Innovia Films introduces recyclable lamination solution for dry food pouches

08 Feb 2022 --- Innovia Films is releasing Propacast KF, a clear cast polypropylene (PP) film designed as a lamination solution for horizontal form-fill-seal, vertical form fill seal and lidding applications.

Propacast KF is fully recyclable, especially in countries which already have the infrastructure to recycle PP films. The solution is designed to be the inner sealing layer for pouch packs.

Stephen Langstaff, business development manager for packaging at Innovia Films, tells PackagingInsights: “All sorts of dry products can be packed in these pouches, including confectionery, baked goods such as cake, biscuits, crisps and nuts.”

When asked about technical challenges, Langstaff says the main obstacle was sealing initiation temperature sufficiently low enough “so it [Propacast KF] could be used in conjunction with a BOPP surface layer.”

Mono-material recyclability
Langstaff explains that conventional pouches typically include several layers of different materials, making them difficult or impossible to recycle.

However, when KF is laminated to Propafilm CHS BOPP film, a fully recyclable pouch pack can be created as both films are PP. 

Innovia’s Propacast KF pouches can be used for dry products like confectionery, baked goods, biscuits, crisps and nuts.“With the drive toward simplified packaging formats, and the need to develop mono-material structures, we developed this cast PP film to act as an inner sealing layer,” he says.

The low temperature sealing film laminated to other PP films, such as Innovia Films’ Propafilm CHS BOPP film with improved thermal resistance and shrinkage properties, creates an “ideal” structure for pouches.

“In the UK, this structure would be recognized by the non-profit organization On-Pack Recycling Label (OPRL) as fully recyclable,” confirms Langstaff.

Easy machine processing
The Propacast KF is available as a 30, 50 or 70 micron film, with a wide heat seal range. The product offers a good coefficient of friction and anti-block properties, ensuring easy processing on a range of packaging machines.

KF has also been “corona-treated” on one side to ensure suitable adhesion during lamination. More specifically, “Propacase KF is corona-treated on one side to 38 dynes, which makes it suitable for lamination and printing,” explains Langstaff. 

“This development will enable better recyclable formats to be created, ensuring the circularity of flexible packaging. So far, all the feedback we have received about KF has been very positive,” he adds.

Last year, PackagingInsights explored trends in confectionery packaging with Innovia Films.

By Natalie Schwertheim