Colloquia

Summary

In response to the EU Packaging and Packaging Waste Regulation (PPWR) and its drive for improved packaging circularity, including increased recycled content in packaging by 2030 and 2040, this research evaluates how post-consumer recycled (PCR) polyolefin films can be formulated and processed to achieve reliable sealing performance for flexible packaging applications. Conducted within the CIFLEX–OPZuid project, the work focuses on linking material design choices and processing conditions to practical performance outcomes relevant to industry.

The research investigates how changes in blend formulation (including PCR content, blend composition and the use of a sealant additive) influence film quality and sealing behaviour, and how the addition of antioxidants and compatibilisers can support performance in monolayer Polyethylene (PE) films. Contaminant information was acquired and gels were quantified, then linked to hot-tack and cold-tack insights and tensile material behaviour. This enabled correlations to be drawn between PCR percentage, gel content and processing parameters, which were then translated into practical sealing and processing guidance.

Broadly, higher PCR loading and changes in blend ratio measurably affected film quality and sealing performance, typically narrowing or shifting the sealing temperature window. Antioxidants were generally beneficial for improving material stability and maintaining more consistent behaviour during sealing. Compatibilisers and the sealant additive showed potential to improve film quality and support sealability across the sealing temperature range.

Overall, these findings were used to inform Design-from-Recycling guidelines that help converters meet PPWR-driven circularity targets without compromising seal integrity.