Polyurethane dispersions for mono material packaging

Innovation stands as our best ally in the global challenge against plastic waste. Polyurethane dispersions (PUDs) have emerged as a game-changing technology, offering a pathway towards simpler, recyclable mono-material packaging.

PU dispersion not only meets environmental demands, but also upholds the performance and protection expected of traditional packaging. Discover how products from allnex ECOWISE™ CHOICE range can offer innovative sustainable packaging solutions with excellent barrier properties.

400 million tones

of plastic are produced globally each year

~4 million t 

cf flexible packaging in EU alone

~ 1 million t 

considered to be non-recyclable

Plastic waste has evolved into a significant global concern in the 21st century. The magnitude of the challenge is clear, with an annual production of approximately 400 million tons of plastics worldwide. Europe alone produces roughly 4 million tons of flexible packaging, a quarter of which is deemed non-recyclable. A mere 18% of this plastic waste enters the recycling stream. This low recovery rate has led to a substantial accumulation of plastic waste.

The current growth rates in recycling are not promising. Projections suggest that even by 2050, we will only achieve a 46% global recycling rate. This rate falls short of the carbon-neutral targets set by numerous organizations and governments worldwide. With recycling rates reaching a plateau at around 80%, further improvement becomes a challenging endeavor.

One way to address plastic waste is by increasing consumer awareness. Heightened understanding of environmental issues has prompted end-users, brand owners, packaging designers and converters to adapt their products and practices. Non-governmental organizations (NGOs) also play a crucial role in educating consumers about the global impact of plastic waste.

Industry and non-governmental organisation (NGO) led initiatives have emerged to promote a circular economy and tackle plastic waste. The aim of initiatives such as Packaging Recovery Organizations (PRO) is to ensure the reuse, recycling and reduction of packaging waste by developing more sustainable packaging solutions. CEFLEX is a collaborative industry initiative that aims to redesign packaging to improve its recyclability and create a circular economy for plastic packaging.

Governments worldwide are stepping up to the challenge by implementing taxes and regulations that limit the production and distribution of certain plastic products. Companies must consider these legislative changes when designing and producing packaging materials. Specific regulatory measures such as the EU Green Deal, UK Packaging Tax, and Swiss VOC Tax each have a unique impact on plastic waste management and sustainable packaging design.

The availability and environmental impact of raw materials play a critical role in addressing the plastic waste issue. The ongoing global crisis has affected the supply of these materials. New sources of raw materials are being explored, such as bio-based, renewable and recycled materials. Bio-based raw materials present a more sustainable alternative but do not guarantee the recyclability of packaging. Additionally, the challenges of incorporating recycled waste streams into packaging materials lie in determining the appropriate use cases and whether downcycling is necessary.

Addressing the plastic waste challenge requires a commitment to circularity in the value chain, where materials are reused in the same applications rather than being downcycled. This approach includes strategies like Extended Producer Responsibility (EPR), which incentivizes the industry to adopt sustainable practices. The goal is to create an ecosystem where design, collection and recycling are integrated, leading to a more sustainable future.

Maintaining the functional requirements of flexible packaging is a requirement for the packaging industry’s move towards a circular economy.

Currently, multi-substrate layers consisting of different types of plastics are used to provide mechanical resistance and barrier properties.

These layers need to preserve nutrition, taste, and consistency of the packaged products while keeping out water, sunlight (UV), and air pollutants. allnex technology offers innovative solutions for sustainable packaging materials while maintaining performance and protection properties. This contribution is crucial in the development of more eco-friendly and circular packaging solutions that align with consumer demands, retailers, and regulatory bodies.

The latest developments within the ECOWISE™ CHOICE range by allnex stands as a beacon of sustainable packaging design. Polyurethane Dispersions (PUDs) offer a range of features and benefits.

The concept of mono-material packaging is gaining ground in the pursuit of a circular economy.

This design strategy involves creating packaging materials from a single type of material, vastly simplifying the recycling process. allnex’s PU Dispersions are instrumental in facilitating this shift. By replacing various barrier coatings found in multi-substrate packaging, PUDs enable the creation of mono-material packaging without sacrificing the functional requirements of flexible packaging.

Through innovative technologies like Polyurethane Dispersions (PUDs), allnex is driving a shift towards sustainable, efficient and recyclable packaging. We are committed to leading this change, aligning with the principles of the circular economy and offering solutions that meet the functional requirements of packaging.

Together, we can create a future where packaging is part of the solution, not the problem. Contact an allnex expert today to learn more.

Let’s answer some of the most frequently asked questions about polyurethane dispersions and their role in sustainable packaging solutions: 

The following article is from a webinar between Daria Samonova (Corporate communications manager, allnex), Andreas Jansen (International Project Manager for Adhesives & Lamination, allnex) and Tom Vanheertum (Marketing Manager, allnex). For the full presentation, please see the video above.