New mono-material stand-up pouch with over 50% chemically recycled content

Three operators in the packaging supply chain – Dow, Macchi and ITP – have jointly developed a circular solution for flexible packaging: a mono-PE stand-up pouch designed for recyclability, containing over 50% plastic from chemical recycling using a mass balance approach. The stand-up pouches will be officially presented at the forthcoming K 2025 trade fair at the Dow and Macchi stands.

The integration of chemically recycled content enables increased use of recycled material in technically complex applications subject to stringent regulations, such as food packaging, which are not currently feasible on a large scale with conventional mechanical recycling, thus reducing dependence on virgin resources. The use of advanced recycled content also ensures that packaging materials are safe for direct food contact, offering consumers peace of mind regarding food safety and protection against gas and moisture.

The pouch proactively responds to future recycled content quotas set by the new EU Packaging and Packaging Waste Regulation (PPWR), which mandates specific recycled content targets for all plastic packaging by 2030, including 10% for food contact applications. This collaboration demonstrates the possibility of incorporating higher volumes of advanced recycled material without compromising performance or safety.

ITP - Industria Termoplastica Pavese, producer of high-quality, sustainable PE films for food and industrial packaging, handled film selection, digital printing, lamination and pouch formation; Macchi, manufacturer of blown film extrusion lines, provided high-performance multilayer extrusion technology; Dow, materials producer, contributed advanced PE resins – including Innate, Elite, Affinity and Bynel – combining excellent processability with high-level functional performance.

Macchi is a reference company in the blown film extrusion line sector and its advanced systems offer maximum flexibility in film structure design and enable significant thickness reduction, ensuring both material savings and greater efficiency in production costs. This evolution fits within the growing demand for environmentally sustainable technologies capable of reducing raw material consumption, facilitating packaging reuse and supporting efficient end-of-life recycling. The latest line developed by Macchi reflects this commitment to sustainability whilst simultaneously meeting market requirements for high-performance process solutions. "This synergy, born from the combined research and experience of three leaders in their respective sectors, represents a fundamental milestone in shaping the future of the plastics industry," commented Anthony Michael Caprioli, CEO of Macchi.

ITP specialises in polyethylene film extrusion using single and triple-bubble extrusion technology and, thanks to fully integrated production, guarantees rigorous control over every process stage. This complete management of all production phases enables optimisation of film recyclability without compromising the technical performance required by the food and beverage sector, achieving high-performance multilayer mono-PE structures. "Through this collaboration, ITP leverages its PE extrusion expertise to offer high-performance films with chemically recycled content, fully compliant with future PPWR requirements and ready to meet market challenges," stated Carlo Poggi, General Manager of ITP.