for flexibles 

Waltz tells us more about how Aicomp’s solutions can help packaging companies respond quickly to market changes, customize products efficiently, and maintain compliance with evolving standards.

Constantia Flexibles’ solutions with Machine Direction Oriented and Bi-axially Oriented PE (image credit: Constantia Flexibles).“Aicomp’s latest solution, Cubicus, is a great example of this shift. It offers industry-specific product configuration as a cloud-based SaaS solution for packaging manufacturers of all sizes,” he adds.

“Technology is the backbone of transformation in flexible packaging. From advanced order entry to AI-supported manufacturing systems, digital tools are enabling smarter, faster, and more sustainable production.” 

Aicomp’s product configuration solutions can support customers in tracking classifications like post-consumer waste recycling percentages of extrusion ingredients throughout the production processes, enabling a detailed sustainability assessment of the finished product.

Waltz says that this illustrates another major trend, digitalization. “It can support packaging manufacturers on their journey toward a circular economy. In general companies are investing in smart packaging, traceability, and data-driven production.”

These developments can push manufacturers to adopt more agile and intelligent systems, which is where Aicomp’s software can play a “crucial” role.

Recycling, protection, convenience 

Katja Killian, business development director for Flexibles at Coveris, argues that technical progress is focused on combining recyclability, product protection, and consumer convenience. 

“Our recent investment in a cast film extrusion line in Halle, Germany, boosts flexibility in material development, enabling future-ready recyclable solutions. The latest example is MonoFlexBP, a monomaterial thermoformable base web with resealable lidding film that protects meat and cheese while reducing waste.”

To address plastic reduction, Coveris also introduced the MonoFlexFibre Pure Max monomaterial paper substrate for bars and tablets. “Despite being paper-only, it delivers robust barriers, high shelf impact, and recyclability in existing paper streams.”

Henkel uses flexible plastic for products such as powder detergents and refill pouches for shampoos (image credit: Henkel).Other paper-based innovations by the company include the latest BarrierFresh MAP tray for meat, fish, and poultry, which can reduce plastic content by 90% while maintaining recyclability and shelf life. 

“Made from board with a specialist ethylene vinyl alcohol copolymer barrier film, it provides a fully printable, hermetically sealed solution for fresh proteins,” adds Killian. 

Similarly, FilmLiteR Stretch offers a fully recyclable pallet wrap with over 30% recycled content, optimized for safe transport in the beverage sector.

Flexibles remain key pack material

Flexible plastics play an important role in Henkel’s packaging portfolio, according to Carsten Bertram, head of Packaging Sustainability for Consumer Brands, and Philippe Blank, global head of Circular Economy for Packaging and Consumer Goods Adhesives.

“They provide efficient solutions for products such as powder detergents or refill pouches for shampoos. In recent years, Henkel has focused on transforming flexible packaging to monomaterial solutions to improve design for recycling and has increased the use of recycled plastics in flexible formats.”

Henkel is developing and testing paper-based flexible packaging, such as with the Somat brand in selected countries, to gain insights into technical performance and consumer acceptance.

Monomaterial flexible packaging solutions are said to be a key focus for Henkel, “with additives, inks, and adhesives contributing to improved recycling quality.”

Advances in recycling processes, including deinking and delamination technologies, are also important, according to Bertram and Blank.

“Henkel addresses these developments as a brand owner implementing packaging solutions and as a technology provider, supplying adhesives and coatings that enable new designs while remaining compatible with recycling processes.”

Meanwhile, Constantia Flexibles says it takes a rounded approach to flexible packaging, offering solutions across aluminum, films (PE & PP), paper, and even biodegradable materials. Grefenstein adds: “Our goal is clear: deliver packaging that protects products, performs on the line, and supports a circular economy.”

“A major milestone was the launch of our Ecolutions family in 2018, starting with EcoLam. It is our mono-PE laminate line available in three different grades: EcoLam, EcoLamPlus, and EcoLamHighPlus.”

Grefenstein says these solutions are designed to replace complex multi-material structures like PET/PE or PET/ALU/PE. At the same time, they provide tailored barrier properties, from moisture protection to high-performance needs, without compromising efficiency or shelf life.

Ensuring circularity 

Coveris’ packaging solutions for recyclability, product protection, and consumer convenience (image credit: Coveris).Moira Stein at Berlin Packaging tells us that the company provides brands across industries with flexible pouches and bags in a variety of shapes, styles, materials, and closure types. 

“Berlin Packaging has exclusive product offerings, like our Sashi refill pouch, and we source flexible pouches from our vast network of global supplier partners. In addition to stock options, our Studio One Eleven design and innovation division provides custom design and branding services to meet all our customers’ needs.”

The company recently entered into an exclusive agreement with Xela Pack to supply its paper-based packets to customers. “They are perfect for a variety of applications and especially great for sample, trial, and small retail-size products with easy bend-and-tear tabs, self-closing orifices for single- or multi-dose, and tamper evidence.”

“Several of our customers use flexible pouches as part of a refill system, reducing their environmental impact due to decreased material use, weight, and transportation emissions associated with flexible packaging.”

Berlin Packaging’s team of sustainability experts conducts LCAs to measure the environmental impact of different packaging options to help its customers select the most effective and impactful solution.