Coextruded sealing layers have a crucial role in the design for recycling of flexible packaging. By customizing the technical properties of a film, we develop the best possible solution to substitute conventional laminates. The focus is particularly on barrier and sealing properties. Ensuring recyclability reduces the choice of high-performance substrates, while product protection and machine runability must be maintained. Weighing up the various priorities, decisions often have to be made on a case-by-case basis in order to achieve a viable solution in terms of design for recycling.

In blown film extrusion, it is possible to use polyethylene based on sugar cane or bio diesel. These PE grades can be considered as drop-in solutions, which means that their property profiles are almost identical to petrochemical PE. The bio-based polyethylenes available on the market include various HDPE, LDPE and LLDPE grades. Since the plant-based raw material stores more CO2 than is emitted during granule production, its share reduces the carbon footprint of a packaging. The recycling of these PEs is comparable to that of conventional polyethylene. It is therefore 100% recyclable.

The use of regranulates made from recycled plastics is subject to certain restrictions. Only a few regranulates are approved for use in food packaging. Furthermore, the processing of regranulates is associated with corresponding requirements to prevent the mixing of virgin and recycled material within the production process. Via our blown film extrusion we produce Coex-PE with portions of mechanically regranulated PCR substrates for hygiene products as well as chemically regranulated material for food applications.

Solventless lamination is the most efficient type of bonding process for laminates. On the one hand, due to its large proportion of solids, it does not require separate drying processes, and on the other hand, comparatively low processing temperatures are needed. Therefore, this process needs less thermal energy than other lamination systems and achieves very good optical quality and high composite adhesion of the laminates.

The technological diversity at ppg > lamination also includes the possibility of producing packaging materials for aggressive products. Solvent lamination is used to produce laminates for particularly demanding requirements in terms of bond strenght and resistance. This means that even products as chemical liquids or industrial oils can be processed reliably and the tightness of the sealing can be guaranteed. Furthermore, precursors for sealing discs and blanks that require extremely high barrier can also be produced.

Among the numerous possibilities for lamination processes in the ppg > group is the use of waxes. Wax-based lamination provides composite grades with a high-quality feel and touch and very good dead fold properties. This process ensures important physical properties of the laminates while maintaining high quality standards, especially for fat products and wrapper applications.

To reduce the use of chemical products and enable materials to be bonded in the most environmentally friendly way possible, the ppg > technology portfolio also includes water-based lamination.