Walki and Dow’s mono-material MDO-PE pouch with a matte finish is set to unlock recyclability and high performance for frozen food packaging in compliance with the Packaging and Packaging Waste Regulation (PPWR).
After the PPWR entered into force last year, brand owners are reportedly looking for lighter, more material-efficient replacements to their rigid packaging formats.
Walki and Dow have jointly developed a flat-bottom pouch prototype made from MDO-PE, initially filled with frozen gyoza dumplings and showcased at interpack 2026. Other potential applications include dry food products like cereals, as well as fresh food in modified atmosphere packaging applications.
The pouch is said to be suitably strong and stiff to meet market demands while also providing ‘excellent’ runnability on existing packaging lines. This is hoped to streamline the transition for food brand owners revising their packaging to comply with the new legislation.
To overcome the heat sensitivity of the film’s MDO layer, the partners have applied a sealant layer made from Dow’s polyolefin plastomers. This approach is said to reduce film blocking, improve machinability, improve performance on high-speed packaging lines, and facilitate robust sealing.
“Dow’s AFFINITY Polyolefin Plastomers are specifically designed to activate and seal at low temperatures, making them fully compatible with the heat-sensitive MDO layer,” explains Ksenija Maksimovic, senior TS&D specialist at Dow Packaging & Specialty Plastics EMEA.
“This enables a higher extrusion output, equipment efficiency, and overall cost savings when producing recyclable packaging.”
When combined with a PE-based sealant film, the pouch becomes an all-PE laminate that claims to align with the PPWR’s design-for-recyclability guidelines.
Due to its clarity, stiffness and barrier performance, the MDO-PE pouch is expected to replace traditional print web films such as oriented polyester.
While MDO films traditionally offer a glossy surface, the pouch’s matte finish is expected to provide a premium finish and help brands present their products as high-quality meals, rather than convenience products.
Walki and Dow also underline the pack’s high-quality printability, which is set to enable product differentiation at point of sale – especially as supermarkets increasingly replace open freezer cabinets with transparent glass-door freezer systems.
“There has been a need for a solution that delivers the functional performance of MDO-PE but with a premium matte appearance,” says Juan Angel Ruiz Salazar, R&D manager at Walki Plasbel.
The material was tested for printing, lamination, and finishing processes on production lines at Walki Plasbel’s plant in Murcia, Spain. The samples were also sent back to Dow Tarragona Pack Studios for further evaluation.
Jonas Skuthälla, head of Sales for Flexible Packaging at Walki, adds: “When designed for circularity, plastic packaging plays a critical role in extending shelf life and preserving food quality.
“Rather than asking which material is ‘better’, the priority is to keep materials in use and within the loop. In food packaging, maintaining product quality and reducing food waste is essential to minimise emissions.”
In another development, Dow worked alongside Macchi and ITP to create a mono-PE pouch prototype containing over 50% chemically recycled content. Intended as a recyclable pack for snacks and other highly regulated products, the pouch aims to lessen reliance on virgin resources while providing a gas- and moisture-resistant material suitable for direct contact with food products.
Meanwhile, Gualapack Ukraine’s flat bottom and side gusset pouch formats are intended for optimal shape use, the ability to stand upright regardless of content level, and enhanced user convenience. Both formats are also available in mono-material structures, which is hoped to support recyclability and help brands meet EU sustainability goals.
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