Baltic region (major aluminum laminate converter / food packaging – butter, cheese)

Challenge:

The client – a major converter in the Baltic region, historically specialized in paper + aluminum + PE laminates for food applications – was implementing a strategic transition to solutions with a better recycling profile. Requirement: maintain the aesthetics and functionality of the classic laminate (paper look, grease barrier, product cubing) while eliminating the aluminum layer.

Solution:

Implementation of paper-like film with high chalk content and a PE layer incorporating bio-based raw materials, with thickness adapted to the client’s cubing process (standard 55 µm). Elimination of the aluminum layer simplified the recycling cycle — post-industrial waste returns to standard mechanical recycling.

Results:

• replacement of paper+Al+PE laminate with a solution offering a significantly better recycling profile
• preserved packaging aesthetics and functionality on the shelf
• compliance with PPWR direction
• simpler ESG communication to the end consumer

Artykuł Conversion from paper–aluminum–PE laminate to paper-like film with chalk for a major converter in the Baltic region pochodzi z serwisu Kablonex.

Central Europe

CHALLENGE

A hygiene products manufacturer (toilet paper / towels) previously used packaging with classic, homogeneous technology optimized for “easy opening.” Client’s goal: plastic footprint reduction (ESG) without losing machine runnability on the packaging line and logistical security, plus the introduction of high PCR content.

SOLUTION

Paradigm shift in film construction – a new, multi-layer formulation with enhanced mechanical parameters enabling downgauging from 35–40 μm to 28 μm, with simultaneous implementation of 35% PCR in the standard line and up to 55% PCR in the premium variant. Integration with NEX PRINT (flexo CI, up to 10 colors) for two of the client’s product lines.

RESULT

• significant reduction in plastic consumption per unit
• fulfillment of ESG goals and PPWR requirements
• maintained machine runnability and logistical security
• premium printing up to 10 colors

Artykuł Downgauging of hygiene film from 35 μm to 28 μm + 35–55% PCR for a toilet paper manufacturer (premium line) pochodzi z serwisu Kablonex.

Poland / Scandinavia (global furniture network)

Challenge:

The client – a global furniture network – was implementing a project to replace traditional film logistics sleeves with a glued paper solution, in line with the group’s ESG policy and end-consumer expectations regarding paper packaging. Requirement: maintain the logistical functionality of the sleeve when transitioning to a paper monomaterial.

Solution:

Development of a glued paper sleeve, formed in-house using paper converting technology, adapted to the client’s logistics process. Paper raw material from certified sources, adhesive, and construction optimized for recycling in the standard paper stream.

Effects:

• replacement of film sleeves with a paper solution without loss of functionality
• full compliance with the client’s ESG policy
• easy recycling in existing paper collection systems

Artykuł Transition from Film Sleeves to Paper Sleeves for a Global Furniture Network — Paper Converting as a Film Alternative pochodzi z serwisu Kablonex.

Poland

CHALLENGE

A bread producer supplying under the brand of a large retail chain was seeking an alternative to polypropylene (30 μm) wicketed bags. Requirements included: preserved transparency and visual appearance of the packaging, stability on the wicket line, and resistance to low temperatures (PP cracked during frozen transport).

SOLUTION

A dedicated PE formulation with a polyolefin blend for bread packaging applications, allowing the replacement of 30 μm PP with 18 μm PE film while maintaining machine runnability on wicket lines and visual appearance on the shelf.

RESULT

• Material consumption reduction by ~40%
• Elimination of cracks in the cold chain • Lower unit cost of packaging
• PE monomaterial compliant with PPWR

Artykuł Downgauging from 30 μm PP to 18 μm PE for a leading bakery chain (–40% material) pochodzi z serwisu Kablonex.

Poland (leading Polish manufacturer of wood pellets and charcoal)

Challenge:

The client packages products on a high-performance, premium FFS line – the fastest in their portfolio. Requirement: maximum reduction in film consumption without compromising line efficiency or bag strength under sharp pellet fractions.

Solution:

We implemented NEX-BAG FFS HQ 50 µm film instead of the standard 80 µm (a thickness reduction of ~37.5%) thanks to a 5-layer construction with mLLDPE and selective layer design for the specific application.

Results:

• one of the thinnest pellet bags available on the European market
• full maintenance of packaging line efficiency
• significant reduction in plastic consumption per bag
• readiness for PPWR requirements

Artykuł Downgauging from 80 to 50 µm in wood pellet and charcoal bags – one of the thinnest pellet bags on the market pochodzi z serwisu Kablonex.

United Kingdom (abrasive materials manufacturer)

Challenge:

The British market introduced a standard of min. 30% PCR in film packaging for the chemical and abrasive materials segment. Additionally, the client required a very narrow bag, outside the standard specifications of production lines, and a reduction in the CO₂ footprint of the entire packaging label.

Solution:

Thanks to the 5-layer NEX-BAG FFS HQ design, we produced a bag outside the typical width specification, with 30% PCR and full mechanical strength for abrasive products. The printing was done using flexo CI technology with water-based inks from the Kablonex line.

Results:

• Full compliance with British PCR requirements
• Significant reduction in CO₂ footprint vs. solvent-based printing
• Narrow bag format suitable for the client’s existing packaging line

Artykuł Narrow FFS bags with 30%+ PCR and water-based ink printing for a British abrasive materials manufacturer pochodzi z serwisu Kablonex.

Poland (national leader in construction chemicals – mortars, adhesives, fillers)

Challenge:

The manufacturer was looking to optimize film consumption in FFS bags while maintaining moisture resistance in the distribution chain (construction markets, multi-month storage).

Solution:

We implemented NEX-BAG FFS HQ 120 µm film instead of the standard 130 µm (downgauging ~8%), combined with a proprietary venting chamber management technology that eliminates moisture ingress into the bag during packing and storage. The 5-layer mLLDPE construction maintained full mechanical strength despite the thickness reduction.

Results:

• significant material savings on millions of bags annually
• no complaints due to product dampness
• maintained FFS line machine parameters

Artykuł Downgauging from 130 to 120 µm + proprietary moisture control technology for a national leader in construction chemicals pochodzi z serwisu Kablonex.

Poland (a leading European manufacturer of sterile pharmaceuticals, including eye drops)

Challenge:

The client packages the finished product in a multi-layer film bag system (bag-in-bag-in-bag) with zero tolerance for microbiological contamination. There was a problem with the sides of the bags tearing during multi-packing and inter-stage transport.

Solution:

We developed a dedicated NEX-BAG FARM formula with enhanced film flexibility and softness, produced under controlled pharma production conditions (caps, documentation per batch, full repeatability). We also resolved the client’s historical quality issues with the previous supplier.

Effects:

• Elimination of bag side tears
• Stable batch quality
• Long-term strategic partnership

Artykuł Bags with Enhanced Flexibility for a Sterile Pharmaceutical Manufacturer – Eliminating Side Tearing During Multi-Packing pochodzi z serwisu Kablonex.

• Poland/export to the German market,
• Global distribution

CHALLENGE

The client was packaging pallets of their crates with an exceptionally thin 50 μm standard stretch-hood. The product’s specific nature required very high film elongation during hood application, making the transition to a thinner film with PCR content technically challenging—most market PCR formulations lose the required mechanical parameters at this thickness. Simultaneously, the client’s recipients, especially German retail chains, reported increasing expectations regarding the share of post-consumer raw material in transport packaging (PPWR, ESG policies, material footprint reporting).

SOLUTION

NEX-HOOD PCR 50 μm in a dedicated “PCR HQ” formulation—with 35% post-consumer recycled content, enhanced mechanical parameters for applications requiring high elongation, and maintained film transparency. The formulation was custom-developed for this application, validated on the client’s line before the first delivery, and compatible with existing hood applicator settings.

RESULT

• 35% PCR in transport packaging without changing thickness or modifying the line
• measurable reduction of the primary plastic material footprint for PPWR and ESG
• stronger client position in discussions with German retail chains regarding sustainability
• maintained film transparency and pallet stabilization despite low thickness and high elongation
• consistent CO₂ and sustainability communication in the client’s supply chain

Artykuł Crate manufacturer for the German market: stretch-hood PCR 50 μm—film with 35% post-consumer recycled content for a demanding export line pochodzi z serwisu Kablonex.

Poland / Western Europe (global home appliance group – washing machines, refrigerators, cookers)

Challenge:

In previous years, the client had performed downgauging from 80 µm to 50 µm and had no intention of reverting to thicker film. Simultaneously, they had an ESG goal: to introduce recycled content in all variants (washing machines / refrigerators / cookers) without modifying packaging lines and without compromising shrink quality.

Solution:

Selection of technology and shrink parameters allowing for the implementation of 35% PCR while maintaining a thickness of 50–70 µm (depending on the application and line type). The film was adapted to the client’s key mechanical parameters so that logistics and package aesthetics would not be negatively affected. The implementation roadmap includes increasing the PCR content to 50%.

Results:

• retention of previous savings from downgauging
• achievement of ESG/PPWR goals without CAPEX for packaging lines
• a ready path for scaling PCR in the client’s portfolio

Artykuł Implementation of 35% PCR (with a roadmap to 50%) in 50–70 µm films for a global home appliance manufacturer without compromising shrink parameters pochodzi z serwisu Kablonex.