Coveris has expanded its MonoFlexLite E portfolio - made with a single-layer polyethylene material - to include a recyclable solution with up to 45% PCR content, designed for wet wipe and cosmetics applications. To find out more about this solution, we spoke to Philipp Niehues, business development director at Coveris.
Can you provide a general overview of this product for readers who might not be familiar with it?
As part of our MonoFlex packaging portfolio, we are expanding our established MonoFlexLite E family of high-performance packaging solutions based on a single-layer polyethylene material. Building on the successful adoption of MonoFlexLite E for free-standing pet food bags, we are now extending the portfolio with a dedicated solution tailored for cosmetics and wet wipes.
How does this product compare with market alternatives?
This product is designed to meet PPWR targets without compromising performance. It is recyclable and integrates up to 45% PCR content, thereby exceeding mandated PPWR rates.
Additionally, by utilizing a surface printing solution, we facilitate the generation of high-quality PCR once the product has been used and collected. This connects directly to our unique ReCover capabilities, where we actively de-ink materials on our state-of-the-art lines to support effective recycling workflows.
Could you give us some insight into the R&D process?
At Coveris, our R&D process is guided by full value chain thinking. Rather than looking at the packaging in isolation, we analyze the entire lifecycle to identify the ideal PCR grade for this specific application.
Addressing the challenge of PCR integration – including comprehensive challenge testing to fulfill cosmetic grade requirements – was the central focus for our teams. By understanding every step from waste collection to final processing, our R&D experts combined our material science expertise with practical recycling insights to create a viable, high-performance solution.
What were the main challenges/obstacles you encountered during the development of this product, and how were they overcome?
There are two main challenges when talking about PCR integration. The first is selecting the right PCR grade that complies with the regulatory requirements for cosmetic applications.
The second is developing a base structure enabling the integration of such PCR while maintaining the necessary mechanical and packaging line performance. We overcame these obstacles by using our recycling knowledge and collaborating closely across the value chain to ensure the material performs reliably.
What does the future hold for this solution, and how do you plan to scale it commercially?
To support the PCR transition and transform more products, we are transferring this knowledge to further wet wipes segments, application areas, and non-contact sensitive fields. This enables us to work alongside retailers and international drugstore chains to offer circular wet wipes packaging.
Together with our waste management partner, Interzero, we are implementing a closed-loop system: we take back the post-consumer waste from these partners, utilize our processing and de-inking expertise to recycle it, and bring it back into the production of our wet wipes film products.
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