Mondi on the MAP: Austrian plant develops recyclable film for fresh and processed foods

20 Jun 2019 --- Mondi has developed a fully-recyclable polypropylene construction for thermoforming applications, which achieves a 23 percent reduction in carbon footprint compared to existing packaging options. The new, coextruded material includes a top and bottom web, with an internal barrier layer that comprises less than 5 percent of the entire structure, qualifying the pack as a mono-material construction that is fully recyclable in existing waste streams.

The Aachen, German-based Institut cyclos-HTP – the Institute for Recyclability and Product Responsibility – has independently certified that both the top and bottom webs of this construction have the highest qualification “Class AAA” in recyclability.

Mondi’s new polypropylene construction is ideal for the thermoforming of flexible films for modified atmosphere packaging (MAP) and vacuum packaging, which is known for its ability to extend the shelf-life of products such as meat and cheese.

“We’re delighted to report that this innovative new film reduces the package’s carbon footprint by 23 percent compared to existing conventional structures,” notes Günter Leitner, Managing Director of Mondi Styria, the Austrian plant that produces the new film.

The previous multi-material construction rendered packages unrecyclable and also resulted in a much higher carbon footprint as confirmed by life-cycle analyses.

“Mondi’s view is that packaging should always be fit-for-purpose – paper where possible, plastic when useful – and sustainable by design. The challenge with this project was to maintain the functionality that is key to such applications, including excellent oxygen and moisture barriers and high puncture resistance – while also enhancing the package’s recyclability. The latter factor was vital as Mondi continues to support the principles of a circular economy,” explains Thomas Kahl, Project Manager EcoSolutions for Mondi Consumer Packaging.

In summary, Mondi customers who use this product can:

• Thermoform a fully recyclable PP film that retains all the functionality of the previous, multi-material construction;
• Achieve great sealability in the resulting package due to both the top and bottom web being the same, compatible material;
• Benefit from excellent optical properties and an outstanding gas barrier that provides for longer shelf life of the packed foodstuffs.

Mondi reaffirms that this latest development is fully in line with the design guidelines of major brand owners and retailers who are prioritizing increased sustainability. This thermoformable food packaging corresponds to their requirements for redesigning flexible packaging to become more sustainable, while also meeting the challenges laid out in the “New Plastic Economy” global initiative which strives to create a more circular economy.

The development of this fully-recyclable polypropylene construction for thermoforming applications follows a string of recent landmark solutions from Mondi. In May, the supplier showcased its new, fully recyclable stand-up pouch made of a monomaterial (polyethylene) with removable wrap-around label at the international trade show PLMA in Amsterdam.

Addressing the demand for sustainability in flexible packaging, Mondi also launched a 100 percent recyclable pouch made from polyethylene in collaboration with Werner & Mertz this year, alongside its existing innovation, the BarrierPack Recyclable.