A producer of irregularly shaped frozen fruit (Poland and DACH) had bags cracking systematically in deep freezing and during logistics operations in cold storage. A dedicated multilayer formulation with mLLDPE, matched to the product shape and to sealing on the customer’s line, brought zero cracks at temperatures down to -25 and -30 °C.

01 Customer

Poland and DACH. A producer of frozen fruit with irregular geometry, packed in characteristic blue bags.

02 Challenge

The irregularly shaped fruit systematically tore the packaging: in deep freezing and during logistics operations in cold storage.

An irregular product shape means point stresses, and at -25 °C polyethylene loses its flexibility and cracks instead of deforming.

03 Solution

• Formulation: dedicated, multilayer.
• Metallocenes: mLLDPE in the formulation.
• Low-temperature flexibility: components that increase flexibility at low temperatures.
• Fit: matched to the specific product geometry and the sealing parameters on the customer’s line.

04 Results

• Cracking: zero cracks at temperatures down to -25 and -30 °C.
• Seal: stable in cold conditions.
• Cold chain: fewer complaints and losses.

05 What this means for you

If your product has sharp edges or an irregular shape, standard freezer film is working at its limit. The problem is solved by choosing the right low-temperature flexibility, not by adding thickness.

Artykuł Frozen fruit producer: no more bag cracking at -25 °C pochodzi z serwisu Kablonex.

A large laminate converter from the Baltic region, supplying packaging for butter and cheese, wanted to move away from a paper, aluminium, PE laminate without losing the paper look, the grease barrier and the ability to wrap the product into blocks. A single paper-like film with chalk, 55 µm as standard, replaced three laminate layers: no aluminium and no paper.

01 Customer

Baltic region. A large laminate converter, food packaging: butter and cheese. The customer had historically specialised in paper plus aluminium plus PE laminates.

02 Challenge

The customer wanted to simplify the pack construction and move away from aluminium, but had to keep everything the laminate provided: the paper look, the grease barrier and the ability to wrap the product into blocks.

Removing aluminium usually means losing the barrier.

03 Solution

• Base: a PE-based paper-like film.
• Composition: a high share of mineral components (chalk) and a share of bio-based raw materials.
• Thickness: adapted to the customer’s block-wrapping process, 55 µm as standard.
• Construction: one film instead of three laminate layers, no aluminium and no paper; the high mineral content reduces the amount of polymer in the pack.

04 Results

05 What this means for you

An aluminium laminate is convenient technically, but it means three materials in one pack. If you pack butter, cheese or fats and want to simplify your pack structure, this is a route that does not require changing your packing machine.

Artykuł Large Baltic converter: paper-like film instead of a paper, aluminium, PE laminate pochodzi z serwisu Kablonex.

A toilet paper and towel manufacturer wanted to reduce the plastic footprint of its packaging and introduce a high share of recycled content without losing runnability on the packing line. A new multi-layer formulation made it possible to go from 35-40 µm to 28 µm with 35% PCR in the standard line and up to 55% PCR in the premium variant, with runnability maintained.

01 Customer

A hygiene products manufacturer in Central Europe: toilet paper and towels. It previously packed using a classic, homogeneous technology optimised for easy opening.

02 Challenge

The goal: a smaller plastic footprint without losing runnability on the packing line and without logistics risk, plus a high recycled content.

The difficulty is that high PCR and thin film impair exactly the parameter that is critical in this application: tear resistance when the pack is carried.

03 Solution

• New construction: a new multi-layer formulation with enhanced mechanical properties instead of the homogeneous technology.
• Downgauging: from 35-40 µm to 28 µm.
• Recycled content: 35% PCR in the standard line and up to 55% PCR in the premium variant, introduced together with the downgauging.
• Printing: integration with NEX PRINT, flexo CI in up to 10 colours, for two of the customer’s product lines.

04 Results

05 What this means for you

55% recycled content in 28 µm films is a level that most of the market does not reach even with thicker constructions. If you have a PCR target written into a contract with a retail chain, this is a benchmark.

Artykuł Toilet paper manufacturer: from 35 to 28 µm with 35-55% PCR pochodzi z serwisu Kablonex.

A global furniture chain was replacing film logistics sleeves with a glued paper solution, in line with the group’s ESG policy. The condition was full logistics functionality. A glued paper sleeve formed in our own plant replaced the film without any loss of that functionality, and the pack goes into the standard paper recycling stream.

01 Customer

Poland and Scandinavia. A global furniture chain which, in line with the group’s ESG policy and consumer expectations, was replacing traditional film logistics sleeves with a glued paper solution.

02 Challenge

The condition: the paper sleeve must keep full logistics functionality.

Paper does not forgive what film does: it does not stretch, it has a fibre direction and it needs a glued seam.

03 Solution

• Construction: a glued paper sleeve adapted to the customer’s logistics process.
• Production: formed in our own plant using paper converting technology.
• Raw material: paper from certified sources.
• Recycling: adhesive and construction optimised for recycling in the standard paper stream.

04 Results

• Film sleeve replaced with paper: without loss of logistics functionality.
• ESG: full compliance with the customer’s ESG policy.
• Recycling: the pack goes into the standard paper recycling stream.

05 What this means for you

Moving from film to paper is not a change of material, but four decisions at once: printing, forming, gluing and working with your line. That is where these projects break. With us, all four are under one roof.

Artykuł Global furniture chain: a paper sleeve instead of a film sleeve pochodzi z serwisu Kablonex.

A bread producer supplying the private label of a large retail chain was looking for a replacement for 30 µm PP wicket bags, which cracked during frozen transport. A dedicated PE formulation with a polyolefin blend made it possible to switch to 18 µm film: around 40% less material while keeping the look on the shelf and runnability on the wicket lines.

01 Customer

A Polish bread producer that supplies the private label of a large retail chain. It packs bread in wicket bags.

02 Challenge

The customer was looking for an alternative to 30 µm polypropylene wicket bags. The PP cracked during frozen transport.

The new packaging had to meet three conditions: transparency and the look on the shelf retained, stability on the wicket line, and resistance at low temperatures. The retail chain does not accept packaging through which the product cannot be seen.

03 Solution

• Material: a dedicated PE formulation with a polyolefin blend for bread packaging.
• Thickness: 18 µm PE film instead of 30 µm PP.
• Line: runnability on the wicket lines retained.
• Shelf: packaging appearance retained.

04 Results

05 What this means for you

Switching from PP to PE sounds like a step back in terms of stiffness. With the right polyolefin blend it is the other way round: you get thinner packaging that does not crack in frost and goes into the PE recycling stream. This is the strongest downgauging argument in our entire portfolio.

*Around 40% is the difference in film thickness: 30 → 18 µm. The case study is anonymised.

Artykuł Bakery chain: 18 µm PE instead of 30 µm PP, 40% less material pochodzi z serwisu Kablonex.

A wood pellet and charcoal manufacturer wanted to take as much film as possible out of the bag on its fastest FFS line, without losing a cycle and without the risk of punctures from sharp pellet fractions. NEX-BAG FFS HQ in a 5-layer construction with mLLDPE made it possible to go from 80 to 50 µm, a reduction of 37.5%, with line speed unchanged.

01 Customer

A wood pellet and charcoal manufacturer in Poland. It packs on the fastest FFS line in its portfolio.

02 Challenge

The brief was to take as much film as possible out of the bag without losing a single cycle on the line and without risking punctures from sharp pellet fractions.

These three conditions usually rule each other out, because thinner film means a smaller puncture margin and a narrower sealing window.

03 Solution

• Film: NEX-BAG FFS HQ 50 µm in a 5-layer construction with mLLDPE.
• Selectively designed layers: instead of slimming all layers evenly, the outer layers took over puncture resistance and the middle layer shed mass.
• Thickness: down by 37.5%.

04 Results

05 What this means for you

If you pack bulk material with sharp fractions and have been told that at your line speed it is not possible to go below 70-80 µm, this case shows that it is. The condition: the film has to be designed for your machine, not picked from a catalogue.

Artykuł A 50 µm pellet bag instead of 80 µm: one of the thinnest on the European market pochodzi z serwisu Kablonex.

A British abrasives manufacturer needed an FFS bag with 30% PCR, a width outside the standard specification of production lines and a smaller CO₂ footprint for the whole package. The 5-layer NEX-BAG FFS HQ construction delivered a bag outside the typical width specification, with 30% PCR and full strength for an abrasive product, and flexo CI printing with water-based inks on the Kablonex line significantly reduced the CO₂ footprint compared with solvent-based printing.

01 Customer

An abrasives manufacturer in the United Kingdom. It packs an abrasive product in FFS bags on its own line, for which it needed a bag with a width outside the standard specification.

02 Challenge

The British market introduced a standard of at least 30% PCR in film packaging for chemicals and abrasive materials. In addition, the customer needed a bag with a width outside the standard specification of production lines and a reduction in the CO₂ footprint of the whole package.

Abrasive material is also one of the most aggressive loads for film.

03 Solution

• Construction: the 5-layer NEX-BAG FFS HQ made it possible to produce a bag outside the typical width specification.
• Recycled content: 30% PCR with full strength for an abrasive product.
• Printing: flexo CI with water-based inks, on the Kablonex line.

04 Results

• 30% PCR: compliance with the British requirement.
• Format: a bag outside the market standard, matched to the customer’s existing line.
• CO₂ footprint: a significant reduction in CO₂ footprint compared with solvent-based printing.

05 What this means for you

If a supplier has told you that your format is “outside the specification”, ask us about it. A non-standard width is usually not a technological limitation, but an organisational one.

Artykuł British abrasives manufacturer: a narrow FFS bag with 30% PCR and water-based ink printing pochodzi z serwisu Kablonex.

A construction chemicals manufacturer wanted to use less film in its FFS bags, even though its mortars sit for months in DIY and builders’ stores and any moisture means a complaint and disposal. We went down from 130 to 120 µm with NEX-BAG FFS HQ and a proprietary technology for managing the venting chambers. The result: zero complaints due to product moisture.

01 Customer

A construction chemicals manufacturer in Poland: mortars, adhesives, skim coats. It packs in FFS bags, and the product goes to DIY and builders’ stores, where it sits for months.

02 Challenge

The manufacturer wanted to optimise film consumption in its FFS bags. Yet any moisture in the mortar means a complaint and disposal.

Thinner film usually means a weaker barrier, so saving material was at odds with product safety.

03 Solution

• Film: NEX-BAG FFS HQ 120 µm instead of 130 µm.
• Venting: a proprietary technology for managing the venting chambers, which eliminates moisture ingress during filling and storage.
• Construction: 5 layers with mLLDPE kept full strength despite the reduced thickness.

04 Results

05 What this means for you

At volumes counted in millions of bags, 8% of thickness is a line you can see in the annual materials budget. But the key was not the thickness, it was venting the bag. If your product absorbs moisture, start the conversation there, not with microns.

Artykuł National leader in construction chemicals: from 130 to 120 µm and zero moisture complaints pochodzi z serwisu Kablonex.

A manufacturer of sterile pharmaceuticals, including eye drops, packs its finished product in a bag-in-bag-in-bag system, and the sides of the bag were splitting during multipacking and transport between process stages. A dedicated NEX-BAG FARM formulation with increased film flexibility and softness, produced under a controlled pharma regime, eliminated the side splits.

01 Customer

A manufacturer of sterile pharmaceuticals in Poland, including eye drops. The finished product is packed in a multi-layer bag system: bag in a bag in a bag, with zero tolerance for microbiological contamination.

02 Challenge

The sides of the bag were splitting during multipacking and transport between process stages. In pharma, a split does not mean a complaint; it means the whole batch loses its sterility.

03 Solution

• Formulation: a dedicated NEX-BAG FARM formulation with increased film flexibility and softness.
• Production regime: a controlled pharma regime, meaning hair covers, documentation per batch and full repeatability.
• Quality: along the way, we closed out the customer’s historical quality issues with their previous supplier.

04 Results

• Splits: bag side splits eliminated.
• Quality: stable, documented quality batch after batch.
• Relationship: a strategic partnership instead of a tender-based relationship.

05 What this means for you

In GMP applications, film is part of the quality system, not a purchasing line item. If your supplier does not keep documentation per batch, in an audit it is you who answers for their process.

Artykuł Sterile pharmaceuticals manufacturer: no more bag side splits during multipacking pochodzi z serwisu Kablonex.

A crate manufacturer exporting to the German market wrapped its pallets in a 50 µm stretch hood, while German retail chains expected an ever higher share of post-consumer recyclate in transport packaging. NEX-HOOD PCR 50 µm in the “PCR HQ” formulation contains 35% post-consumer recyclate without making the film thicker and maintains its stretch performance in a demanding application.

01 Customer

A crate manufacturer from Poland, exporting to the German market with global distribution. It secures its pallets with a stretch hood.

02 Challenge

The customer wrapped its pallets in an exceptionally thin 50 µm stretch hood in the standard version. The nature of the product requires very high film stretch during hood application, so adding PCR at this thickness was technically difficult: most recyclate formulations on the market lose the required mechanical properties under these conditions.

At the same time, German retail chains were signalling growing expectations regarding the share of post-consumer material in transport packaging.

03 Solution

• “PCR HQ” formulation: a dedicated NEX-HOOD PCR 50 µm formulation.
• Recyclate: 35% post-consumer material at the same 50 µm thickness.
• Mechanical properties: enhanced for high-stretch applications.

04 Results

05 What this means for you

50 µm is a thin gauge for a stretch hood. Adding a third of recyclate to that without losing holding force is where most PCR projects stall. If your customers expect recyclate in transport packaging and you work with a thin hood, what matters is the formulation, not a thicker film.

Artykuł Crate manufacturer for the German market: 35% recyclate in a 50 µm stretch hood pochodzi z serwisu Kablonex.