ExxonMobil Signature Polymers, Hosokawa Alpine and BW Converting have worked together to create a 25-micron mono-material polyethylene (PE) bread bag designed for recyclability*, intended as an alternative to traditional PP/PE structures.
The packaging focus of the project centred on downgauging and improving compatibility with recycling streams while maintaining stiffness, tear resistance and clear optics. Traditional coextruded PP/PE bread bags, typically 30–38 microns, meet performance requirements but present challenges for recyclability due to their multi-material construction.
Using Machine Direction Orientation (MDO) technology on a five-layer coextrusion line, Hosokawa Alpine produced 25-micron MDO PE films. According to Frank Bernotat, technical sales manager, blown film at Hosokawa Alpine, the technology “contributed to the high stiffness of the thinner bags” and helped deliver optical performance “normally found when using polypropylene-based formulations”. Unique TRIO and vacuum systems further reduced trim wastage.
ExxonMobil Signature Polymers supplied the PE resins, including Exceed HD 6107 for MDO processing, Exceed Stiff+ m 0238 for stiffness and mechanical performance, and Exceed Stiff+ m 0820 for processability and durability. The company said the grades allowed different stiffness levels to be formulated depending on market requirements.
BW Converting converted the MDO PE films into gusseted bread bags on Hudson-Sharp Apollo wicketed bag machines. Peter Sztehno, sales director EMEA bag converting and printing at BW Converting, said trials confirmed successful bag making, while Heidi Hilbert from the marketing team said this was the thinnest film run on the company’s lines to date.
HOBA assessed the bags on its manual and automated closing systems and confirmed their suitability for automated bread packaging. “This was a great collaboration, resulting in an innovative solution,” said Kevin Plomp, sales at HOBA.
Across the trials, the partners reported:
- successful production of 25-micron bags on Hudson-Sharp lines
- trouble-free running on dual-use PE/PP bag lines, supporting cost-efficient changeovers
- critical transverse-direction tear resistance suitable for crusty bread
- low film haze values of 6–7.5, comparable with PP-based films
- anticipated strong performance under freezer conditions
The mono-material MDO PE bags are designed as a recyclable* alternative to PP/PE structures while maintaining performance required for bread packaging.
*Recyclability depends on local infrastructure.
