Monomaterials put to the test: Ready for the PPWR?

The basic idea is clear: the more uniform a packaging material is, the easier it is to sort and recycle. In many cases, difficult-to-separate multilayer structures are being replaced by PE- or PP-based mono solutions, and in certain applications by paper-based packaging. Monomaterials are already well established in the cold-seal segment. In horizontal flow-wrap applications using heat sealing, mono-PP, mono-PE, and mono-PET are also already in use today – for example in the cookie, cracker, and biscuit segments.

But recyclability is only the starting point. Packaging is only fit for real-world use if it also performs under actual production conditions. A cookie with nut pieces visible on the surface, for instance, places different demands on barrier properties and seal integrity than a bar fully coated in chocolate. With crackers, moisture can be the critical factor in preserving the desired crunch. Packaging therefore has to do more than support recyclability: it must protect the product, secure shelf life, and prevent waste. Because if a more sustainable pack leads to higher food losses, little has been gained. From both an ecological and an economic perspective, food waste often carries more weight than the packaging itself.

The real challenge becomes apparent during sealing. Conventional multilayer films have been developed over decades for a high level of process reliability. They are comparatively forgiving when it comes to time, pressure, and temperature. Heat-sealable monomaterials, by contrast, have a narrower thermal processing window. Heat has to be applied far more precisely: enough to create a secure seal, but not so much that the material shrinks, warps, or becomes unstable.

In practice, this can limit line speed. Some applications can be converted with virtually no loss in performance, while others require optimized sealing tools, adapted heating concepts, or changes to the line layout. This means the PPWR is not only a question of material choice, but also of machine compatibility.

The countdown to the PPWR is therefore above all a practical challenge. Monomaterials are already realistic in many applications today, but they require preparation. This is exactly where Syntegon comes in: not only at the point of machine conversion, but already when assessing packaging materials, product requirements, and process capability. Together with customers and packaging material suppliers, Syntegon can test material samples, determine sealing parameters, evaluate retrofit options, and identify potential performance limits at an early stage.

This early alignment is particularly important where high cycle rates, narrow sealing windows, and demanding barrier properties come together. Syntegon sees itself not merely as a machine supplier, but as a partner on the path toward more sustainable packaging processes. Manufacturers that start testing now will know sooner which packaging materials work, which lines require a retrofit, and where packaging can be reduced further. In this way, regulatory pressure becomes a manageable conversion process – and monomaterial becomes a solution that brings circularity and industrial practice together.

We can support customers by reviewing existing packaging concepts and identifying technical solutions that help prepare for future regulatory requirements.

• New Sealing Technology – Best-in-class sealing technology for all material concepts. Testing shows higher performance than all competitor solutions.
• Paper On Form – Testing and implementing alternative material concepts, e.g. multilayer film to paper based film.
• Glue Reduction – Lower material use and improved recyclability though electric glue applicators. Futher, drastic reduction of maintenance.
• Customized Modernization – Machine modifications for future packaging needs, designed as partners and customized to your specific needs.