As the packaging industry moves swiftly towards recyclable mono-material solutions, extrusion line manufacturer Reifenhäuser is set to showcase a compelling answer at K 2025: an advanced technological approach that makes sustainable flexible packaging commercially viable.
At the heart of Reifenhäuser’s innovation is its patented EVO Ultra Stretch MDO unit, which enables the production of ultra-thin, process-stable mono-material films – including the world’s first 18 µm MDO PE film with further downgauging potential. This technology, integrated directly into the haul-off of the blown film line, stretches the film from the first heat, ensuring consistent stability and reducing one of the key limiting factors in downgauging.
“The technological path towards MDO mono-material films is set – now the race for profitability begins,” said Marcel Perrevort, chief sales officer of the Reifenhäuser Group. sp-eaking at the K 2025 Preview press conference attended by PKN. “Thanks to its distinctive technological approach, our MDO unit Ultra Stretch gives manufacturers a clear competitive advantage – while at the same time ensuring the highest quality and processability of the films.”
By orienting polymer chains in the direction of stretch, Reifenhäuser’s MDO units enhance mechanical properties, allowing producers to replace PET layers in laminates with recyclable mono-PE alternatives. The shift not only supports circular economy goals but also makes business sense: thinner films mean reduced material usage and lower production costs.
Where PET-PE laminates typically rely on a 12 µm PET layer, Reifenhäuser’s MDO PE film, at 16–17 µm, delivers comparable strength thanks to lower density and effective orientation. The result is a recyclable mono-PE structure that can rival conventional laminates in both performance and cost.
In addition, EVO Ultra Stretch boosts the barrier efficiency of EVOH – a high-cost raw material often used in barrier applications – by enhancing its effect through the stretching process, thereby reducing the quantity needed.
Looking ahead, Perrevort said Reifenhäuser aims to push the downgauging envelope even further through formulation development, underscoring the company's goal to prove that recyclability and cost-effectiveness can go hand in hand.
At K 2025, Reifenhäuser will present this next-generation technology as a key enabler for the economically viable transition to recyclable flexible packaging – setting a new benchmark for the industry.
K 2025, the world's leading trade fair for plastics and rubber, will take place from 8-15 October 2025 in Dusseldorf, Germany.
