Boost sustainability with mono-material packaging

Sustainability demands are rising, and a shift towards mono-material product lines represents a potentially impactful strategy. Keeping converters informed on the latest trends is key to Shell Polymers’ (Real)ationships approach, so let’s take a deeper dive into these mono-material designs and examine some real-life examples.

How mono-material packaging stands out

As a refresher, the term “mono-material” is used to describe packaging made from a single type of resin, such as polyethylene.¹

This contrasts with product designs that use several types of resins or other materials. For example, many packaging tubes – such as those used for cosmetics – have a polyethylene body with a polypropylene cap.

Brands employ several different polymers due to a combination of their cost, performance characteristics, and efficiency during the production process.

There are challenges to consider with switching to mono-material packaging, including ensuring that materials are compatible with performance requirements.

If you need assistance navigating mono-material designs, reach out to Shell Polymers today

. Our polymer experts can advise and troubleshoot new designs and applications on state-of-the-art equipment in our Monaca, Pennsylvania facilities.

How mono-material packaging boosts recycling

Mono-material designs can improve recycling results as there’s no need to separate product and packaging parts to make them compatible with recycling infrastructure.

The result can be simpler sorting, improved efficiency, higher quality recyclables, and higher recycling rates.²

Brands that enable easier recycling can market these contributions on their packaging labels, websites, and other mediums, in order to win business from consumers who value products that are more sustainable.³

Benefits for brands go beyond sustainability

A mono-material packaging approach can boost recycling rates, and brands can leverage their sustainability approach in their marketing to build brand loyalty and awareness.

There are operational benefits to consider, too. One brand reported to Beauty Packaging that switching to a one-piece, mono-material PE flip-top tube design reduced its injection cycle times and the assembly process, which in turn cut energy consumption costs.⁴

Another packaging firm reported that mono-material packaging can expedite the time it takes to conduct formula compatibility testing, getting their products to market more quickly.

There are potential design and coloration benefits, too. Beauty Packaging reported that using the same resin for a bottle and its cap makes it easier to match the color injection to a single benchmark, whereas using differing materials will often result in a color mismatch.

Finally, mono-material designs can help brands meet evolving sustainability regulations, such as those in California and the European Union that mandate all packaging to be designed for recycling or composting over the coming decade.⁵

Mono-material packaging continues to hit the market

Mono-material designs are a bonafide trend in the packaging space, according to PreScouter, which predicts that mono-materials will “dominate” the flexible packaging space by 2030, with the main drivers being cosmetics, personal care products, and food pouches.⁶

The number of mono-material products on the market continues to grow. Let’s explore a few examples:

PKG Group offers mono-material pump bottles for personal care products. The bottles contain a PE bellows spring instead of a traditional metal spring. The entire pump can be recycled in one piece.^7 8 Recent projects show the mono-material pump market reached $108.2 million in 2023, with an anticipated surge to $186.6 million by 2033 – a CAGR of 5.6%. The rise is attributed to heightened environmental awareness, prompting a shift towards mono-material pumps due to their recyclability and eco-friendly nature.⁹

DNP Group provides mono-material materials for standup pouches, flat pouches, and rolls that incorporate barrier properties to protect contents without using aluminum foil or other materials.¹⁰ Containing more than 90% of either PE or PP, the material conforms to the guidelines of the Circular Economy for Plastic Packaging.¹¹

Siegwerk and Borouge have developed a portfolio of mono-material solutions, including a barrier stand-up pouch using polyethylene. The pouch incorporates a primer solution, CIRKIT Clearprime, to enable smooth laminate de-inking. The design enables all used inks and coatings to be removed from the printed film during the recycling process, better enabling the re-use of the recycled PE.¹²

Rieke and Madel Spa have developed a pouch cap fitment with significantly reduced plastic content, available in high-density polyethylene or polypropylene. The design, with capacities ranging from one liter to 200 liters, enables the final packaging to be recyclable when combined with a monolayer, recyclable pouch.¹³

Polysack says its mono-material PE films branded as Pack 'N' Cycle can match the performance of polyethylene terephthalate pouches, which has long been dominant in flexible packaging^.14

Lageen’s mono-material tubes feature PE tube bodies, heads, and caps suitable for cosmetics, toiletries, food, and pharmaceuticals. The tubes can be recycled as a single unit.¹⁵

Costs to consider

The good news for those wishing to pursue a mono-material approach is that compatibility with current molding tools and decorating applications continues to improve^.16

There are still costs and hurdles to weigh, including:

• Mono-material packaging could require initial investment in new machinery, materials, and research and development
• Swapping in a different resin may not offer the same level of barrier protection, which could impact shelf life¹⁷
• Using a single material may present design constraints that make it difficult to achieve brands’ distinctive packaging preferences¹⁸

Depending on the situation, companies may spend the same amount of money on mono-material production as they did on multi-material production after start-up costs, though that could change in the future as equipment and processes evolve, according to Beauty Packaging.

Brands must balance these cost and benefit considerations to determine if a mono-material approach can boost their business.

If you need help, our polymer experts can assist customers with assessing and testing new applications and designs.

¹https://www.epa.gov/system/files/documents/2023-07/SWM_PlasticWaste-Final.pdf

²https://www.lythouse.com/blog/top-4-sustainable-packaging-trends-in-2024

³https://www.beautypackaging.com/issues/2023-10-01/view_features/how-mono-material-packaging-speaks-to-consumers/

⁴https://www.beautypackaging.com/issues/2022-10-01/view_features/mono-materials-answer-the-call-for-recycle-ready-packages/

⁵https://www.beautypackaging.com/issues/2023-10-01/view_features/how-mono-material-packaging-speaks-to-consumers/

⁶https://spnews.com/mono-material-flexible-packaging-will-dominate-by-2030/#:~:text=We%20anticipate%20that%20mono%2Dmaterials,and%20the%20food%20pouch%20industry

⁷https://pkggroup.com/products/?swoof=1&pa_sustainable=one-material-pump-compatible

⁸https://www.beautypackaging.com/issues/2022-10-01/view_features/mono-materials-answer-the-call-for-recycle-ready-packages/

⁹https://www.digitaljournal.com/pr/news/future-market-insights/mono-material-pump-market-poised-1669891190.html

¹⁰https://www.global.dnp/biz/solution/products/detail/10161321_4130.html

¹¹https://guidelines.ceflex.eu/guidelines/design-choices/#:~:text=Material%20choice&text=Mono%2Dmaterial%20polyolefin%2Dbased%20packaging,mono%2DPP%20structures%20where%20possible

¹²https://packagingeurope.com/news/pipeline-of-recyclable-mono-materials-from-siegwerk-and-borouge-in-progress/11226.article

¹³https://www.impackedpackaging.com/content/blog-articles/our-favorite-8-new-eco-friendly-packaging-components-of-2024

¹⁴https://www.polysack.com/mono-material/

¹⁵https://lageentubes.com/pe-mono/

¹⁶https://www.beautypackaging.com/issues/2022-10-01/view_features/mono-materials-answer-the-call-for-recycle-ready-packages/

¹⁷https://www.packworld.com/design/materials-containers/video/22793392/pros-and-cons-of-mono-and-multilayer-materials-for-sustainable-packaging

¹⁸https://www.beautypackaging.com/issues/2023-10-01/view_features/how-mono-material-packaging-speaks-to-consumers/