In brief

Under the draft EU Regulation on packaging and packaging waste (PPWR), from 2030 all packaging placed on the market is to be recyclable. In practice this means the need to switch to mono-materials or to structures equivalent to them in terms of recycling.

The key question is:

Can mono-materials be rolled out without the risk of downtime and loss of packing quality?

What are mono-materials in flexible packaging?

Mono-materials are packaging made from a single type of raw material, most often:

• PE (polyethylene)
• PP (polypropylene)

Unlike classic multi-material laminates (e.g. PET/ALU/PE), mono-material structures are designed so that they:

• are recyclable in existing streams,
• meet PPWR requirements,
• retain the functionality required in the food industry.

One thing is key: mono-material ≠ no barrier.

Properly designed structures still provide protection against oxygen, moisture and aroma loss.

Mono-materials and the reality of packaging lines

From a production perspective, the biggest risk is not the change of material itself, but leaving it untested.

Poorly chosen mono-materials can cause:

• problems with film tracking,
• unstable seals,
• differences in stiffness,
• a drop in line throughput.

That is why rolling out mono-materials must start with machine trials.

Where do mono-materials already work today?

Mono-materials for dry products

Coffee, dried fruit and nuts, dietary supplements — mono-material barrier films with EVOH or barrier coatings effectively replace aluminium laminates while retaining:

• the oxygen barrier,
• aroma protection,
• packing stability.

Mono-material doypacks

Doypack pouches made entirely from PE or PP:

• meet recycling requirements,
• stay tight,
• can be tested on existing packaging lines.

Mono-films for bulk packaging

In the cosmetics and chemical sectors, mono-materials are already used today as bulk films with high-quality flexographic print, without complicating the material structure.

Mono-materials and the EU 2030 directive

A phased approach is key:

• treating mono-materials as a transitional project,
• testing them as an alternative or a backup supplier,
• protecting yourself against sudden changes in the rules and time pressure.

This approach minimises the risk of downtime and lets you maintain production continuity.

How do we roll out mono-materials at Mardruk Opakowania?

We treat mono-materials not as a "product", but as a technical process.

We offer:

• advice on the transition from multi-material laminates to mono-materials,
• selection of packaging structures while retaining barriers and functionality,
• production of recycling-ready packaging with multi-colour flexographic print,
• support in packing trials and validation on production lines.

Thanks to our cooperation with raw-material producers and research laboratories, we roll out mono-materials that work in production, not just on paper.

Mono-materials – better to test today than to scramble tomorrow

• tests mono-materials in advance,
• or rolls them out under pressure from deadlines and retail chains

Summary — mono-materials

• Order free mono-material samples for machine trials
• Check the feasibility of rolling out mono-materials

Sounds like your project?

Write or call — our technologist will advise on the structure and quote your volume within 24 hours.

Free quote +48 731 819 963