Reducing packaging weight while preserving performance continues to be a key priority for flexible packaging converters.
Through a joint development involving Borealis, Hosokawa Alpine, HP Inc., Leygatech, Bostik, Nordmeccanica and Karlville Swiss, a mono-material PE pouch structure has been developed with a 10% reduction in total packaging weight. This result is achieved through the combination of a 15-micron MDO PE film and an optimized solvent-free lamination process using optimized coating weight.
Suitable for applications such as dry food, personal care and home care, the structure demonstrates how incremental material savings, when scaled, can significantly enhance resource efficiency.
A downgauged mono-PE pouch structure
- A 15-micron MDO PE film manufactured on a Hosokawa Alpine MDO line, using advanced Borstar® technology PE resins from Borealis, replacing the conventional 25-micron layer typically used in similar structures
- A solvent-free laminating adhesive from Bostik, applied with an optimized coating weight to minimize adhesive usage
- A 75-micron PE sealant film provided by Leygatech, delivering strong mechanical properties combined with low temperature sealing
By combining downgauged film with optimized adhesive application, the structure achieves an overall 10% reduction in packaging weight.
Although a 10% reduction may appear limited at the level of a single pouch, the cumulative effect becomes substantial when extended to high production volumes.
Next steps
Further downgauging opportunities may be considered, particularly through reducing sealant film thickness depending on converter requirements.
The partners are currently working on similar mono-PE pouch structures incorporating barrier functionalities, with the aim of extending this approach to applications requiring enhanced product protection while maintaining a PE-based structure.
Designed with converter requirements in mind
The structure has been developed to support efficient converting and pouch production through several key features:
Resource efficiency through optimized adhesive usage
The solvent-free laminating adhesive from Bostik is applied with an optimized coating weight, reducing overall adhesive consumption while maintaining required lamination performance.
Excellent processability during converting
The combination of the 15-micron MDO PE film and the PE sealant film ensures stable and reliable processing during lamination and pouch-making operations.
Solvent-free adhesive technology
The lamination process uses a solvent-free adhesive system already widely implemented in flexible packaging production. The adhesive is RecyClass-certified and currently used in various commercial applications.
High-quality digital printing enabling premium aesthetics
Printing was performed using the HP Indigo 200K Digital Press (HP Inc.), delivering high-quality digital results suitable for premium packaging. The structure was produced using Enhanced Productivity Mode (EPM), enabling CMYK-equivalent output while eliminating black ink, contributing to reduced energy consumption and a lower CO₂ footprint per square meter.
HP Indigo LEP inks for packaging comply with CEFLEX recyclability guidelines.
Collaboration across the packaging value chain
- Resin supply – Borealis Provided the polyethylene resins used in the 15-micron MDO PE film.
- Film production – Hosokawa Alpine Supplied the extrusion and MDO technology required to produce the thin MDO PE film.
- Printing – HP Inc. Responsible for digital printing of the structure using the HP Indigo 200K Digital Press.
- Sealant film – Leygatech Delivered the PE sealant film used in the pouch structure and is also active in MDO and barrier films.
- Adhesive technology – Bostik Supplied the solvent-free laminating adhesive applied with optimized coating weight.
- Lamination – Nordmeccanica Lamination was performed using a Nordmeccanica laminating machine. A global leader in lamination and coating, Nordmeccanica drives higher converting efficiency while promoting sustainable packaging and reduced material usage.
- Pouch manufacturing – Karlville Swiss Converted the laminated structure into finished pouches.
