Sustainability Goals Drive Interest in Mono-Materials

Mono-material packaging can combine recyclability with recycled content and other eco-attributes. © warloka79 – stock.adobe.com

Mono-material packaging can combine recyclability with recycled content and other eco-attributes.

By Tom Egan, Vice President of Industry Services at PMMI, The Association for Packaging and Processing Technologies

When working toward sustainability goals, processing and packaging professionals look for materials that are recyclable, offer the potential for recycled content, and/or are derived from renewable, bio-based sources. Mono-material structures like glass, aluminum, and steel containers, fiber-based substrates, and various plastics often can deliver one or more of these characteristics.

This is prompting phaseouts of less-recyclable materials, especially multi-material structures, according to the PMMI Material Transitioning Dashboard. This customizable tool from PMMI, The Association for Packaging and Processing Technologies, provides insight into what materials are being used in 44 industry categories, the top 10 materials being phased out, and what replacements will be most in demand during the next three to five years. To make the data more useful, the output can be tailored to an industry or business.

Environmental Attributes

With mono-material structures seen as possessing desirable environmental attributes, development efforts have been focused on innovations that can offer barrier, performance, and machinability properties equivalent to multi-material predecessors. For plastics, this is accomplished via various technologies including multilayer constructions and biaxial orientation, which can enhance toughness and tear resistance.

Market introductions have included commonly recycled plastics such as polyethylene and polypropylene in mono-material thermoforms, tubes, films, blisters, stand-up and spouted pouches, pumps, and cosmetic compacts. Many structures contain recycled content, and a few are designed to be refillable. In some cases, the materials are compatible with hot-filling and pasteurization.

PACK EXPO Southeast Showcases Sustainability Innovations

For manufacturers striving to meet sustainability goals, the inaugural PACK EXPO Southeast 2025 (March 10–12, 2025; Georgia World Congress Center, Atlanta) will serve as a premier platform to explore the latest technologies and innovations.

The show, produced by PMMI, The Association for Packaging and Processing Technologies, will feature hundreds of solutions from 500 exhibitors spread over 110,000 net square feet. Attendees will see machinery in action and the latest materials to enhance manufacturing operations for 40+ vertical markets and be able to take advantage of an array of educational and networking opportunities. Of special interest is the Reusable Packaging Pavilion, sponsored by the Reusable Packaging Association. It will highlight how reusable transport packaging products and services can reduce waste, lower costs, enhance supply chain efficiency, achieve a smaller carbon footprint, and support a circular economy.

Educational sessions include Industry Speaks where top experts from the PACK EXPO Partner Program share valuable insights on the latest industry trends and pressing topics. Representing diverse verticals, these thought leaders will explore key themes such as workforce development, remote services and monitoring, cybersecurity, and evolving industry standards.

On the Innovation Stage, leading exhibitors present free, 30-minute seminars discussing breakthrough technologies, exploring innovative applications, and delivering insights into proven strategies.

Networking opportunities (show badge required) include the Opening Reception, sponsored by Multi-Conveyor LLC and Domino North America, on Monday, March 10, from 4:00–5:30 p.m. Another event, the Young Professionals Networking Reception, targets the next generation of industry leaders. RSVP required. It will be held on Monday, March 10, from 7:00–10:00 p.m. in the entertaining, relaxing environment at Wild Leap Atlanta.

The Packaging & Processing Women’s Leadership Network Reception, sponsored by Morrison Container Handling Solutions on Tuesday, March 11, from 4:00–6:00 p.m., provides an opportunity to connect with influential women in the packaging and processing industry. RSVP required.

Several tools will help attendees make the most of their time at PACK EXPO Southeast. My Show Planner, a personalized collection of “must-sees,” provides a way to track interests before, during, and after the show. In addition to providing a planning tool and directory of exhibitors and sessions, My Show Planner offers appointment scheduling capabilities.

Personal agendas also can be created and saved in the PACK EXPO Southeast Mobile App, sponsored by ProMach. This free app streamlines show floor navigation with interactive maps, provides access to exhibitor, product, and educational session listings, and delivers show news and information about demos, giveaways, and other activities.

As packaging options continue to evolve, investments in sustainable packaging solutions, cutting-edge machinery, and automation will be critical for staying competitive. With the launch of PACK EXPO Southeast, packaging and processing professionals, who want to keep up with demands for more sustainable business practices, have a new resource in Atlanta, a regional manufacturing hub and easily accessible destination. For more information and to register, visit packexposoutheast.com.

Designing for Recyclability

Development often begins with guidelines from the Association of Plastic Recyclers (APR). Following the APR Design® Guide for Plastics Recyclability helps end users and converters design for recyclability. Other important design considerations include consumer accessibility to a collection system for recycling the material, adherence to the U.S. Federal Trade Commission’s Green Guides to ensure appropriate label claims, and an accessible market for the recycled resin.

Proactive converters also may obtain How2Recycle status, which provides consumers with on-pack instructions about proper disposal. Another proactive tactic is third-party testing and certification to verify performance and sustainability claims, thereby ensuring consumers and regulators that sustainability claims are legitimate, and there is no greenwashing.

Transitioning to Mono-material Packaging

To support flexible film transitioning, PMMI Media Group Custom Research has published Transitioning Flexible Materials Best Practice. Crafted in conjunction with the Flexible Packaging Association and PMMI’s OpX Leadership Network, it serves as a guide for consumer packaged goods (CPG) companies and their OEMs. It notes, the transitioning process requires careful planning, testing, and evaluation to determine whether the new materials are compatible with existing machines or require new machines.

A flow chart defines tasks required for transitioning flexible films, and a RACI matrix shows the responsibilities of the groups that should be involved in the process, including Packaging Design and Development, Operations and Engineering, Marketing/Brand Owner, OEMs, and Materials Suppliers/Converters. Step-by-step guidance leads the transition through feasibility; design and development; pilot testing; tracks for legacy or new equipment; commissioning, qualification, and verification; supply chain scale-up/commercialization; and evaluation.

Important Considerations

Although much of the activity in mono-material packaging is associated with plastics, other options exist. Mono-material aluminum bottles, steel cans, glass containers, and fiber-based containers, cartons, and cases are recyclable and often contain recycled content to help achieve circular economy goals. Fiber-based materials, which are derived from renewable sources, offer yet another advantage.

Whatever mono-material choice is made, CPG companies and OEMs will need to factor in equipment needs. Can existing equipment handle the new material or will machines need to be replaced or upgraded? Other considerations in any material transition include cost and return on investment, product quality and safety, regulatory compliance, supply chain constraints, and shifting consumer preferences.

For more information on the future of packaging materials, download “The Packaging Compass,” at: https://www.pmmi.org/report/2023-packaging-compass. and “Transitioning Flexible Materials Best Practices,” at https://www.pmmi.org/report/2023-transitioning-flexible-materials-best-practice.

About the Author

Tom Egan serves as the vice president of Industry Services for PMMI, the Association for Packaging and Processing Technologies. He joined the PMMI staff in 2003 following more than 20 years in the packaging industry during which he was also an active PMMI member. His previous work experience includes tenures at Eaton Corp. and as Vice President, Marketing & Sales, for Hoppmann Corporation. He has an MBA from Baldwin-Wallace College, and a BEE in Electrical Engineering from Villanova University. Visit: https://www.pmmi.org