The Future of Film Design

New online modeling tools can predict film performance and compare properties of resins and blends, making it possible to design eco-friendly flexible packaging. © Tricky Shark – stock.adobe.com

Modeling Technology and Material Advancements Support Circular Packaging Solutions

By Bill Pardo, Market Manager, Food Packaging at NOVA Chemicals

The durability and versatility of plastic packaging are unmatched by any other material, making them an integral part of the global economy. But plastics are capable of even more. The push for more circular plastic use is driving change as governments enact new legislation designed to combat pollution and plastic waste such as single-use plastic bans, post-consumer recycled (PCR) content requirements, and extended producer responsibility (EPR) policies.

Consumers are showing their preference for more circular packaging options and brands are committing to reducing their environmental footprint. As society attempts to move away from the take-make-waste model of consumption to a circular economy for plastics, how can the industry unlock the full potential of plastics beyond their first use?

Changing the way plastic packaging is designed is a good place to start. As brand owners and retailers become more focused on circularity, packaging designers must consider the entire life cycle of plastics during the initial design phase. In their analysis of some of the largest food and beverage companies in the world, PwC found that comprehensive packaging optimization that involves players across the value chain can reduce costs by up to 30% while reducing emissions. An innovative approach to packaging design that focuses on using less material and increasing recyclability is not only cost-effective but is the responsible thing to do for the environment.

In the rapidly changing world of plastics, performance alone is no longer enough. New digital technology and material advances are enabling the next generation of film designs that maintain the protective properties of plastic packaging while also improving efficiency and designing for recycling where facilities exist. Resin suppliers, converters, brand owners and retailers must work together to continuously research and develop new products and applications to transform the way plastics are produced, used, and recycled.

Designing for a Circular Future

The packaging design process should address recyclability from the start. This includes considerations about the types of materials, how they are produced, and how they can be reused. Polyethylene (PE) is a versatile plastic that has been adapted to meet the needs of many different types of packaging and processes while also enabling mono-material designs that have the potential to be recyclable and can contribute to higher quality recyclate for future uses.

Circular designs do not apply only to new packaging formats but should also be used to reevaluate and improve upon existing packaging designs. For example, conventional laminate structures that utilize coatings and metallized layers to provide the necessary protection for demanding barrier applications. Using the latest in PE film technology, all-PE laminates are now possible. These films are printable, and in many cases, deliver the required barrier performance, and reduce energy consumption during production.

Improving the Design Process

Advances in computer modeling and simulation allow for rapid and cost-effective exploration of innovative packaging designs. Databases of performance information allow packaging designers to move ideas quickly from concept to testing while reducing the number of physical trials needed. With the introduction of online modeling tools, users can predict film performance and compare properties of resins and blends. These tools are essential for developing more circular alternatives since they can be used to identify the ideal structure to provides the necessary performance and processing characteristics that are needed in flexible packaging designs.

Material advances and new digital technology like NOVA Chemical’s BONFIRE® Film Development Platform are enabling the next generation of film designs to maintain the protective properties of plastic packaging while also improving efficiency and designing for recycling where facilities exist. Image courtesy of NOVA Chemicals.

Sharing Knowledge

Packaging designers use these innovative tools to conduct research that helps them uncover more circular packaging alternatives. For example, they can explore new film designs that offer more opportunities for recyclability compared to traditional designs that were historically very difficult or impossible to recycle. When multiple companies collaborate, everyone benefits from new product developments and improvements. Sharing knowledge across the value chain can help uncover industry needs, pinpoint gaps in the market, and create products tailored to market opportunities.

Collaboration across the value chain is how industry transformation will be achieved. Building the recycled content pipeline requires cooperation between resin suppliers, recyclers, and packaging manufacturers. Increasing recycling rates and recyclable packaging options secure the supply, while high-performance recycled materials build demand for the recycled content. This holistic approach ensures PCR content availability and validates the economic model of investing in recycling facilities and operations.

Developing New Solutions

A commitment to ongoing research will open doors to even more packaging possibilities. Good products can always be made better. For PE films, suppliers and converters can continue to find new applications for PE structures, adapt resins to run on different types of commercial packaging equipment, and design resins that maintain their physical properties throughout the recycling process. Barrier films are particularly versatile, with the latest resins offering ultra-low water vapor transmission rates and excellent toughness. These effective moisture barriers allow brand owners to use less film in downgauged structures while keeping food fresher longer and reducing food waste.

Measurable, lasting change is possible when industry players work together. The future of plastic packaging lies in cutting-edge research and designing for circularity from the beginning. Collaboration accelerates innovation, helping more companies take advantage of new technologies and materials that meet and exceed performance expectations while supporting the transition to a circular economy.

About the Author

Bill Pardo is the food packaging market manager at NOVA Chemicals. In this role, Bill is responsible for leading a cross-functional team to deliver polyethylene solutions to the toughest food packaging challenges for converters, including recycle ready multilayer film structures.

Learn more at www.novachem.com.