In a unique value chain collaboration, Siegwerk, ExxonMobil, Henkel, Kraus Folie, and Windmöller & Hölscher have created a recyclable stand-up mono-material PE pouch. This innovation won the Gold award in the Sustainability category of the German Packaging Awards on September 13, 2023. The awards are described as being dedicated to the “who’s who of the best ideas.”

The award was one of only four Gold awards out of 34, and was granted in recognition of the breakthrough development of the fully recyclable mono-material PE pouch created through the collaboration.  The new pouches utilize the latest polymers, inks, functional coatings, adhesives and converting technology.

The product allows for pouches that provide a high oxygen barrier, outstanding package integrity and excellent shelf-appeal, and produces an almost colorless recyclate after the removal of printing ink and the oxygen-barrier coating layer.

According to the jury adjudicating this year’s award, “This technology, which now also allows internally printed laminates to become high-quality recyclate again in material recycling, has set another milestone on the path toward a fully functioning circular economy.”

The project partners agree on the added value of the new collaboration:

“Given the increased regulatory and consumer demands for less packaging waste and more sustainable packaging structures, the benefits of sharing knowledge in strategic partnerships such as this one cannot be overstated,” comments Ralf Leineweber, head of global technology development at Siegwerk, adding, “This initiative proves that functionality and performance don’t have to be sacrificed to achieve recyclability.”

Joachim Laun, senior polyethylene technologist at ExxonMobil, says, “The project underpins the importance of collaboration across the value chain to drive innovation toward a more circular economy. With recyclability becoming a key requirement of packaging, the combination of performance polyethylene with materials and processes designed to feature sustainability benefits allows for a realistic alternative to today’s multi-material packaging.”

“This successful cooperation shows in an impressive way that the challenges of a circular economy can only be overcome through strategic partnerships along the value chain and working together toward a common goal. With the oxygen barrier coating developed in cooperation with Siegwerk, as well as with a laminating adhesive compatible with recycling, we could make an important contribution to this innovative mono-material flexible packaging for dry food products,” comments Stefan Glötzel, senior manager of business development at Henkel.

Wolfgang Sprehe, manager, technical center at Windmöller & Hölscher, comments, “At Windmöller & Hölscher, we’ve always strived to push the boundaries of innovation in the packaging industry. Working with industry leaders on this project has been a remarkable journey. This recognition reaffirms our commitment to delivering cutting-edge solutions that drive sustainability in the world of packaging.”

What the jury said

Jurors at the German Packaging Awards had high praise for the project, commenting, “Climate change is acknowledged as one of the greatest threats to humanity. A functioning circular economy is a vital instrument for reducing the greenhouse gases that cause climate change and thus limiting the rise in temperature. When it comes to packaging, the challenge is often that necessary functions of the packaging, such as protection against spoilage or information obligations, compromise the recyclability of the packaging. Color residues and non-material barriers restrict the use of the recyclate in many applications.

“Five companies from the end-to-end process chain took on this unsolved problem and set out to develop a system whereby the packaging ultimately becomes colorless, high-quality recyclate again,”
the jury continues.

“This submission to the German Packaging Awards has achieved this in an outstanding way. By using a highly effective printed oxygen barrier in combination with a new type of primer for delamination and deinking, as well as an adhesive certified for this process, a mono-PE packaging with an internal barrier and color layer has been produced to meet the highest demands. After an alkaline aqueous hot wash – already standard practice in PET reprocessing – it becomes transparent mono-PE again during recycling.”