Mono-material polypropylene ultra-high barrier film for recyclable OTC unit doses
AIMPLAS is developing a recyclable mono-material polypropylene film with an ultra-thin EVOH barrier layer for single dose packaging, ensuring high barrier performance and recyclability. This solution supports circular economy goals by offering a sustainable alternative to non-recyclable laminates.
Overview
The mono-material polypropylene (PP) ultra-high barrier film is an innovative packaging solution designed for over-the-counter (OTC) unit doses. This recyclable film combines a thin EVOH barrier layer, enhancing its barrier properties while maintaining compatibility with existing recycling systems. The film is designed to meet RecyClass guidelines for recycling in the PP stream, ensuring it supports circular economy initiatives by reducing the use of virgin plastics. This solution is compatible with conventional form-fill-seal (FFS) lines, working efficiently at temperatures between 120–200 °C, offering a cost-effective and sustainable alternative to complex non-recyclable laminates.
Technical specifications
- Mono-material design: Constructed primarily from polypropylene with an ultra-thin EVOH layer (<5% by weight) for enhanced barrier properties.
- Enhanced barrier options: An optional PVOH water-based coating can be added to further improve barrier performance without affecting recyclability.
- Compatibility: Designed to work seamlessly with existing FFS lines operating at 120–200 °C.
- Sustainability: Fully recyclable in the PP stream as per RecyClass guidelines, supporting waste management systems and circular economy goals.
- Validation process: Extensive in-house validation covering the full packaging value chain, including polymer synthesis, compounding, co-extrusion, sealing, thermoforming, and recycling.
Technology readiness level
This solution is at Technology Readiness Level 6, having been validated in relevant environments. Future phases involve industrial trials and optimization to ensure performance and sustainability targets are met.
About AIMPLAS
AIMPLAS is an independent, non-profit applied research and technology organization in Valencia, serving industry as a sector-focused institute with extensive labs, pilot lines, and certification capabilities. Based on a technology‑park campus, it delivers contract R&D from formulation and prototyping to pre‑industrial trials, with co‑located teams that speed iteration. Accredited laboratories provide compliance testing and regulatory guidance, while industry consortia, training, and short courses connect companies to talent and standards work. Research is supported by competitive European and national funding alongside member and contract revenues. A dedicated technology transfer function supports IP strategy, licensing, and routes to commercialization.
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