The Truth About Mono-material Flexible Packaging
- Published: February 27, 2026
By Owen Lightbody, Application Development & Circular Economy Team Leader at NOVA Chemicals
When it comes to plastic recycling, flexible packaging is the new frontier. While rigid plastics have higher rates of recycling due to established collection streams and recycling facilities, flexible packaging remains challenging in terms of collection, recycling, and building end markets for post-consumer recycled (PCR) films. One of the main barriers is that many flexible films are constructed from multiple materials that cannot be separated by existing mechanical recycling systems.
To address this incompatibility, packaging producers are increasingly embracing the concept of designing for recyclability. Advances in resin technology have made mono-material packaging possible for popular flexible packaging formats like bags and pouches. Polyethylene (PE), known for its versatility, performance, and cost effectiveness, has emerged as a frontrunner for mono-material solutions. In the past, it was thought that PE films would have to be significantly thicker to match the performance of multi-material laminates. However, new resin grades and orientation technologies are enabling PE films to offer equivalent lightweight, durable performance in flexible packaging that aligns with today’s recycling infrastructure.
But material innovation alone is not enough to build a circular economy for plastics. Despite the growing availability of high-performance oriented PE films and PE sealant webs, industry adoption of mono-material structures has been slow. These films offer exciting new possibilities for flexible packaging that can enter recycling streams, but transitioning to new materials and processes requires significant adjustments from material suppliers, converters, and packaging engineers. Companies often hesitate to pursue new solutions due to concerns about supply security, equipment changes, performance differences, and increased costs.
While earlier voluntary commitments and corporate goals to rethink plastic packaging have driven incremental changes, the expansion of packaging-related legislation, including Extended Producer Responsibility (EPR) laws in the U.S. and the Packaging and Packaging Waste Regulation (PPWR) in Europe, is pushing the industry to prioritize designing for recyclability. Although each law has its own rules and regulations, recyclability and recycled content are increasingly tied to fee structures that directly impact packaging producers.
Converters play an important role in supporting the market adoption of mono-material structures. By learning about the latest material technologies and capabilities, converters can dispel misconceptions about the feasibility of mono-material packages and identify solutions that best serve their customers.
Oriented Film Technologies
Oriented PE films have enhanced performance properties compared to traditional blown films.
- Biaxially oriented PE (BOPE): Recent innovations in high-density BOPE (BOPE-HD) resins make them suitable for commercial tenter frame lines and Double / Triple Bubble® film lines. While tenter frame lines are still being optimized for HDPE, BOPE-HD films will offer substantial economies of scale due to the high output capacities of the equipment.
- Machine direction oriented (MDO) PE: MDO technology for films has been in use for more than 50 years. Breathable MDO films were used primarily in personal hygiene products. Today, high performance MDO PE films can be customized for numerous packaging applications and are being used as a replacement for BOPP and BOPET in all-PE structures.
Expanding Resin Options for MDO
With any new packaging material, there are concerns about availability and reliability of supply. The MDO process requires low gel resins with wide orientation windows that result in films with sufficient stiffness and heat resistance for conversion. The supply of qualified resins is steadily growing as major resin suppliers are specifically designing new grades for MDO lines. These films maintain registration during printing and offer a very low haze and high gloss or matte finish options, making them ideal for food packaging with designs that need eye-catching shelf appeal.
PE-based solutions can now deliver the quality, performance, and shelf appeal once thought to require multi-material laminates. Image courtesy of NOVA Chemicals.
Processability Considerations
Thermal stability is essential for the MDO process. Any defects in the film, such as crosslinked or unmelted gels, will be magnified when the film is stretched, which compromises the overall appearance and performance of the film and can reduce production efficiency if there are film breaks during the stretching process. Many factors can contribute to defects and imperfect film appearance, including resin process technology, additive formulations, extrusion temperatures, stretching ratios, and equipment conditions.
Equipment Optimizations
Even with improved resin formulations, there may be lingering doubts about the efficiency of the overall MDO process. Historically, MDO resulted in thick edges which required trimming and led to high levels of scrap. As MDO expands for mono-material packaging design, original equipment manufacturers (OEMs) are focused on making production more efficient. New technologies are emerging to reduce neck-in and scrap production. For BOPE, resin suppliers, film manufacturers, and OEMs are collaborating to optimize production on tenter frame lines.
The reality is that oriented PE films are different from the legacy materials they are replacing. Successful adoption requires time, resources, and a willingness to test and adjust new processes and equipment settings. Effective change management is critical to realize the full potential of these materials, and teams must be aligned on objectives, timelines, end goals and troubleshooting options during the development phase.
Rethinking Cost in a Circular Economy
In a circular economy, cost calculations are more complicated than raw material pricing and production costs. EPR laws and PCR mandates are evolving rapidly, creating new compliance obligations with tangible financial consequences. Non-recyclable structures may be subject to fees, underscoring the importance of designing for recyclability.
In addition, mono-material packaging is a cornerstone in expanding the supply of high-quality feedstock for recycled PE (rPE). By keeping plastics in circulation through high-value applications, the industry can shift toward a new economic model that maximizes resource efficiency. This shift requires not just technical innovation, but also a willingness to move beyond traditional practices at the systems level from material production to end-of-life processes.
Collaboration across the value chain is key for adjusting to new cost structures. By partnering with resin suppliers, OEMs, brand owners, and even retailers, the industry can streamline development of new systems and technologies to accelerate innovation. Becoming a mono-material solutions provider could also unlock new business opportunities with customers who are looking for EPR-compliant packaging materials.
Performance Capabilities and New Applications
Oriented films are an important building block for mono-material packaging, and they also support the development of other PE innovations. When partnered with a PE sealant web, oriented films enable other new technologies to expand the options of mono-material packaging solutions. With a smooth surface, oriented PE films form an ideal substrate for barrier coatings. The combination of high moisture barrier HDPE resins with advanced barrier coatings results in a solution that is capable of replacing ethylene vinyl alcohol copolymer (EVOH) in conventional high barrier films, dramatically reducing the amount of non-PE material in the package.
The momentum for mono-material packaging is steadily increasing. Advancements in oriented films have opened the door to a new era of flexible packaging that can meet today’s demands for functionality while supporting a circular future for plastics. PE-based solutions can now deliver the quality, performance, and shelf appeal once thought to require multi-material laminates. Resin suppliers and equipment manufacturers continue to refine resin design and processing capabilities to offer more efficient, consistent production. The path forward will demand shifts in packaging design, development approaches, and lifecycle cost accounting, which is why collaboration and knowledge-sharing are more important than ever.
About the Author
Owen Lightbody is an experienced professional in the field of polymer chemistry, currently serving as the Application Development & Circular Economy Team Leader at NOVA Chemicals. He focuses on transitioning flexible packaging manufacturers to monomaterial recyclable alternatives, with a significant emphasis on developing high-density BOPE technology. He can be reached at This email address is being protected from spambots. You need JavaScript enabled to view it..
