Challenge:
Contribute to a more circular economy by developing heavy duty sack (HDS) films containing PCR content, while maintaining mechanical properties and thickness
The Selene Group, a leading polyethylene (PE) film converter and recycler based in Italy, wanted to develop heavy duty sack films (Selene NextBag™) containing 50% post-consumer recycled (PCR) PE (Selene Premium Recycle Polymer) content in response to brand owner commitments, consumer feedback and regulatory changes.
“As a converting and recycling company, we can help the value chain respond to evolving sustainability needs by including PCR material in our solutions,” said Luca Massari, R&D Manager, Selene. “We need to ensure that the heavy duty sacks fulfill their primary function of protecting and transporting products effectively, maintaining the mechanical properties and thickness of the film. Plus, the end user’s machine settings, such as sealing bars temperature and output, should not need to change, so that it’s an easy solution to adopt.”
Solution:
Include 50% PCR PE with Exceed™XP and Exceed™ performance PE polymers for high integrity heavy duty sacks
Pallets with Selene NextBag™ HDS which contain 50% PCR PE passed acceleration tests at ESTL, according to EUMOS40509.
ExxonMobil and Selene worked together to test formulations for heavy duty sack films based on 50% high-quality PCR PE combined with Exceed™ XP and Exceed™ performance PE polymers which help boost performance in recycled solutions. The PCR PE is sourced from a logistics center where resin bags are opened and then emptied to fill bulk trucks. The waste bags are sorted, washed, de-inked, and re-pelletized by Selene into a premium recycled product. A thorough risk assessment of the final resin bag material is conducted by Selene to confirm product safety for the intended use.
The inclusion of Exceed™XP 8318 in the formulation delivers excellent toughness to the heavy duty sack films, compensating for possible degradation in the properties of the PCR PE during the recycling process. The inclusion of Exceed™1012 increases bag drop resistance and enhances sealing performance
“Compliance to fulfill regulatory obligations and safety assurance for the intended use are key focus areas,” said Klaus Urbano, Sales Director, Selene. “We undertake a rigorous process to ensure the PCR PE is a consistent high quality. Recycling material traceability and adequacy are confirmed by the appropriate documentation.”
The recycling line at the Santa-Margherita plant, Italy where bags are sorted, washed, de-inked, and re-pelletized into a premium recycled product.
Results:
High-integrity heavy duty sacks containing 50% PCR PE that are easy to process
NextBag™ by Selene incorporate Exceed™ and Exceed™ XP performance PE polymers and deliver:
- A sustainable solution that incorporates 50% PCR PE.
- Mechanical properties in line with industry standards for high integrity sacks.
- Bag drop performance that outperforms reference virgin PE formulations.
- Creep resistance and pallet stability: pallets passed acceleration tests according to EUMOS40509.
- No forseeable operational changes to the end-user’s bagging machine settings (sealing bars temperature, output).
“The solution fulfills demand for a sustainable approach to flexible film applications by introducing post-consumer recycled (PCR) content,” said Marco Rubertà, Technical Director, Selene. “The use of recycled plastic in other flexible packaging films is gaining traction in Europe and we are experiencing considerable interest from the value chain.”
What some might view as solutions that will only happen in the future, ExxonMobil PE is making possible today – through our innovative and reliable products, collaborative approach, technology leadership and support, and our unmatched global supply and resources. Why wait for tomorrow to advance your business today? Learn more about how we’re helping our customers create more sustainable solutions now. Contact your ExxonMobil PE representative and begin experiencing tomorrow’s performance today in flexible packaging.