ExxonMobil Signature Polymers has collaborated with Windmöller & Hölscher, B&B and Henkel to develop a recyclable mono-material polyethylene pouch for flexible packaging applications. The development addresses industry efforts to replace multi-material structures, including PP/PE and BOPP-based laminates, that present challenges for mechanical recycling.
The project aligns with increasing regulatory pressure, including requirements under the EU Packaging and Packaging Waste Regulation, which prioritises packaging formats designed for recyclability while maintaining functional performance. The partners focused on achieving stiffness, optical quality and mechanical strength within a polyethylene-only structure.
Windmöller & Hölscher applied its machine direction orientation technology to produce a 25 μm MDO PE film. The oriented substrate was designed to deliver clarity, printability and stiffness comparable to conventional BOPP films, while enabling downgauging. This film was laminated to a five-layer PE sealant web formulated using resins from the ExxonMobil Signature Polymers portfolio.
Henkel supplied a polyurethane adhesive compatible with polyethylene recycling streams, allowing the laminated structure to remain mono-material. The laminate was converted into stand-up pouches by B&B using its STBB 8K converting equipment, demonstrating stable processing and consistent output.
Testing showed that the finished pouch maintained high stiffness at elevated temperatures, strong seal integrity and clear visual appearance. Drop testing recorded full survival from a height of two metres, indicating sufficient mechanical robustness for distribution and handling. The collaboration illustrates how coordinated material, process and converting developments can support recyclable flexible packaging solutions without compromising line efficiency or established production.