Standard wet tissue packaging is made of multi-layer flexible film unsuitable for recycling. Polysack offers new solution for all those who care about sustainability and the environment

Use of wet wipes is surging. Since the outbreak of the corona their use has proliferated, not only for baby care or to remove makeup, but also as a disinfectant and for cleaning almost any public surface, including medical equipment, tables and chairs in restaurants, floors, handles and electrical outlets.

The wet wipes market is set to grow at a CAGR of over 7% from 2020 to 2025, driven by rising concerns over hygiene. With this rapid growth comes increasing concern about packaging waste, as the standard laminates in use are not suitable for recycling.

This concern is especially understandable when examining the types of packaging used for this product. For the most part wet wipes usually come in two types of packaging: flexible packaging of a pack of wet wipes (with or without a stiff opening) and packaging of a single wet wipe – sachet. The latter is particularly wasteful in terms of the packaging waste produced. Add to this the sharp increase in demand – and we find ourselves facing a real problem. At a time when the goal is to reduce the use of plastic packaging, the wet wipes industry is doing exactly the opposite!

Wet wipes packaging materials

So why can’t wet tissue packaging be recycled? The main function of packaging is to protect the packaged product throughout the value chain up to its final use by the end customer. In the case of wet wipes, the most significant material property that must be maintained is the wipes moisture in order to prevent their drying. To achieve this, standard wet wipes packaging is made of several layers of various polymers, usually PE and PET, as well as materials that prevent moisture transfer. A layer of aluminum and paper is also sometimes added. This combination of materials perfectly provides the required properties for the packaging: moisture and gas barrier, low COF, high heat resistance for trouble-free sealing, and die-cutting capabilities.

Unfortunately, these materials are incompatible and therefore non-recyclable. The most environmentally “friendly” thing that can be done is to dispose them in landfills or to burn them in order to produce energy (energy recovery). In the worst case, in places that lack organized waste collection system, the packages find their way to the environment and remain there for years, polluting and harming both animals and plants. This is especially true when it comes to sachet packaging that encourages carrying and using wet wipes anywhere, even in places where there is no orderly waste collection.

The solution – mono material packaging

To promote the sustainability of flexible packaging products we developed films that can serve as an excellent substitutes. These films are based on HDPE, a polymer with some of the highest moisture barrier properties in the packaging industry. As such it eliminates the need for other barrier layers in the packaging such as aluminum.

Polysack Pack ‘N’ Cycle films for wet wipes laminates offer an excellent barrier to keep moisture and volatiles inside (low WPTR), enabling high productivity and efficiency of the flow-pack packaging line while allowing package recycling in the PE stream.

How do we obtain the desired properties in films made of only one material?

A unique technology, Machine Direction Orientation (MDO) serves us in the production prosses. In this technology the film is stretched in only one direction and thus achieves improved properties: enhanced mechanical strength, improved optical properties, easy tear and improved moisture barrier (WPTR – water vapor transfer rate). Mono Oriented PE (MOPE) film is manufactured in several stages that include heating, stretching, annealing to remove stresses and cooling. The stretched film is suitable for supplementary processing processes such as printing and lamination, without requiring special adjustments. The films can be used for sachet packaging as well as for the packaging of wet wipe packs manufactured using horizontal flow pack machines, without hindering the rate of work or compromising the product protection they provide.

This solution serves as a substitute for PET or BOPP lamination films that are incompatible with the interior PE layers. The result is packaging that is a purely PE film and can undergo sorting and recycling anywhere in the world.

Advantages of MDO packaging

Replacing standard multi-layer flexible packaging with mono-material packaging paves the way for sustainable packaging for recycling of wet wipe packaging as well. This solution meets the increasing regulatory requirements in Europe and England, as well as the commitments of leading industry brand owners to meet challenging goals focused on reducing the use of plastic and promoting its recycling. Join us. We will be glad to help you find the suitable sustainable packaging to meet your needs.