Packaging: ExxonMobil develops thermoformed packaging with 95% PE content

ExxonMobil develops thermoformed packaging with 95% PE content

US materials firm ExxonMobil, working with key partners, has developed a fully recyclable thermoformed packaging featuring 95% polyethylene (PE) content. Targeted at hot fill and aseptic applications in the food and beverage sectors, the new packaging design is said to offer a high oxygen barrier, excellent optics and enhanced puncture resistance while maintaining optimised formability.

The packaging comprises a thermoformed bottom web and machine direction oriented (MDO) PE lid film, both engineered with the company’s premium resins such as Exceed XP, Enable and Exact plastomers, along with Eval Evoh resins for barrier properties.

The barrier lines were developed by Germany-based machinery firm Hosokawa Alpine Group for the production of these films, delivering what ExxonMobil calls a “durable and recyclable solution that meets modern packaging requirements for sustainability without sacrificing performance.”

To further enhance the packaging’s environmental credentials, ExxonMobil says its design minimises material usage while still offering superior protection and sealing properties. By reducing the overall weight and maximising recyclability, the company says its new solution not only supports sustainability goals but also helps converters and brand owners meet increasingly stringent regulations on plastic packaging scrap and recycling targets.

The new packaging was successfully tested on Germany-based Multivac’s R245 machine, ExxonMobil says, achieving “excellent” machinability with high line speeds and ensuring the integrity of the package even under rigorous conditions.

“This innovation aligns with the industry’s shift toward more sustainable, circular packaging solutions that reduce environmental impact while ensuring product protection,” the company says.

Packaging with recycling potential in China

Elsewhere, in China, ExxonMobil worked with Chinese converter Huangshan Novel Co Ltd to develop a solution that would help address the problem of recycling multimaterial flexible packaging waste.

While improving potential for recycling, Huangshan Novel needed to make sure that packaging performance is maintained or even boosted.

ExxonMobil worked with Huangshan Novel to test formulations of stand-up-pouches (SUP) made of MDO PE//PE laminate film including ExxonMobil’s Exceed XP and Exceed 2012 performance PE.

The films showed high stiffness and good optical performance, as well as “outstanding” bag drop and package integrity, satisfying end users’ needs for packaging performance, while helping them deliver sustainability benefits due to the mono-material structure that can improve recyclability.

Compared to conventional laminated films, the MDO PE//PE show equivalent optics vs. BOPP//PE film, and similar stiffness to BOPP//PE and BOPA//PE films.

During the bag drop test from 1.5 m height, better performance than that of BOPET//PE film and equivalent to BOPA//PE film is demonstrated, says ExxonMobil.

“Exceed XP performance PE’s extreme performance, such as tensile strength, is critical for smooth MDO production. Together with medium density Enable 4009, the substrate film made using the MDO process can provide excellent stiffness and optical properties for shelf appeal; while the sealant film based on Exceed 2012 provides low SIT and high seal strength for package integrity. The performance of MDO PE//PE SUP is well-proven on packaging lines and in transportation tests,” said Wang Changchun, Deputy General Manager of Huangshan Novel.

The full PE solution has been commercialised and the Chinese company says it is receiving “positive market feedback with interest from more and more brand owners”.

Wang added, “Due to the increasing global demand for packaging that can be recycled, for example the strong regulatory drive for ‘design for recyclability’ in Europe, we believe it has great potential in flexible packaging for food, dairy, pet food and personal daily care products, and will significantly help improve our competitiveness in both domestic and export business.”

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