New mono-material PE film aims to enhance recyclability in bread packaging without compromising performance.
ExxonMobil, in collaboration with Hosokawa Alpine and BW Converting, has developed an ultra-thin, mono-material polyethylene (PE) bread bag designed for recyclability. The initiative, part of ExxonMobil’s Signature Polymers portfolio, addresses key challenges in flexible packaging by reducing material complexity while maintaining performance.
Bread packaging, though often perceived as simple, requires a balance of tear resistance, visual clarity, and compatibility with high-speed production lines. Conventional coextruded PP/PE films, typically 30–38 microns thick, deliver on these requirements but pose limitations in recycling due to their multi-material composition.
To tackle this issue, the three companies leveraged Machine Direction Orientation (MDO) technology to produce a 25-micron mono-material PE film. This new structure is reported to match the mechanical and optical qualities of traditional PP/PE films, while offering a more streamlined path to recyclability.
ExxonMobil contributed key resins to the solution:
- Exceed™ HD 6107 supported MDO processing
- Exceed™ Stiff+ m 0238 contributed to mechanical strength
- Exceed™ Stiff+ m 0820 enhanced processability and durability
BW Converting successfully ran the ultra-thin film on its Hudson-Sharp Apollo wicketed bag machines, achieving the thinnest film ever processed on these lines. HOBA verified that the resulting bread bags are compatible with both manual and automated closing systems.
The project delivered several technical milestones, including:
- Production of 25-micron PE bread bags
- Seamless operation on dual-use lines for PE and PP bags
- High transverse-direction tear resistance suitable for crusty bread
- Optical performance comparable to PP films, with low haze levels (6–7.5)
- Anticipated durability under freezer storage conditions
This development illustrates how cross-industry collaboration can enable thinner, recyclable packaging formats without compromising functionality, aligning with broader goals for sustainability in packaging systems.