The New Standard in Recyclable Flexible Packaging: High-Barrier, Low Impact Solutions

For years, the trade-off has been simple and frustrating: if you want a high-barrier pouch, you accept a metallised PET structure that can't be recycled. If you want recyclability, you accept lower barrier and shorter shelf life. Customers have lived with this trade-off for a long time.
‍

We've launched a recyclable mono-material PE laminate that matches the barrier performance of metallised PET. Same protection and shelf life as metallised PET, but recyclable in soft plastics streams where collection exists.
‍

The structure is roughly 99% polyethylene, with a thin metallised PE coating (VMPE) doing the barrier work.

‍

This innovation sets a new standard in packaging by delivering a sustainable option that meets performance needs typically handled by complex multi-material layers.

‍

Where it fits

This is built for products that currently rely on metallised PE structures and want a recyclable alternative without losing shelf life. The flexibility and protective strength of this material make it a valuable option for diverse sectors:

• ‍Food and Beverage: Keeps products fresh and extends shelf life, helping to reduce waste. This includes ground coffee.
• Personal Care: Maintains quality by protecting moisture-sensitive products.
• Pet Products: Preserves the nutritional integrity of pet foods.
• Pharmaceuticals: Provides secure packaging for medications and supplements.

This high-barrier laminate delivers high performance while remaining recyclable. Key advantages include:

• Outstanding Protection: Keeps products fresh and secure, comparable to the best multi-material packaging.
• Recyclability: Works with soft plastic recycling programmes, including those specifically for Number 4 plastic.
• Sustainable Content: Can contain up to 55% recycled content, reducing carbon emissions and supporting the circular economy.
• Versatile Across Applications: Adaptable to a wide variety of packaging formats, supporting many industries and needs.

• Less Fossil Fuel Usage: Uses fewer fossil resources compared to traditional packaging.
• Reduced Carbon Footprint: Incorporates up to 55% recycled content, cutting down on carbon emissions.
• Recyclable and Circular-Friendly: Designed to be fully recyclable, promoting circularity and a more sustainable future.

‍

Compliance position

‍

For UK and EU brands, this matters. Under PPWR, recyclable mono-material structures qualify for the highest Design for Recycling (DfR) grade (Grade A), which translates to lower EPR fees.

Under UK EPR, the same logic applies via RAM scoring. A mono-material structure rates significantly better than the multi-material structures it replaces.

‍

For US brands, it carries a How2Recycle Store Drop-off classification where soft plastics infrastructure exists.

‍

Packaging styles

‍

This material is ideal for a range of packaging styles, including:

This material is also optimised for roll stock and high-speed production lines, thanks to a modified outer layer with rigidity similar to conventional materials.

‍

MOQ: 10,000 units

‍

‍

Technical specifications

‍

Water vapour transmission rate (WVTR): ≤0.50 g/m²/24hr

‍Oxygen transmission rate (OTR): ≤0.50 cm³/m²/24hr/0.1MPA

‍

How we made it work

‍

Two key technological advancements paved the way for this high-barrier mono-material laminate:

1. Advanced Metallisation Technology: An ultra-thin metallised coating strengthens resistance to moisture, gases, and light, delivering excellent product protection while maintaining recyclability.
   ‍‍
2. Enhanced LDPE Technology: The outer layer undergoes a special treatment to boost strength and durability, allowing smooth integration with high speed production lines.

‍

The honest trade-offs

‍

Cost is higher than conventional metallised PET. Recyclability depends on local soft plastics infrastructure (UK kerbside rollout under Simpler Recycling, US store drop-off, AU REDcycle replacement schemes). For brands selling into multiple markets, the recyclability claim needs to be qualified by region.
‍

For CPG brands currently using metallised PET who want a recyclable upgrade without changing shelf life or production line, this is the most direct path we've found.

‍

‍

Moving towards a more sustainable future for flexible packaging
‍

High-barrier, recyclable laminates mark a big step forward for sustainable packaging. Offering the barrier protection demanded by various industries, this innovation is designed to reduce environmental impact and promote a circular economy. As the packaging industry advances, these kinds of solutions are key for brands committed to sustainability.

‍
‍

Ready to explore what this material can bring to your products? Contact our team today for more information.