Bandera and ExxonMobil Signature Polymers have jointly developed a mono-material polyethylene (PE) pet food pouch designed for recyclability by replacing conventional PET-based substrate films with a PE alternative produced on standard blown film extrusion equipment. The development demonstrates an approach to creating recyclable flexible packaging without requiring machine direction-oriented (MDO) film technology.
The case study combines Bandera’s blown film extrusion technology with ExxonMobil Signature Polymers’ PE materials to produce a full PE pouch intended for pet food packaging. While MDO PE films can improve mechanical, barrier and optical properties, their adoption typically requires investment in specialised processing equipment. The new solution instead utilises conventional blown film extrusion lines to achieve comparable performance characteristics for printing and lamination.
According to the companies, the substrate film was manufactured on a conventional Bandera blown film extrusion line, producing a non-oriented PE film with high stiffness, optical clarity and dimensional stability at elevated temperatures. These properties are important during downstream converting processes, including printing and lamination, while enabling the replacement of PET in mono-material pouch structures designed for recyclability.
For the sealant layer, the partners produced an EVOH-containing film on a Bandera Barrier FLEX® extrusion line using ExxonMobil Signature Polymers’ Exxtra™ Seal enhanced polymer. The sealant film provides a broad sealing window while maintaining the functional requirements of flexible packaging for pet food applications.
The innovation focuses on enabling converters to manufacture PE mono-material pouches using conventional blown film extrusion technology rather than investing in dedicated MDO production lines. This approach could reduce barriers to producing flexible packaging structures intended to support recycling where appropriate collection, sorting and recycling infrastructure exists.
The companies noted that the pouch was designed with features intended to support recyclability. Actual recyclability, however, depends on local collection, sorting and recycling infrastructure, as well as the condition and configuration of the packaging after use.