Abhay Avadhani's Interpack Diary Day 4

The relentless push toward circularity driven by PPWR and EPR mandates has made sustainable films the star of Interpack in Dusseldorf. While the buzz often centres on compostable or biodegradable films, the engineering breakthrough I’ve spotted is the overhaul of conventional films to achieve true, high-performance recyclability through mono-material structures. The war on multi-layer plastics is in full swing.

Cosmo First, a specialty film player, is leading the charge by fundamentally redesigning some of the industry’s most challenging materials. Their SSPF-0 High Shrink PET Film is a good example of this pivot. This transverse-oriented PET film is designed to be 100% recyclable, positioning it as an eco-friendly alternative to non-recyclable PVC and PETG. Crucially, the film is compatible with existing PET bottle recycling streams and supports de-inking processes, successfully bridging the gap between performance (up to 75% transverse direction shrinkage) and circularity.

The focus shifts to mono-material laminates for snacks and confectionery, where complexity traditionally hinders recycling. Readers of WhatPackaging? magazine will recall that Cosmo First has developed new solutions to replace multi-material structures typically containing problematic layers like MET PET and PE. These are the high seal strength metallised BOPP Film (C1-CD-010): This film is designed to serve as both a barrier and sealant layer in multi-layer structures, offering enhanced seal strength (1500 g/in). By replacing MET PET, it facilitates the creation of fully mono-PP based laminate structures, making them recyclable and highly sustainable.

Then there is the high barrier metallised CPP film (C1-CD-011): This metallised cast polypropylene (CPP) film is engineered to replace both metallised BOPET and PE layers. The result is a simplified, recyclable polyolefin-based solution for biscuits and snacks that maintains high barrier properties (OTR < 30 cc/m2/day) and processing efficiency.

I spoke to an industry expert, and he said, "Even as the industry strives for simplified structures, high barrier performance cannot be sacrificed, especially for shelf-life-sensitive food products."

In this connection, what captured my attention was Toppan’s new 28MPUSOBZ. This is a white cavitated metallised BOPP filmwhich demonstrates that achieving an Ultra-High Barrier (WVTR and OTR rated at an industry-leading 0.10) is possible in next-generation films. Engineered with a unique metallised high-gloss surface and a pearl-finish white cavitated core, this film ensures durability, superior shelf life, and a low Seal Initiation Temperature (95°C) for high-speed lines.

The message from InterPack is clear: for sustainable flexible packaging, the immediate future is less about relying purely on a single "biodegradable" solution, and more about achieving genuine, high-volume recyclability through advanced mono-material and recycling-stream-compatible film technologies.