Borstar®-based Full PE Laminate solution improves recyclability of flexible packaging materials

Borealis and Borouge, leading providers of innovative, value-creating plastics solutions, announce the introduction of a step-change concept in flexible plastic packaging, the Full PE Laminate solution. Based on the proprietary Borstar® bimodal polyethylene (PE) technology in combination with machine direction oriented (MDO) processing technology, this novel monomaterial solution offers a second life to PE-based packaging as valuable end products, without compromising on product efficiency or integrity. Developed and tested in cooperation with a consortium of leading partners along the value chain, the Full PE Laminate solution is now being showcased at the K Fair 2016 in Düsseldorf.

Flexible packaging and recyclability: the status quo
Flexible plastic packaging, typically in the form of stand-up pouches, films, bags, liners, or wraps, is one of the fastest growing segments of the packaging industry. Flexible packaging helps safeguard the quality and safety of consumer and industrial products, but also fulfils consumer demand for value-added functionality and convenience. Compared to rigid packaging alternatives such as glass and metal, flexible plastic packaging demonstrates better performance when it comes to sustainability parameters such as lower overall carbon footprint.

Yet up until now, a significant drawback in flexible plastic packaging involved its complex structure. While rigid materials are primarily monomaterial-based (e.g. entirely of glass, aluminium etc.), flexible materials have traditionally been multimaterial. This makes recycling less efficient and therefore less attractive. What is more, multimaterial recyclate is of only limited use, for example in lower-quality moulded applications.

A second life for polyethylene-based flexible packaging materials thanks to Borstar
Borealis and Borouge, in cooperation with leading partners along the value chain, now present a sustainable solution to the complex issue of inferior recyclate: a monomaterial PE for flexible packaging based on the proprietary Borstar bimodal technology in combination with MDO processing technology.

Packaging solutions of Full PE Laminate are as efficient in terms of performance as other flex pack structures and serve as 100% substitutes for multimaterial film solutions in pouches and packs. Most compellingly, the recyclate gained from Full PE Laminate packs can be used for valuable end products with no loss in efficiency, and can even be used to produce PE film products.

The production-related advantages are also persuasive:
Very high stiffness, at levels found only in conventional substrates
Excellent toughness and abuse resistance
More efficient operations in the MDO process itself, and film of especially high quality
Resulting film is easy to print, laminate and convert for demanding packaging applications such as stand-up bags and pouches.

“Borealis and Borouge believe that plastics are too valuable to be thrown away and should be recycled for a second, third or even fourth life,” explains Anton Wolfsberger, Borealis Head of Marketing Consumer Products and Pipe. “Making flexible packaging more recyclable goes a long way to improving overall environmental performance. By leveraging our proprietary Borstar technology and working closely with our valued partners, we have been able to further enhance the life cycle attributes of flexible packaging.”

The path to a second life: partnering with experts along the value chain
Developing the Full PE Laminate solution has been a joint effort among Borealis, Borouge and a consortium of leading firms across the value chain, each representing the most advanced expertise within their respective areas.

Borealis and Borouge: the combination of the proprietary Borstar bimodal PE technology and Borealis resins forms the foundation of PE films with excellent performance characteristics, efficiency, and pleasing aesthetics.

Source: Borealis