Innovia Films has produced white, cavitated BOPP film using PureCycle’s recycled polypropylene resin, unlocking over 40% post-consumer recycled content for food-contact applications.
The film uses a specially formulated one-pellet version of PureCycle’s PureFive Choice resin grade, specifically engineered for film applications.
All PureFive resins are produced through PureCycle’s patented dissolution recycling process, which removes colour, odour, and contaminants from post-consumer polypropylene to prepare recycled resin for a broad range of end uses.
During the trial process, Innovia conducted process evaluations to assess resin behaviour across the full cavitated BOPP production sequence.
Reportedly, the PureFive Choice resin yielded similar results to the virgin polypropylene resins currently used in commercial applications, including comparable mechanical, barrier, and sealing properties.
Traditionally, market players have faced a shortage in high-quality and/or food-contact post-consumer recycled content for use in film and flexible applications.
By incorporating PureFive resin into their soft packaging, converters and brand owners are expected to align with legal requirements without impacting performance or processability.
This includes the Packaging and Packaging Waste Regulation’s mandatory recycled content targets for plastic packaging and the virgin plastic reduction mandated in California’s SB 54.
Like its traditional counterpart, Innovia and PureCycle’s BOPP film is set to offer mechanical performance and moisture barrier properties alongside light weight, opacity, printability, and a ‘paper-like’ texture.
The new film is anticipated for use in conventional food-contact applications for white, cavitated BOPP films, including confectionery products and roll-fed labelling.
“This film produced with PureFive resin represents a major milestone and shift in the sustainability of flexible packaging,” said Chris Freshwater, market manager at Innovia Films. “Our research and development specialists are always looking to improve the sustainability of our products.
“PureCycle’s dissolution recycling technology is a real gamechanger. Not only are we introducing post-consumer recycled content to our films, but we’re doing so with an energy-saving recycling technology.”
“The successful production of white, cavitated BOPP film is a major step forward for PureCycle and for the flexible packaging industry,” said Pete Dias, senior director of Market, Product, and Application Development at PureCycle. “This film can be found all over your grocery store, whether it’s in the candy aisle, an ice cream freezer or on snack shelves.
“Brand owners have been searching for a way to incorporate certified recycled content without compromising performance or appearance. By working with Innovia, we have demonstrated that our PureFive resin for film is up to that challenge and strengthens our conviction that PureCycle can serve as a foundational PCR supplier for the global flexible packaging market.”
In other news, Smart Planet Technologies has designed its HyperBarrier PE film to be recyclable in the polyethylene stream and align with the Packaging and Packaging Waste Regulation. It is also said to deliver 300 times the oxygen barrier performance of a standard PE film, and to improve its moisture barrier performance.
Also, Mondi has launched its 35% post-consumer recycled re/loop FlowWrap solution for wet wipe packaging. This format is expected to replace non-recyclable laminates for personal care applications requiring a customizable barrier.
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