The demand for convenience foods continues to rise, with Statista.com projecting an annual growth rate of 6.51% in the global market from 2024 to 2028.
This growth is significantly supported by a range of innovative packaging solutions tailored for convenience products. For instance, film overwrap trays enhance product presentation on shelves while also preserving freshness and extending shelf life. Fresh produce, which is typically sold loose, can be grouped in trays that protect them from handling and damage.
Moreover, cling film acts as a barrier to isolation, containing odors and preserving flavor integrity. Additionally, this type of packaging enhances hygiene and food safety, minimizing the risk of cross-contamination—a crucial factor given the rising concerns surrounding food allergies.
The Necessity for Sustainable Alternatives
Historically, polyvinyl chloride (PVC) film has been the preferred material for food and drink packaging due to its flexibility, strength, and clarity for packing fresh items.
However, as manufacturers, retailers, and consumers increasingly prioritize sustainability in their packaging choices, the recyclability of PVC has come under scrutiny. Legislation is also evolving to enforce requirements for broad recyclability. Notably, recent amendments to the EU’s Packaging and Packaging Waste Directive aim to ensure that all packaging in the EU market is recyclable in an economically viable manner by 2030.
The Challenges of PVC Recycling
Recycling PVC poses challenges due to its complex composition, requiring specific low melting and processing temperatures, which makes it incompatible with other commonly used polymers in packaging, such as polyethylene (PE), polypropylene, and polyethylene terephthalate (PET). Even minimal amounts of PVC can degrade during processing with these other polymers, leading to the production of hazardous constituents, such as hydrochloric acid and chlorine, which can corrode processing equipment and make recyclates unusable.
Consequently, PVC necessitates a dedicated waste collection stream to maintain the quality of kerbside and front-of-store waste streams. Unfortunately, the current infrastructure for collecting and sorting PVC films remains limited across European markets.
This reality urges food and drink packaging companies to seek alternatives that deliver similar benefits to PVC but with a greater environmental focus.
The Pursuit of Alternatives
Switching to recyclable PE film for overwrapped trays presents one potential solution, ensuring a more consistent supply of used film. However, PVC possesses specific advantages that have solidified its status as the go-to material for stretch film applications, in addition to the general protective and presentation benefits offered by plastic film.
A standout feature of PVC is its uniform stretch, which caters to products of various shapes and sizes while retaining excellent clarity without unsightly marks or blemishes. Packs can endure multiple handling sessions without showing finger dents, thus ensuring exceptional shelf presentation.
Therefore, any alternative film must effectively replicate the advantages of PVC. Equally, it is imperative that they are compatible with current wrapping machinery to avoid requiring additional investments from manufacturers.
Encouragingly, work is already underway. As countries implement legislation aimed at enhancing packaging sustainability, the industry has been addressing these challenges for years.
Efforts to identify and develop alternatives to PVC film have been a central focus of ongoing technical development. At Berry, for instance, we began exploring this challenge in 2019.
A PE Solution
This initiative leveraged our extensive experience with PE films. The material already exhibited essential characteristics, such as impact resistance and clarity, which we enhanced through technical expertise to improve stretching behavior and elastic recovery.
The outcome is our Omni Xtra+ low gauge, recyclable PE film, designed to merge the beneficial properties of both PVC and PE. This film not only matches the strength, stretchability, and clarity of PVC but also maintains PE’s remarkable puncture resistance.
Furthermore, the new film boasts improved memory properties, reducing the likelihood of finger marks during handling.
Recyclability
Importantly, Omni Xtra+ film aligns with retailer demands and emerging legislative requirements by being fully recyclable within European kerbside and front-of-store PE waste streams. This film also represents a significant reduction in material usage compared to PVC, achieving over 25% weight reduction through density improvements. Additionally, Omni Xtra+ film’s enhanced mechanical properties facilitate the creation of a thinner film while retaining strength and resistance to puncturing.
While PVC remains a strong option for fresh food applications, increased attention from manufacturers and consumers toward sustainable packaging has highlighted its drawbacks and sparked the demand for viable alternatives. The introduction of recyclable PE films such as Omni Xtra+ offers a groundbreaking solution that combines the performance attributes of PVC with the durability of PE, signifying a pivotal innovation for the food and drink packaging industry.
