Packaging company Walki and materials supplier Dow have jointly developed a mono-material machine direction orientation polyethylene (MDO-PE) pouch with a matte surface for food packaging applications.
The packaging is intended to support recyclability and align with Packaging and Packaging Waste Regulation (PPWR) requirements.
The project combined the companies' technical expertise to develop an MDO-PE laminate for recycling, with the current prototype aimed at frozen food pouches.
Walki Plasbel R&D manager Juan Angel Ruiz Salazar and Dow EMEA packaging and speciality plastics senior TS&D specialist Ksenija Maksimovic have worked together on material concepts for several years.
Their latest work led to a prototype mono-material MDO-PE laminate with a matte finish.
MDO-PE can replace conventional print web films such as oriented polyester and, when paired with a PE-based sealant film, forms an all-PE laminate that complies with design-for-recyclability guidance.
Dow’s team in Spain travelled to Walki Plasbel’s site in Murcia, where the material was tested on production lines.
The samples were later returned to Dow Tarragona Pack Studios for additional assessment.
The sealing was a key technical point because the outer MDO layer is sensitive to heat once the MDO-PE film is laminated.
They said a sealant layer is needed that can bond at a low enough temperature to prevent damage to the MDO layer during sealing.
It reduces film blocking, improves machinability and has excellent high-speed packaging line performance and robust sealing.
The material is also suitable for applications beyond frozen food. The companies identified dry foods such as cereals and fresh food packaging using modified atmosphere packaging with gas as other possible applications.
Skuthälla said: “When designed for circularity, plastic packaging plays a critical role in extending shelf life and preserving food quality. Rather than asking which material is 'better', the priority is to keep materials in use and within the loop. In food packaging, maintaining product quality and reducing food waste is essential to minimise emissions.”
